OWNER/OPERATOR MANUAL

MODEL 6036/6044/8036/8044
10044/10056
ROUGH TERRAIN FORKLIFT

OM-4009
 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.

6036/6044/8036/8044 OWNER/OPERATOR MANUAL

Copyright December 1999

Pettibone Michigan, L.L.C.
Technical Publications
Baraga, MI

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

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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

continued on next page

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

(Continued on next page)

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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

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

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 NOTES

THIS PAGE
INTENTIONALLY
LEFT BLANK

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INTRODUCTION

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.

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

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 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

WARNING
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.

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

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 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 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.
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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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 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

Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODELS 6036/6044/8036/8044
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 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
Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODELS 6036/6044/8036/8044
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• 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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DECALS

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.

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Left Side View of Machine Decals

5
9
7

10
11
6

15
13

12
16, 17

14
18
3
2

4
1 19

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Decals Located Behind Seat

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Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODEL 6036/6044/8036/8044
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Hydraulic and Fuel Tank Decals

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Illustrated Decal Locations--Part No. Listing

REF Part No. Description Req'd

1 LL-4778 Work Horse Decal 2

2 BL-9969 Boom Angle Indicator Decal 1
3 LL-7278 Pettibone Logo Decal 2
4 See Parts Manual Extendo Decal 2
5 LL-6466 Explosion Warning 1

6 LL-6480 Pinchpoint Danger 2

7 LL-6467 Hot & Pressurized Fluid 2
8 LL-6039 Made in U.S.A. Pettibone Decal 2
9 See Parts Manual Left Rear Model Decal 1
See Parts Manual Right Rear Model Decal 1
10 LL-6469 Moving Belts & Spinning Blades 2
11 LL-6471 Hot Exhaust Pipe Warning 1
12 LL-6476 Caution Watch your Step 2
13 See Parts Manual Load Chart Decal 1
14 LL-6482 No Riding Warning 2
15 LL-6677 Weight Tag 1

16 LL-6477 No Step Caution 1

17 LL-6494 High Pressure Hydraulic Fluid Warning 1
18 LL-6464 Falling Boom or Load Decal 1
19 LL-6468 No Riding Warning 1
20 LL-6453 Welding and Modification Warning 1

21 See Parts Manual Lube Chart Decal 1

22 LL-6457 Pre-start Checklist Decal 2
23 LL-6492 Carbon Monoxide Hazard 1
24 LL-6472 Personal Injury Hazard 1
25 LL-6475 Machine Tip Over Hazard 1

26 LL-6489 Falling Boom or Load Decal 1

27 LL-6474 Backward Tip Over Hazard 1
28 LL-6465 Electrocution Hazard 1
29 LL-6497 Untrained Personnel Warning 1
30 LL-6470 Machine Tip-Over 1

31 LL-6463 Machine Roll Away Warning 1

32 FL-6458 Safe Operation Checklist 1
33 LL-6490 Fall Hazard 1
34 LL-5940 Steering Selector Decal 1
35 LL-6491 Uncontrolled Machine Motion & Energy 1

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 Standard Decals Used--Part No. Listing

REF Part No. Description Req'd

36 LL-1994-600 Prevent Roll Away Decal 1

37 LL-7157 Contents Under Pressure 1
38 LL-6456 Combustible & Flammable Fluids 1
39 LL-6455 Diesel Fuel Only Decal 1
40 LL-6454 Hydraulic Oil Only Decal 1

Standard Decals Used--Service Bulletin Reference

Service Bulletin Reference

Number Date Subject Changes

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 TRAVERSE LIFT

! WARNING
NO RIDING
LL-6482

#1: TWO (2) TOTAL: ONE BOOM, TOP FRONT; ONE ON LEFT OUTER SIDE
OF DASHBOARD PANEL OF OPERATOR’S CAB.

#2: ONE (1) LOCATED ON LEFT SIDE OF BOOM

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

Page 24
#3: ONE (1) #4: ONE (1)
LOCATED LOCATED
INSIDE
OPERATOR’S
! WARNING INSIDE
OPERATOR’S
CAB ON CAB ON
LEFT FRONT SAFE OPERATION CHECKLIST: LEFT FRONT
CAB FRAME Follow proper operating procedures CAB FRAME
ABOVE for the safety of all personnel. BY HAND
HAND GRIP, BELOW
GRIP Wear seatbelts at all times. “Machine
Never allow riders on machine. Roll Away”
DECAL
Wear personal protective equipment.

Clear all people and obstacles from

work area.

Keep clear of overhead power lines.

! WARNING
Operate machine from seat position
only.

Allow proper warm-up time and wait

for all gauges to register properly.

Check operation of all controls and

functions.

Position machine to allow good visibility

of work area.

Never use boom or attachment as

personnel carrier.

Position boom and load as low as

possible to maintain maximum stability.

Know machine's operating capabilities

and limitations.

Know hand signals used in work area.

Ground boom and engage hand brake

before leaving machine.

Shut down machine when:

MACHINE ROLL AWAY
not functioning properly.
Can cause death or severe volt meter, water temperature or
injury. transmission oil temperature
exceed normal limits.
Before dismounting: leaving machine.
engage parking brake. engine oil pressure too low.
lower boom attachment and drive oil pressure too low.
load to ground. See machine manuals for additional
safety precautions and operating
follow other shutdown procedures.
procedures.
LL-6463

LL-6458

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Page 25
 TRAVERSE LIFT
Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL

! CAUTION
PRE-START MAINTENANCE CHECKLIST: clean?
Conduct pre-start maintenance inspections to
Hydraulic components: no leaks, loose fittings
ensure machine is in proper and safe operating
or damage?
condition.
Hydraulic oil: no leaks, proper level?
Battery and electrical system: no loose
Machine components: clean, no cracks,
connections, frayed wires, damage?
damage, signs of vandalism, or missing or
Engine air cleaner: no inlet restriction or loose parts?
damage?
Radiator: clean, free of dirt and debris, no
Engine compartment: clean, free of dirt, leaks, proper fluid level?
debris and flammable materials?
Safety decals: clean, legible, secure?
Page 26

Engine oil: no leaks, proper level?

