PETTIBONE Extendo Series User manual

Operator’s Manual PMOM-4021
736-744-936-944-1032-1144-1157
T944-T1157

i
Extendo and Traverse Operation and Maintenance Manual
800GOPETTIBONE
CONTENTS
SAFETY...................................................................................................................................................................................1
Safety Rules ..................................................................................................................................................................1
Safety Statements ......................................................................................................................................................1
Safety Messages..........................................................................................................................................................2
Operator Qualifications............................................................................................................................................5
Safe Operating Practices..........................................................................................................................................5
Transporting Safely....................................................................................................................................................8
Parking the Machine .................................................................................................................................................8
Safety Decals............................................................................................................................................................. 10
Decal Locations ............................................................................................................................................... 11
Main Decal Kit, LL-7858 ........................................................................................................................ 11
0L1-10298-000, USE BOTH HANDS ................................................................................................... 12
FL-10561, SERVICE BRAKE .................................................................................................................... 12
LL-1803-499, ACCUMULATOR.............................................................................................................. 12
LL-4780, TRANSMISSION OIL FILL ..................................................................................................... 12
LL-6163, MOTOR OIL .............................................................................................................................. 12
LL-7932, ASSEMBLED IN USA............................................................................................................... 12
LL-6173-1, OPERATOR MANUAL WITHIN ......................................................................................... 13
LL-7700, WELDING AND MODIFICATION ........................................................................................ 13
LL-7605, HYDRAULIC OIL ONLY ......................................................................................................... 13
LL-6455, DIESEL FUEL ONLY................................................................................................................. 13
LL-6456, COMBUSTIBLE AND FLAMMABLE FLUIDS..................................................................... 14
LL-7984, SAFE OPERATION CHECK LIST .......................................................................................... 14
LL-6462-6, EXCESSIVE HYDRAULIC PRESSURE .............................................................................. 15
LL-6463, MACHINE ROLL AWAY ..........................................................................................................15

ii Extendo and Traverse Operation and Maintenance Manual 800GOPETTIBONE
CONTENTS
LL-6465, ELECTROCUTION HAZARD ................................................................................................ 15
LL-6466, EXPLOSION HAZARD ........................................................................................................... 15
LL-6467, HOT AND PRESSURIZED ..................................................................................................... 16
LL-6468, NO RIDING ............................................................................................................................... 16
LL-6469, MOVING BELTS AND SPINNING BLADES ....................................................................... 16
LL-6470, MACHINE TIP-OVER ............................................................................................................... 17
LL-6471, HOT EXHAUST PIPE ............................................................................................................... 17
LL-6472, PERSONAL INJURY................................................................................................................. 17
LL-6474, BACKWARD TIP-OVER........................................................................................................... 17
LL-6475, MACHINE TIP-OVER ............................................................................................................... 18
LL-6476, WATCH YOUR STEP................................................................................................................. 18
LL-6477, NO STEP..................................................................................................................................... 18
LL-6480, PINCH POINT............................................................................................................................ 18
LL-6482, NO RIDING ................................................................................................................................ 18
LL-6489, FALLING BOOM OR LOAD ................................................................................................... 18
LL-6490, FALL HAZARD ......................................................................................................................... 18
LL-6492, CARBON MONOXIDE ........................................................................................................... 19
LL-6494, HIGH PRESSURE HYDRAULIC FLUID ................................................................................ 19
LL-6497, UNTRAINED PERSONNEL..................................................................................................... 19
LL-7405, FASTEN SEAT BELT ................................................................................................................. 20
LL-7406, FORWARD & REVERSE .......................................................................................................... 20
LL-7430, FALLING LOAD ........................................................................................................................ 20
LL-7474, CALIFORNIA PROPOSITION 65 WARNING .................................................................... 20
LL-7534, ELEVATE PERSONNEL ........................................................................................................... 20
LL-7535, ELEVATE PERSONNEL ........................................................................................................... 20
LL-7536, LIFTING PREP & SETUP ........................................................................................................ 21
LL-7537, UNCONTROLLED MACHINE................................................................................................ 21
LL-7539, OSHA TRAINED ....................................................................................................................... 21
LL-7566, HYD. OIL FILL PROCEDURE ................................................................................................ 22
LL-7599, PRE-START MAINTENANCE ................................................................................................ 22
BL-9969, ANGLE INDICATOR ................................................................................................................ 23
00L-09870-000, NO RIDING.................................................................................................................. 23
Decal Add-On Kits ........................................................................................................................................... 28
GENERAL INFORMATION............................................................................................................................................. 33
Material Safety Data Sheets (MSDS) ................................................................................................................ 33
Directional Reference ............................................................................................................................................ 34
Identification............................................................................................................................................................. 35
Forklift Description ......................................................................................................................................... 35
Forklift Identication Plate................................................................................................................... 35
Standard Engine Description ..................................................................................................................... 35