Walking, climbing, and control surfaces:
Fan and drive belts: no loose or worn belts? clean, and free of dirt, fluids, debris, tools,

ON RIGHT FRONT CAB FRAME

INSIDE OPERATOR’S CAB
#5: ONE (1) LOCATED
Fuel: no leaks, proper level? rags, unsecured items?
MODELS 6036/6044/8036/8044

Gearbox and transmission: no leaks, proper Attachments: properly secured?

fluid level?
Grease fittings: lubricated? See machine manuals for additional
Guards and shrouding: installed, secure, maintenance recommendations.
LL-6457
 #7:
FRONT JOYSTICK
LIFT
DOWN

BOOM BOOM
IN OUT

LIFT
UP

FORK TILT
FORWARD

SIDE TILT SIDE TILT

LEFT RIGHT

FORK TILT
BACK

REAR JOYSTICK

SWAY SWAY
LEFT RIGHT

LL-7378

LL-7265-6

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TRAVERSE LIFT

#9:

! DANGER

PINCH POINT
LL-6480

! CAUTION #11:

DIESEL FUEL ONLY.

Must meet following standards to avoid
machine damage:

AMBIENT CONDITIONS GRADE

o o
Below 32 F (0 C) Winterized No. 2-D
o o
Above 32 F (0 C) ASTM D975 Grade No. 2-D

LL-6455

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Page 28
 ! WARNING

COMBUSTIBLE AND FLAMMABLE

FLUIDS
Can cause death or severe injury.
Keep sparks, flames and lighted materials away
from fuel and hydraulic fluid.
Do not refuel while engine is hot or running.
Do not refuel without proper ventilation. LL-6456

#12:

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 TRAVERSE LIFT

#13:

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Page 30
 #14:

! WARNING
WELDING AND MODIFICATION
HAZARD
Can cause death or severe injury.
Welding may cause electrical or structural
damage to machine.
Disconnect battery cables and alternator
connections before welding on machine.
Do not weld on any structural member or make
modifications without factory authorization.
Modifications made without factory authorization
will void warranty. LL-6453

#15:

! CAUTION
NO STEP LL-6477

#16:

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 TRAVERSE LIFT

#18:
CRAB

Steering Modes
2
W
H
E
E
L
4 WHEEL LL-7376

! WARNING
CONTENTS UNDER PRESSURE.

REMOVE FILLER CAP SLOWLY!

Check Breather Daily for Obstructions.

LL-7157

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

Page 32
 ! DANGER
#19: ONE (1)
LOCATED
INSIDE CAB ON
RIGHT PANEL

ELECTROCUTION HAZARD
Will cause death or severe injury.
Stay clear.
Do not allow machine or load within 10
ft. (3m) plus 2 times line insulator
length of any power line.
Notify power company to de- energize #20: ONE (1)
lines before operating machine. LOCATED
LL-6465
INSIDE CAB ON
RIGHT PANEL,
BELOW
“Electrocution

! DANGER Hazard” DECAL

FALLING BOOM OR LOAD

Will cause death or severe injury.
Do not move boom or load over personnel.

LL-6489

WARNING
#21: ONE (1)
! LOCATED
INSIDE CAB ON
RIGHT PANEL,
BACKWARD TIP-OVER HAZARD BELOW “Falling
Can cause death or severe injury. Boom or Load”
Do not operate on upward slope with boom DECAL
fully raised and retracted.
LL-6474

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 TRAVERSE LIFT

! WARNING #22: ONE (1) LOCATED

INSIDE CAB ON RIGHT PANEL,
BELOW “Backward Tipover
Hazard” DECAL

MACHINE TIP-OVER OR STRUCTURAL

DAMAGE
Can cause death or severe injury.
Do not exceed rated lift capacities.
Level machine before raising boom.
Lower boom before traveling.
Operate on firm, level surface. LL-6470

! WARNING
PERSONAL INJURY HAZARDS
Can cause death or severe injury.
Wear required personal protective
equipment at all times.

LL-6472

#23: ONE (1) LOCATED ON LEFT OUTER SIDE OF

DASHBOARD PANEL, BELOW “No Riding” DECAL

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Page 34
 #24: ONE (1)
! WARNING LOCATED ON
LEFT OUTER SIDE
OF DASHBOARD
FALL HAZARD BELOW “Personal
Can cause death or severe injury. Injury Hazard”
Do not lift, lower or carry personnel. DECAL
Do not fit machine with any type of work
platform. LL-6490

! DANGER

FALLING BOOM OR LOAD

Will cause death or severe injury.

LL-6464

#25: ONE (1) LOCATED ON

THE UNDERSIDE OF FRONT BOOM, ACTUAL SIZE: 12” x 12”
Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODEL 6036/6044/8036/8044
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TRAVERSE LIFT

! WARNING #26: TWO (2) TOTAL:

ONE ON EACH SIDE
OF FORK CARRIAGE

NO RIDING LL-6468

! CAUTION
HYDRAULIC OIL ONLY.
Must meet following standards to avoid
#27 ONE (1) LOCATED machine damage:
ON TOP OF
HYDRAULIC TANK Hydraulic System Operating ISO
Temperature Range* Viscosity Grade

-5 to 140 °F (-21 to 60 °C) 22

5 to 170 °F (-15 to 77 °C) 32
15 to 190 °F (-9 to 88 °C) 46
30 to 210 °F (-1 to 99 °C) 68

*Temperatures shown are cold (ambient) start-up to maximum

LL-6454

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

Page 36
 #28: ONE (1) LOCATED
BENEATH ENGINE
COWLING ON
! WARNING
PISTON ACCUMULATOR

HIGH PRESSURE HYDRAULIC FLUID

Can penetrate skin causing death, gangrene or other severe
injury.
Seek immediate medical help to remove fluid.
Keep hands and body away from areas ejecting fluid. Use
piece of cardboard to check for leaks.
Wear proper hand and eye protection.
#29 ONE (1) LOCATED
ON TOP OF Relieve hydraulic pressure before loosening any hydraulic
ENGINE COWLING connections.
NEAR RADIATOR CAP Tighten all hydraulic connections before applying hydraulic
pressure.
LL-6494

! WARNING
HOT AND PRESSURIZED FLUID
Can cause severe burns.
Let system cool before removing cap.
Remove cap slowly.

LL-6467

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TRAVERSE LIFT

! WARNING
CARBON MONOXIDE
Can cause death or severe injury.
Operate machine outdoors or in a well
ventilated area.

LL-6492

#30: ONE (1) LOCATED ON RIGHT SIDE OF FRAME,

UNDER FRAME TILT HOSING

! WARNING
HOT EXHAUST PIPE
Can cause severe burns.
Do not touch exhaust pipe when hot or
when engine is running.

LL-6471

#31: ONE (1) LOCATED ON FRAME NEAR EXHAUST PIPE

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Page 38
 #32: TWO (2) NEEDED: ONE

! WARNING
ON EACH SIDE OF FRAME

MOVING BELTS AND SPINNING

BLADES
Can cause loss of fingers or hands.
Keep hands, hair and loose clothing clear
while engine is running.
Disconnect battery before working in engine
compartment.
LL-6469

#34: ONE (1) LOCATED

BEHIND OPERATOR’S
SEAT ON COVER OF
MANUAL
COMPARTMENT

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 TRAVERSE LIFT

MATERIAL SAFETY DATA SHEETS (MSDS)

The Federal Occupational, Safety and Health Administration (OSHA) Standard 29 CFR 1910.1200 and
in some cases, state and local Right-To-Know laws, may require that specific Material Safety Data
Sheets be available to employees prior to operating this equipment. These sheets include information on
substances contained in the equipment such as antifreeze, battery acid, diesel fuel, engine oil, grease and
hydraulic oil.

Upon written request, Pettibone Michigan, L.L.C. will provide the Material Safety Data Sheets
applicable to our product line, at no extra cost. Write to:

Pettibone Michigan L.L.C.

P.O. Box 368
Baraga, MI 49908

Ph. 906-353-6611
Fax 906-353-6325

The customer’s return address, machine model and serial number must be included to ensure a prompt
response.

IDENTIFICATION NUMBERS
Write the machine’s model number, Product Identification Number and serial numbers on the lines
provided below. If necessary, give these numbers to the dealer when parts or information are needed for

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

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

EQUIPMENT
the machine.

Make a record of the numbers. Keep the record in a safe place. If the machine is stolen, report the
numbers to the local law enforcement agency.

MACHINE MODEL NUMBER _________________________________________

PRODUCT IDENTIFICATION NUMBER _________________________________________

ENGINE SERIAL NUMBER

_________________________________________

ROPS SERIAL NUMBER _________________________________________

SAFETY

MACHINE INSPECTION AND DELIVERY REPORT

The Machine Inspection and Delivery report is shipped loose in the back of this manual. Make
sure your dealer performs a checkup within the first 150 hours of operation or 30 days after delivery,
whichever comes first.

NOTE
The customer’s cost for this inspection will be for filters, oil or other accessories.
If the dealer comes to the machine, there may also be a cost for the time and
travel.

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

Page 42
 RIGHT, LEFT, FRONT AND REAR OF MACHINE
All directional references (right, left, front and rear) used in this manual are as seen from the operator’s
seat.

FRONT

LEFT RIGHT

REAR

Figure 2. Directional Reference

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 TRAVERSE LIFT

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
damage to the equipment.

EXPLANATION OF “NOTES ”

Notes are statements that simply provide additional information.

SAFETY PRECAUTIONS

1. Read and fully understand the operator’s manual before attempting to operate the forklift.

2. Always pay attention to decals located on the forklift. Failure to do so can result in death,
serious injury and/or damage to equipment.

3. Only qualified personnel who have received OSHA-required training should operate the forklift.

NOTE:
Effective December 31, 1999, OSHA requires all forklift operators to be trained
according to rule 29CFR1910.178(1).

4. Under no circumstances are passengers allowed to ride on the forklift.

5. Always wear the seat belt when operating the forklift, making sure that the seat belt is properly
fastened and securely tightened. Failure to do so can result in death or serious injury.

6. Controls are to be operated only by the person seated in the operator’s compartment.

7. No personnel should ever walk or stand under a raised boom or walk alongside a moving forklift.

8. Do not operate the forklift near electrical power lines.

9. Do not use the forklift to lift personnel.

10. Raise the boom only if there is sufficient overhead clearance.

Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODELS 6036/6044/8036/8044
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11. Make certain that the load is positioned squarely and evenly on both (or all) forks before
raising.

12. Do not attempt to remove a load from the forks by stopping the forklift suddenly.

13. Do not attempt to raise or land loads that exceed the forklift’s capacity. Refer to the
Specifications table or the Load Chart located in the operator’s compartment.

14. Always pick up a load with consideration to its center of gravity. Position the load on the forks
accordingly.

15. Never land a load in such a way that it may topple. Always land the load squarely on a solid,
level landing area, never on an uneven surface. Stacking loads is not advisable; however if
stacking is unavoidable, exercise extreme caution.

16. Do not operate the forklift or handle loads in a reckless manner.

17. Position the load no higher than eye level when transporting.

18. Always be aware of the machine and load width and the width of the path in which you are
operating.

19. Make certain that the load is stable before transporting. Do not transport or lift loads that are
obviously unsafe or questionable.

20. When driving, do not make any sudden stops or turns.

21. When possible, do not park the forklift on an incline. If parking on an incline is unavoidable,
apply the parking brake and chock the wheels.

22. Do not make modifications to the forklift. Unauthorized modifications can result in death
and/or serious injury to personnel, damage to equipment and/or poor equipment
performance.

23. When leaving the operator’s compartment, always lower the forks to the ground, apply the
parking brake, stop the engine and turn off the key.

24. Prior to starting the forklift, warn all personnel in the area.

25. Do not operate a forklift that is in need of maintenance. Make sure a “Do Not Operate”
lockout tag is placed on a forklift in need of maintenance.

26. Do not operate the forklift in a closed building. Death or sickness from carbon monoxide
poisoning could result. Always operate in a well ventilated area.

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 TRAVERSE LIFT

INTRODUCTION
The Extendo rough-terrain forklift is manufactured by Pettibone Michigan L.L.C., a subsidiary of
the Pettibone L.L.C. The Extendo is designed to provide years of reliable operation with minimal
maintenance.

IDENTIFICATION
FORKLIFT IDENTIFICATION PLATE

The forklift identification plate is located outside, on the left end of a rear frame member of
the operator’s compartment. It contains the equipment model number, serial number and gross
vehicle weight (GVW). (See Figure 3.)

FORKLIFT
IDENTIFICATION
PLATE

Figure 3. Forklift Identification Plate Location

ENGINE IDENTIFICATION PLATE

The Cummins engine identification plate is located on the timing cover at the engine’s left front
(right side of forklift). (See Figure 4.)

TRANSMISSION IDENTIFICATION PLATE

The transmission identification plate is located atop the transmission housing, centered behind the
engine. It contains the model, specification number and serial number. (See Figure4.)