iii
Extendo and Traverse Operation and Maintenance Manual
800GOPETTIBONE
Engine Identication Plate................................................................................................................... 35
Transmission Description ............................................................................................................................. 36
Transmission Identication Plate....................................................................................................... 36
Axle Description .............................................................................................................................................. 36
Axle Identication Plate ........................................................................................................................ 36
Work Platform Reference Guide................................................................................................................. 36
Preparation and Prevention ................................................................................................................ 37
Using a Personnel Platform Attachment......................................................................................... 37
Options and Accessories....................................................................................................................... 38
Ordering Parts........................................................................................................................................... 38
FORKLIFT OPERATION .................................................................................................................................................. 39
Operational Safety .................................................................................................................................................. 39
Forklift Description ......................................................................................................................................... 41
Safe Operating Practices............................................................................................................................... 41
Pre-Startup Inspections ................................................................................................................................ 42
Walk-Around Inspection ....................................................................................................................... 42
Check Engine Oil...................................................................................................................................... 42
Check Transmission Oil.......................................................................................................................... 42
Check Radiator Coolant Level ............................................................................................................. 42
Check Hydraulic Fluid Level................................................................................................................. 43
Tires and Rims........................................................................................................................................... 44
Inspection for Leaks................................................................................................................................ 44
Hydraulic Fluid Level .............................................................................................................................. 44
Entering the Operator’s Compartment ................................................................................................... 44
Operator’s Seat................................................................................................................................................. 44
Seat Position Adjustment..................................................................................................................... 44
Arm Rest...................................................................................................................................................... 44
Seat Suspension Adjustment ............................................................................................................. 44
Seat Belt ...................................................................................................................................................... 45
Instrument Panel ..................................................................................................................................... 45
Fuel Gauge ................................................................................................................................................. 45
Engine Coolant Temperature Gauge ................................................................................................ 45
Engine Hour Meter.................................................................................................................................. 45
Transmission Temperature Gauge..................................................................................................... 45
Transmission Oil Pressure Gauge....................................................................................................... 46
Inclinometer .............................................................................................................................................. 46
Parking Brake Switch.............................................................................................................................. 46
Clutch Cut-o Switch ............................................................................................................................. 47
Rear Axle Lock Warning Light ............................................................................................................. 47
Rear Axle Restricted Mode................................................................................................................... 47
CONTENTS

iv Extendo and Traverse Operation and Maintenance Manual 800GOPETTIBONE
Brake Oil Pressure Warning Light....................................................................................................... 47
Parking Brake Indicator Light.............................................................................................................. 48
Low Voltage Warning Light.................................................................................................................. 48
Engine Oil Pressure Warning Light .................................................................................................... 48
Ignition Switch.......................................................................................................................................... 48
Steering Selector ..................................................................................................................................... 48
Fixed Boom Hydraulic Controls.................................................................................................................. 49
Remote Control Joystick ....................................................................................................................... 49
Function...................................................................................................................................................... 49
Traversing Boom Hydraulic Controls........................................................................................................ 50
Remote Control Joystick ....................................................................................................................... 50
Function...................................................................................................................................................... 51
Throttle and Brake Controls......................................................................................................................... 51
Brake Pedal................................................................................................................................................. 52
Throttle Pedal............................................................................................................................................ 52
Transmission Controls.................................................................................................................................... 52
Powershift Transmission Controls...................................................................................................... 52
Twist Grip Gear Shifter/Directional Selector.................................................................................. 52
Steering Wheel ......................................................................................................................................... 52
Boom Features.................................................................................................................................................. 52
Fork Leveling............................................................................................................................................. 52
Frame Tilt (Sway)...................................................................................................................................... 52
Gauges and Indicators........................................................................................................................... 52
Changes in Performance....................................................................................................................... 52
Start-up and Driving....................................................................................................................................... 53
Weight and Distance .............................................................................................................................. 55
Location of Load Range Capacity Charts ........................................................................................ 55
Raising the Load....................................................................................................................................... 84
Transporting the Load ........................................................................................................................... 84
Inclines and Unstable Surfaces .......................................................................................................... 84
Landing the Load .................................................................................................................................... 84
Shutdown................................................................................................................................................... 85
Emergency Operations.......................................................................................................................... 85
MAINTENANCE................................................................................................................................................................ 87
Safety While Servicing the Machine ................................................................................................................. 87
Maintenance and Service Kits............................................................................................................................. 89
Routine Maintenance............................................................................................................................................. 90
DAILY (or 8 hours)............................................................................................................................................ 90
WEEKLY (or 30 hours) ..................................................................................................................................... 91
Fluids and Lubricants..................................................................................................................................... 91
CONTENTS