AXLE IDENTIFICATION PLATE LOCATION

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 ENGINE
IDENTIFICATION
TRANSMISSION PLATE
IDENTIFICATION
PLATE

TRANSMISSION RIGHT VIEW ENGINE LEFT VIEW

Figure 4. Transmission and Engine Identification Plate Locations.

AXLE IDENTIFICATION PLATE

(LOCATED ON FRONT RIGHT OF AXLE)

Figure 5. Axle Identification Plate Location.

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 TRAVERSE LIFT

The axle identification plate is located on the backside of the axle, to the right of the differential. The
plate contains the axle part number, serial number and build date. The front axle is mounted with its
backside toward the front of the forklift. (See Figure 5.)

EQUIPMENT DESCRIPTION
FORKLIFT DESCRIPTION
The Extendo is a low profile, rough-terrain forklift with an approximate gross vehicle weight of 24,000
pounds (depending on the options used) and a lifting capacity of 6,000 to 8000 pounds. The Extendo is
equipped with four-wheel drive and a steering system that is capable of two-wheel steering, four-wheel
steering and oblique (crab) steering as selected by the operator.

STANDARD ENGINE DESCRIPTION

The Extendo is equipped with a Cummins Model 4BT3.9-CPL engine. This engine is a liquid-cooled,
four cylinder, four stroke, diesel engine with a displacement of 239 cubic inches (3.9L). The engine is
fuel injected and turbocharged with a rated output of 110 horsepower at 2500 rpm. The compression
ratio is 17.5:1.

TRANSMISSION DESCRIPTION
The transmission has three forward speeds and three reverse speeds. The transmission is equipped with
a mechanical disc-type parking brake, located on the output shaft to the forward drive axle.

AXLE DESCRIPTION
The forklift is equipped with two steerable drive axles. Both axles are equipped with internal, wet-type
disc brakes, located inside the planetaries, and a parking brake in both axles.

OPTIONS
Your Pettibone dealer offers a wide assortment of options for the Extendo forklift, including a variety of
forks, carriages, buckets and more. Contact your dealer for additional information and prices. PRE-
OPERATIONAL CHECKS AND SERVICES

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Page 48
 Notes

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TRAVERSE LIFT

Notes

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Page 50
 OPERATION
This section describes the location and func- 3. Release lever to lock.
tion of each gauge and control in the
operator’s compartment. With the engine
“off”, practice reaching for these controls as ! Do not adjust the operator’s seat
you read about them. This should help you while the vehicle is moving. Operating this
become familiar with their location. machine with one or both hands away from
the steering wheel may result in a loss of
vehicle control.

Entering the Operator’s Compartment Arm Rest

Raise the arm rest for safe entering or exiting
Proper care should be used whenever entering of the operator’s compartment. (See Fig. 2-1)
or leaving the operator’s compartment. Use
the step and grab handle provided and always
keep them clear of debris.

NEVER USE THE STEERING WHEEL

OR ARM REST AS A GRAB HANDLE!

! Use both hands when climbing on

machine. Failure to comply may result in
personal injury.

! Never jump down from the

operator’s compartment when leaving the
machine.

Operator’s Seat
The operator’s seat can be adjusted to move
forward or back. The horizontal adjustment
lock lever is located under the front of the
seat. (See Fig. 2-2)
Fig. 2-1, Arm rest shown in the up position
Adjust the seat as follows: for entering and exiting the operator’s com-
partment.
1. Move lock lever to the left and hold.
Seat Suspension Adjustment (optional)
2. Slide the seat forward or back to your The adjustment for the suspension is located
desired position. under the front of of the operator’s seat. To
adjust for a firmer ride, rotate the knob clock-
wise. To adjust for a softer ride, rotate the
knob counterclockwise. (See Fig 2-2)
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 TRAVERSE LIFT

Fig. 2-2, Location of the seat adjustments. Fig. 2-3, Insert until it “clicks” into place.

Seat Belt
Fasten the seat belt as follows:

1. Position both belts across your lap. If latch belt

is too tight to pull, slide the latch plate up along
the belt webbing. This will provide more belt
slack.

Position the belt across your waist as low on the

hips as possible. This is necessary to spread the
force of the belt over the hipbone instead of
across the abdomen.
Fig. 2-4, Pull loose end of belt to tighten.
2. Insert latch plate into buckle until a “click” is
heard(See Fig. 2-3). Pull the loose end of the belt
to tighten(See Fig. 2-4). To unlock the seat belt,
press button on buckle and pull latch plate from
buckle(See Fig. 2-5).

Make sure that seat belt fits snugly across your

waist with a minimal amount of slack. If the belt
has too much slack, it may not be able to restrain
you in an accident.

Never wear a twisted seat belt.

Pettibone recommends that operators use the

seat belt at all times when driving this machine
Fig. 2-5, Press the button to release the belt.
and will not be held responsible if the operator
does not use the safety restraints available..
Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODELS 6036/6044/8036/8044
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Instrument Panel
The instrument panel indicates the location of each
standard and optional gauge, warning light and control.

Fuel Gauge
Indicates the level of diesel fuel in the fuel tank. The
fuel gauge is electrically-operated and registers only
when the ignition switch in the “on” or “start” posi-
tions. (#4)

Engine Coolant Temperature Gauge

Indicates the temperature of the fluid in the engine
cooling system. Normal coolant temperature for the
Cummins 4BT3.9 engine is 160 - 194° F (70 - 90° C).
(#3)

Do not operate engine if coolant temperature exceeds

212° F (100° C).

Engine Coolant Temperature Warning

Light (Optional)
This light glows red and activates an alarm if the
engine coolant temperature rises above approximately
212° F (100° C).

Engine Hourmeter
Indicates acual hours of engine operation. It records up
to 9,999.9 hours and then restarts at zero. (#5)

Transmission Temperature Gauge

Indicates the temperature of the transmission oil.
Normal Operating Range: 180-250°F (82-121°C)
Red Lined Temperature: 250°F (121°C) (#1)

Transmission Oil Pressure Gauge

Indicates the pressure of the transmission oil.
Normal Operating Range: 240-280 PSI @2200 RPM
(1655-1930 kPa) (#2)

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TRAVERSE LIFT

GAUGES WARNING
LIGHTS

EXTENDO INSTRUMENT PANEL COMPOSITE PARK BRAKE AND CLUTCH

CUT-OFF SWITCHES

INCLINOMETER

Bottom Area of Dash

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Page 54
Inclinometer Axle Lock Warning Light
This instrument shows the degree of deviation (left This light glows orange when the vehicle is in
or right) of the machine frame relative to horizon- axle lock mode (boom above 25°, parking brake
tal ground level. It helps you keep your load level on). (#9)
when operating over uneven terrain. The frame is
approximately level when the inclinometer indi- Brake Oil Pressure Warning Light
cates 0° deviation. (#6)
This light glows red and activates a warning
buzzer if there is low hydraulic brake oil pressure.
(Normally, light should not come on at engine
Parking Brake Switch start-up). (#10)

This switch activates the parking brake when it is

in the up postition, and releases it when it is in the
down position. (#7)

Park Brake Indicator Light

This light glows red when the parking brake is
applied and goes out when brake is released.
BRAKE OFF BRAKE ON NOTE: Parking brake should be applied whenever
any maintenance is performed. (#11)

Clutch Cut-off Switch

This toggle switch disengages the transmis-
sion when you apply the service brake pedal.
Use this feature to increase the speed of your
hydraulic functions. (#8)

Low Voltage Warning Light

This light glows red and activates a warning
buzzer if there is a malfunction of the charging
system. (Light should come on at engine start-up
and go out when engine is revved.) (#12)

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TRAVERSE LIFT

Engine Oil Pressure Warning Light

This light glows red and activates warning
buzzer if the engine oil pressure drops below
normal. (Light should come on at engine
start- up and go out when oil pressure rises to
normal.) (#13)

Ignition Switch
The ignition switch has four positions: ACC,
OFF, ON, and START. (#14)

Sonalert (Warning Buzzer)

BUZZER INGITION
SWITCH
Steering Selector
This lever controls the steering modes: ob-
lique, two-wheel or four-wheel.

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Page 56
 Hydraulic Controls

DISPLAY, CONTROL, OR INDICATOR FUNCTION

HYDRAULIC CONTROLS All hydraulic controls (except the steering

selector) are self-centering to neutral. When
you release them, they return to their center
REMOTE CONTROL JOYSTICK (neutral) positions.

Both joysticks are located on a console to

your right. They control the following boom,
fork frame, and machine frame motions:
1. Raise boom
2. Lower boom
3. Extend boom
4. Retract boom
5. Fork tilt up
6. Fork tilt down
7. Fork side tilt left
8. Fork side tilt right
9. Frame sway right
10. Frame sway left

As shown, the boom and fork frame

functions are controlled by the forward most
joystick and the machine sway functions are
controlled by the rearward joystick. The fork
frame side tilt function is operated by pressing
and holding the left button to tilt the fork
frame left and the right button to tilt the fork
frame right. The front button will tilt the fork
frame forward and the rear button will tilt the
fork frame back. Pushing the rear joystick to
the right will sway the machine to the right
and pushing it to the left will sway the ma-
chine to the left.

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

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TRAVERSE LIFT

Throttle and Brake Controls

DISPLAY, CONTROL, OR INDICATOR FUNCTION

THROTTLE AND BRAKE CONTROLS The throttle and brake controls are shown
below.

BRAKE PEDAL
Depress this pedal to apply brakes to all four
wheels.

THROTTLE PEDAL
Depress this pedal to increase engine speed.

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

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 Transmission Controls

DISPLAY, CONTROL, OR INDICATOR FUNCTION

POWERSHIFT TRANSMISSION
This machine is equipped with a 3 speed
CONTROLS
forward, 3 speed reverse, CLARK-HURTH
COMPONENTS T-12000 Powershift
Transmission.

TWIST GRIP GEAR SHIFTER /

DIRECTIONAL SELECTOR The twist grip on the control lever shifts the
transmission gears and also selects the direc-
tion.

STEERING WHEEL

The steering wheel and gear are of the con-

ventional type. Turning the wheel clockwise
turns the vehicle to the right; turning the
wheel counterclockwise turns the vehicle to
the left.

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

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 TRAVERSE LIFT

1. With engine off, pull the engine oil dipstick from the engine and wipe it clean.

2. Insert the dipstick back into its position in the engine block and withdraw it again.

2. Look into the radiator filler neck to check the coolant level. The proper level is approximately 3/4
inch below the bottom of the radiator filler neck. Add coolant as needed.

3. Replace the radiator cap by pressing down while turning it clockwise.

CHECK TRANSMISSION OIL

1. Start the engine and allow it to idle with the transmission in neutral until the transmission reaches
operating temperature.

2. Remove the transmission dipstick and check the oil level on the dipstick.

ENGINE
OIL
DIPSTICK

Figure 9. Cummins Engine Oil Dipstick.

3. Using a wrench, remove the breather, add transmission oil as needed and insert the dipstick back into
the transmission. Install the breather.

Check the fuel level as indicated on the fuel gauge. Add fuel if necessary.

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

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 3/4 INCH

Figure
CHECK HYDRAULIC FLUID LEVEL10. Radiator Coolant Level Check

The boom should be in the down (frame level) position and fully retracted. Check hydraulic fluid level
as indicated on the sightglass, located on the side of the hydraulic tank. Add hydraulic oil as needed.
Do not overfill hydraulic tank.

TIRES AND RIMS

Inspect the tires for punctures, wear and if applicable, proper tire pressure. Check the rims for missing
lug nuts and wheel studs.

CAUTION
The tire specifications of the Extendo apply to the machine as it was tested in
accordance with ASME B56.6A-1994. Any replacement of tires must meet or
exceed these specifications for sidewall stiffness.

FILTER ELEMENT

DIPSTICK AND
FILL TUBE

IDENTIFICATION PLATE

DRAIN PLUG

Figure 11. Transmission Fluid Dipstick.

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

INSPECTION FOR LEAKS

Visually inspect the area beneath the forklift for puddles, indicating a leak. Locate the cause of the leak
and correct the problem before operating the forklift. Recheck all fluid levels at this point.

GENERAL INSPECTION

Perform a walk-around inspection of the forklift, looking for loose items (tools, shop towels etc.) that
may have been left on forklift. Remove any such items.

The following checks and services are to be performed during forklift operation:

GAUGES AND INDICATORS

Observe all gauges and indicators and be prepared to halt operation in the event of any abnormal indica-
tion. Be constantly aware of the fuel level, engine coolant temperature, transmission oil temperature
and electrical system voltage.