v
Extendo and Traverse Operation and Maintenance Manual
800GOPETTIBONE
Filter Kits ............................................................................................................................................................. 91
Grease Fitting Location Charts ................................................................................................................... 92
7K Models Fixed Grease Fittings ........................................................................................................ 92
9K Models Fixed Grease Fittings ........................................................................................................ 93
9-11K Models Fixed Grease Fittings.................................................................................................. 94
1157 Models Grease Fittings ...............................................................................................................95
7K Traversing Models ............................................................................................................................. 96
9K Traversing Models ............................................................................................................................. 97
11K Traversing Models........................................................................................................................... 98
Replace Fuel Filter Elements........................................................................................................................ 99
Service Air Cleaner........................................................................................................................................100
Drain and Rell Cooling System...............................................................................................................101
Thermostat Test..............................................................................................................................................102
Drive Belt Tension Adjustment .................................................................................................................102
Battery Replacement....................................................................................................................................102
Fuse Replacement.........................................................................................................................................103
Engine Oil Change.........................................................................................................................................103
Transmission Oil Change ............................................................................................................................104
Transmission Filter Element Replacement ...........................................................................................104
Axle Lubricant Change ................................................................................................................................104
Required Scheduled Maintenance Log ........................................................................................................105
50 Hours of Operation ........................................................................................................................106
250 Hours of Operation ......................................................................................................................106
500 Hours of Operation, or 6 Months ............................................................................................106
750 Hours of Operation ......................................................................................................................106
1000 Hours of Operation, or 1 Year ................................................................................................107
1250 Hours of Operation ...................................................................................................................107
1500 Hours of Operation, or 18 Months .......................................................................................107
1750 Hours of Operation ...................................................................................................................107
2000 Hours of Operation, or 2 Years ..............................................................................................108
Operation Under Severe Conditions .....................................................................................................108
Service Maintenance Chart........................................................................................................................109
Specications..................................................................................................................................................110
Tire Pressures...........................................................................................................................................110
Hydraulic Oil............................................................................................................................................110
Diesel Fuel ................................................................................................................................................110
CONTENTS

vi Extendo and Traverse Operation and Maintenance Manual 800GOPETTIBONE
CONTENTS

1
Extendo and Traverse Operation and Maintenance Manual
800GOPETTIBONE
SAFETY
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.
See the dealer for any questions. Failure to read
and follow these instructions could result in death,
serious injury or damage to the machine.
READ THIS MANUAL COMPLETELY and be sure
to understand the speed, stability and steering
characteristics 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/Traverse Lift, LLC 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. 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.
SAFETY STATEMENTS
This is the safety alert symbol. It is used
to alert you to potential personal injury
hazards. Obey all safety messages that
follow this symbol to avoid possible injury
or death.
DANGERA
Indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
WARNINGA
Indicates a hazardous situation which, if not
avoided, could result in death or serious
injury.
CAUTIONA
Indicates a hazardous situation which, if not
avoided, could result in minor or moderate
injury.
NOTICE
Indicates a situation which, if not avoided,
can cause damage to the machine, personal
property and/or the environment or cause the
equipment to operate improperly.
Note: Provides additional information.

SAFETY
2Extendo and Traverse Operation and Maintenance Manual 800GOPETTIBONE
SAFETY MESSAGES
DANGERA
The safety messages that follow have
DANGER level hazards. These safety
messages describe a hazardous situation
which, if not avoided, will result in death or
serious injury.
Electrocution Hazard
Avoid contact with high voltage power lines•
and underground cables.
Before driving or operating in an area with•
high voltage lines or cables that are not
terminated or completely installed, isolate
the power source and turn the voltage OFF.
Know the location of and keep a safe•
working distance from any high voltage
power equipment.
Observe federal, state/provincial and local•
safety codes and regulations that apply to
the job site.
WARNINGA
The safety messages that follow have
WARNING level hazards. These safety
messages describe a hazardous situation
which, if not avoided, could result in death or
serious injury.
Tip Hazard
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 and overhangs.
Walk around the work area before starting•
the forklift and look for hazards.
Crush Hazard
• No personnel should ever walk or
stand under a raised boom or walk
alongside a moving forklift.
Be alert and always know the location of all•
workers in the area.
Keep all other persons completely away from•
the machine.
Do not attempt to remove a load from the•
forks by stopping the forklift suddenly.