HYDRAULIC FLUID LEVEL

Perform a daily check of the hydraulic oil level and temperature as indicated on the sightglass, located
on the side of the hydraulic tank. Add hydraulic oil if necessary.

CHANGES IN PERFORMANCE

Be constantly alert to changes in the equipment’s operating characteristics. Such changes in

performance are sometimes an indication of a malfunction.

TABLE IV. TIRE PRESSURES

SIZE PLY RATING FRONT REAR

Goodyear 13:00 x 24 12 65 psi 65 psi

Galaxy 13:00 x 24 14 80 psi 80 psi

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

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 OPERATIONAL CHECKS & SERVICES

OPERATING INSTRUCTIONS
STARTUP AND DRIVING

CAUTION
Never operate the starter for more than 20 seconds continuously. Allow 2
minutes between starting efforts. If using starting fluid for a cold weather start,
inject the starting fluid only while the engine is cranking.

1. Start the engine by applying the parking brake, placing the transmission in neutral, inserting the
ignition key into the switch and turning the key clockwise. Release the key when the engine starts.

WARNING
The forklift must be standing still when selecting the steering mode. Serious
injury and/or equipment damage could occur if the mode is selected while the
forklift is moving.

2. Determine which of the following steering modes is to be selected:

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

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 TRAVERSE LIFT

a. OBLIQUE. (Shown in Figure 12 on the following page.) In this position all four wheels will
turn in the same direction. This steering mode should not be used at speeds exceeding 2
MPH.

b. TWO-WHEEL STEER. (Shown in Figure 13 on the following page.) In this position only
the front wheels will steer. Before selecting this mode, the rear wheels must be turned
straight using the 4 WHEEL STEER mode. Use ONLY 2 WHEEL STEER mode when
travel speeds exceed 10 MPH.

c. FOUR-WHEEL (CRAB) STEER. (Shown in Figure 14 on the folling page.) In this mode
the rear wheels will turn in the opposite direction from the front wheels, providing the
shortest turn radius. Do not use 4 wheel steer at speeds over 10 mph.

3. Position the steering selector lever (Figure 15) in the desired mode of steer, either, OBLIQUE (left
position) , TWO-WHEEL STEER (center position) or FOUR-WHEEL STEER(CRAB)
(right position) .

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

Page 64
 STEERING
MODES

Figure 12. Oblique Steering Mode. Figure 13. Two-Wheel Steering

Mode.

Figure 14. Four-Wheel (Crab) Steering

Mode.
Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODEL 6036/6044/8036/8044
Page 65
 TRAVERSE LIFT

4. Raise the forks to a safe travel height by pulling the boom control joystick to the rear until a safe
height is reached.

5. Hold the brake pedal down and select either forward (F) or reverse (R) travel, using the forward
and reverse gear shift lever. While continuing to hold the brake pedal down, select either 1 for
first gear, 2 for second gear, 3 for third gear or 4 for fourth, using the gear shift lever.

6. Make certain that the area around the forklift is clear. Continue to hold the brake pedal down and
release the parking brake.

7. The forklift is now ready to drive by carefully releasing the brake pedal.

WARNING
The Extendo forklift is capable of a maximum speed of 20 mph regardless of
direction. Make certain the intended direction has been selected. Death, serious
injury or damage could result from acceleration in an unintended direction.

HYDRAULIC CONTROL
IGNITION JOYSTICKS
SWITCH

TRANSMISSION
SELECTOR

STEERING FRAME TILT

SELECTOR LEVER

ACCELERATOR

BRAKE
PEDAL

Figure 16. Startup and Driving.

Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODELS 6036/6044/8036/8044
Page 66
RAISING THE LOAD

NOTE
Refer to Figure 16, “Startup and Driving,” for identification of components
mentioned in this procedure.

1. Inspect every load before attempting to lift. Make certain the loads are properly bound and will
not fall apart while lifting and transporting. Also, make sure the weight of the loads are within
the safe lifting range of the forklift.

2. Position the forklift directly and squarely in front of the load.

3. Lower the boom by pushing the front joystick forward until the forks are at the necessary level to
engage the load.

4. If machine is equipped with the Fork Rotate function, level the forks by depressing and holding
either button on the rear joystick. Press the joystick forward to rotate fork frame to the left and
pull the joystick back to rotate the fork frame to the right. (See instruction decal on page 76.)

5. If necessary, adjust the width of the forks to accommodate the load.

6. To position the load for transport:

a) tilt the forks back by pulling the rear joystick back without pressing any buttons,
b) retract the boom by moving the front joystick to the left, and
c) once the boom is down, ensure the forks are tilted back to a stable position by pulling the
rear joystick back without pressing any buttons.

7. Pull the front joystick back to lift the load only enough to clear obstacles. Keep the top of the
load below eye level. The load is now ready to transport.

WARNING
Do not attempt to transport stacked loads. The top of a stacked load may
not be visible to the operator . If the load is too tall, it should be transported
in two or more moves. Failure to do so could result in death, serious injury
or damage to the equipment.

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

Page 67
 TRAVERSE LIFT

Refer to Figure 16, “Startup and Driving,” for identification of components

mentioned in this procedure.

1. Make certain that all the steps outlined in “STARTUP AND DRIVING” have been performed.

2. Always observe the path ahead and be aware of anything to the sides of the path that may pose a
problem and act accordingly. DO NOT OVERDRIVE THE CONDITIONS.

3. Be constantly aware of the area overhead and make sure, before entering an area with limited
overhead, that the forklift will fit. NEVER OPERATE NEAR POWER LINES.

4. Keep the load as close to the ground as possible when moving and DO NOT STOP
SUDDENLY. Approach turns, uneven and/or slippery surfaces slowly. Sound horn and drive slowly
in congested areas.

WARNING
Never attempt to drive across an excessively steep incline, regardless of
circumstances. Serious injury and/or death could otherwise result.
EXERCISE GOOD JUDGEMENT.

5. Driving on inclines or unstable surfaces is unsafe but sometimes unavoidable. If driving

on an incline cannot be avoided, level the forklift by using the Frame Tilt lever as follows
(see Figure 17.):

a. Pull lever to left to tilt the forklift frame to the left.

b. Pull the lever to right to tilt the forklift frame to the right.

6. When traveling on inclines, do so as follows:

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

Page 68
 Maintenance
INTRODUCTION
The information provided on the following pages will allow the owner to establish an effective
preventive maintenance plan. Close adherence to such a plan will add greatly to the equipment’s
performance and longevity. Always keep an accurate record of the maintenance performed. The
maintenance procedures included in the following are those that can be accomplished by the owner,
using common hand tools. For more complex maintenance, contact an authorized dealer or service
representative.

WARNING
Safety while servicing is the user’s responsibility. Only qualified and authorized
personnel should be permitted to maintain, repair, adjust and inspect the machine.

TABLE V. SCHEDULED MAINTENANCE

SERVICE Daily 20 hr 40 hr 50 hr 100 hr 200 hr 500 hr 1000 2000
hr hr

Engine Oil C *CR CR

Engine Oil Filter *CR CR

Fuel Filter CR

Engine Vent Tube Clean

Alternator Belt Adjust

Transmission Fluid C *CR CR

Transmission Filter *CR CR

Hydraulic Fluid C CR

Hydraulic Filter CR

Air Cleaner Element Clean CR

Radiator Coolant C

Battery C

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

Page 69
TRAVERSE LIFT

TABLE IV. SCHEDULED MAINTENANCE . . . (CONTINUED)

SERVICE Daily 20 hr 40 hr 50 hr 100 hr 200 hr 500 hr 1000 2000

hr hr

Axle Differential *CR C CR

Planetary Hubs *CR C CR

Boom Pivot Lube

Front Tilt Cyl. Pivots Lube

Rear Tilt Cyl. Pivots Lube

Quick Attach Pivots Lube

Frame Tilt Cylinder Lube

Fork Tilt Cylinder Lube

Attachments/Hyd. Options Lube

Axle U-joints Lube

Steer Cyl. Pivots Lube

Steer Spindles Lube

Tie Rod End Pivots Lube

Driveshaft U-joints Lube

C= Check Fluid levels and add fluid as necessary * = First hours of operation
CR= Change fluid or replace filter

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

Page 70
 TABLE VI. FLUIDS AND LUBRICANTS
#22.+%#6+10 &'5%4+26+10

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5+0).')4#&' %%/%5RGEKHKECVKQP&QT&

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$GNQYFGITGGU(
FGITGGU% #TEVKE1KN

VQFGITGGU(
VQFGITGGU% 5#'9

VQFGITGGU(
VQFGITGGU% 5#'9

VQFGITGGU(
VQFGITGGU% 5#'9

'0)+0'1+. #2+5GTXKEG%NCUUKHKECVKQP%'QT%'

/7.6+)4#&' %%/%5RGEKHKECVKQP&QT&

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VQFGITGGU% 5#'9

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VQFGITGGU% 5#'9

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VQFGITGGU% 5#'9

'0)+0'%11.#06 ,QJP&GGTG.QY5KNKECVG#PVKHTGG\GQTGSWKXCNGPV

64#05/+55+10(.7+& 6JGHQNNQYKPIJ[FTCWNKEVTCPUOKUUKQPHNWKFUCUCRRNKECDNG

#VVGORGTCVWTGU

#DQXGFGITGG(
FGITGGU% 6[RG%
GZEGRV)TCFG

$GNQYFGITGG(
FGITGGU% 6[RG%
GZEGRV)TCFGYKVJCWZKNKCT[RTGJGCVVQTCKUG
VGORGTCVWTGVQCDQXGFGITGGU(
FGITGGU%
#DQXGFGITGGU(
FGITGGU% 6[RG%QT6[RG%)TCFG

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

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 TRAVERSE LIFT

TABLE VI. FLUIDS AND LUBRICANTS (CONTINUED)

#22.+%#6+10 &'5%4+26+10

#:.'.7$4+%#06 /WNVKRWTRQUGIGCTNWDTKECPVUOGGVKPI/+.5RGE

5+0).')4#&' .CPFUWKVCDNGHQT#2+5GTXKEG%NCUUKHKECVKQP).

5#'964#%6'.(5(

#:.'.7$4+%#06 /KNVKRWTRQUG.KDTKECPVUOGGVKPI/+.5RGE

/7.6+)4#&' .%CPFUWKVCDNGHQT#2+5GTXKEG%NCUUKHKECVKQP).

#VVGORGTCVWTGU

VQFGITGGU(
VQFGITGGU% 5#'9(+0#210610+%/2:

VQFGITGGU(
VQFGITGGU% 5#'(+0#210610+%/2:

016'(+0#210610+%/2:)GCT1KNKUUWKVCDNGHQT
NKOKVGF5NKRFKHHGTGPVKCNU
(TQPV#ZNG+HGZEGUUKXGEJCVVGT
QEEWTUVJGCZNGOWUVDGFTCKPGFCPFTGHKNNGFYKVJQ\QH
CFFKVKXG2CTV0Q#22CPFVJGPHKNNGFYKVJ(+0#
210610+%/2:WRVQVJGPQTOCNNGXGN

)4'#5'<'4-5 0.)+

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

Page 72
 LUBRICATION
All grease fittings on the Extendo are to be serviced with NLGI-2 grease at the intervals specified on
Table IV., “Scheduled Maintenance”. Figures 18a. through 18e., used in conjunction with Table VII.,
“Lubrications Points” show the locations of the various grease fittings.

2
1

5 4

Figure 18a. Machine Lubrication Points

10 3
9 11
8
7
6

17
13 12
18
15 14 19 19
6
16 20 20
21 22
View, Rear of Boom.

Figure 18b. Boom Lubrication Points.

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

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TRAVERSE LIFT

23 24

Figure 18c. Drive Shaft Lubrication Points

25 25

26 26

Figure 18d. Axle Lubrication Points

27
27

28 28

Figure 18e. Chassis Lubrication Points

Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODELS 6036/6044/8036/8044
Page 74
 TABLE VII. LUBRICATION POINTS

ITEM # GREASE POINT LOCATION(S)

1 Lift cylinder, shaft end (2)

2 Lift cylinder, base end (2)
3 Boom pivot pin (2)
4 Hydraulic system return line filter (1)
5 Wheel nuts, four locations
6 Tilt cylinder bushings (2), one on each end of cylinder
7 Machine boom side wear pads (2)*
8 Middle boom spacer blocks (2)
9 Front chain sheave (1)
10 Large boom spacer blocks (2)
11 Large boom side wear pads (2)*
12 Extend cylinder wear pad (1)*
13 Lube line for small boom top wear pads (2)*
14 Large boom bottom wear pad (1)*
15 Middle boom bottom wear pad (1)*
16 Fork frame pivot pin (2)
17 Middle boom rear top wear pads (2)*
18 Rear chain sheave (2)
19 Middle boom rear side wear pads (2)*
20 Small boom rear side wear pads (2)*
21 Small boom rear bottom wear pad (1)*
22 Middle boom rear bottom wear pad (1)*
23 Front drive shaft (3)
24 Rear drive shaft (3)
25 Steering knuckle (8)
26 Axle trunnion mounts (4)
27 Rear stabilization cylinder bushings (2) one on each end of cylinder
28 Sway cylinder bushings (2), one on each end of cylinder

* NOTE: No lube required on Nylatron wear pads

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

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 TRAVERSE LIFT

TROUBLESHOOTING
The following troubleshooting tables provide some of the most common problems occurring in forklifts
and their possible causes. If, after following the recommendations provided, the malfunction is still
present, consult an authorized dealer or service representative.

HOW TO USE TROUBLESHOOTING TABLES

Locate the symptom in the “SYMPTOM” column of the table. Move across the page to the next
column, “PROBLEM.” This column will give the most probable cause(s) of the malfunction. The
“SOLUTION” column will provide the necessary maintenance action to correct the problem. If a
problem cannot be solved by using the troubleshooting tables, contact an authorized dealer or service
representative.

TABLE VIII. ENGINE TROUBLESHOOTING

SYMPTOM PROBLEM SOLUTION

Engine hard to start or will not Improper starting Review starting procedure
start procedure

No fuel Check fuel level

Air in fuel line Bleed fuel line

Cold weather Use cold weather starting aids

Slow starter speed See “Starter Cranks Slowly”

Crankcase oil too heavy Use proper viscosity oil

Improper type of fuel Consult fuel supplier; use

proper type fuel for conditions

Water, dirt or air in fuel Drain, flush, fill and bleed

system system

Clogged fuel filter Replace filter element

Dirty or faulty injection Have authorized dealer or

nozzles engine distributor check
injectors

Injection pump shut-off not Turn key switch to ‘OFF” then

reset to “ON”
Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODELS 6036/6044/8036/8044
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 TABLE VIII. ENGINE TROUBLESHOOTING (Continued)

SYMPTOM PROBLEM SOLUTION

Engine knocks Low engine oil level Add oil to engine crankcase

Injection pump out of time See authorized dealer or

engine distributor

Low coolant temperature Check thermostat

Engine overheating See “Engine Overheats”

Engine runs irregularly or Low coolant temperature Check thermostat

stalls frequently

Clogged fuel filter Replace filter element

Water, dirt or air in fuel Drain, flush, fill and bleed

system system

Dirty or faulty injection Have authorized dealer or

nozzles engine distributor check
injectors

Below normal engine Defective thermostat Check thermostat

temperature

Defective temperature Check gauge, sender and

gauge or sender connections

Lack of power Engine overloaded Reduce load

Air intake restriction Service air cleaner

Clogged fuel filter Replace filter element

Improper type of fuel Use proper fuel

Overheated engine See “Engine Overheats”

Low engine temperature Check thermostat

Improper valve clearance See authorized servicing

dealer or engine distributor

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

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 TRAVERSE LIFT

TABLE VIII. ENGINE TROUBLESHOOTING (Continued)

SYMPTOM PROBLEM SOLUTION

Lack of power (con’t) Dirty or faulty injection Have authorized servicing

nozzles dealer or engine distributor
check injectors

Injection pump out of time See authorized servicing

dealer or engine distributor

Leaking exhaust manifold See authorized servicing

gasket dealer or engine distributor

Defective aneroid control See authorized servicing

line dealer or engine distributor

Restricted fuel hose Clean or replace fuel hose

Low fast idle speed See authorized servicing

dealer or engine distributor

Low engine oil pressure Low oil level Add oil

Improper type oil Drain, then fill crankcase

with oil of proper viscosity
and quality

Clogged inlet screen on oil See authorized servicing

pump pickup tube dealer or engine distributor

Faulty oil pump See authorized servicing

dealer or engine distributor

High oil consumption Crankcase oil too light Use proper viscosity oil

Oil leaks Check for leaks in lines,

gaskets, and oil drain plug

Restricted crankcase vent Clean vent tube

tube

Engine emits white smoke Improper type of fuel Use proper fuel

Low engine temperature Warm up engine to normal

operating temperature
Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODELS 6036/6044/8036/8044
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 TABLE VIII. ENGINE TROUBLESHOOTING (Continued)

SYMPTOM PROBLEM SOLUTION

Engine emits white smoke (con’t) Defective thermostat Check thermostat

Defective injection nozzles See authorized servicing

dealer or engine distributor

Engine out of time See authorized servicing

dealer or engine distributor

Engine emits black or gray Improper type of fuel Use proper fuel
exhaust smoke

Clogged or dirty air cleaner Service air cleaner

Engine overloaded Reduce load

Injection nozzles dirty See authorized servicing

dealer or engine distributor

Engine out of time See authorized servicing

dealer or engine distributor

Engine overheats Engine overloaded Reduce load

Low coolant level Fill radiator, check radiator and

hoses for loose connections or
leaks

Faulty radiator cap Have serviceman check

Loose or defective fan belt Adjust belt tension; replace

as required

Low engine oil level Check oil level; add oil as

required

Cooling system needs Flush cooling system

flushing

Defective thermostat Remove and check thermostat

Defective temperature Check coolant temperature with a

gauge or sender thermometer and replace gauge
or sender as necessary
Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODEL 6036/6044/8036/8044
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 TRAVERSE LIFT

TABLE VIII. ENGINE TROUBLESHOOTING (Continued)

SYMPTOM PROBLEM SOLUTION

High fuel consumption Improper type of fuel Use proper type of fuel

Clogged or dirty air cleaner Service air cleaner

Engine overloaded Reduce load

Improper valve clearance See authorized servicing

dealer or engine distributor

Injection nozzles dirty See authorized servicing

dealer or distributor

Engine out of time See authorized servicing

dealer or engine distributor

Low engine temperature Check thermostat

TABLE IX. ENGINE ELECTRICAL TROUBLESHOOTING

SYMPTOM PROBLEM SOLUTION

Undercharged system Excessive electrical load Remove accessories or install

from added accessories higher output alternator

Excessive engine idling Increase engine rpm when using

heavy electrical load

Poor electrical connections Inspect and clean as

on battery, ground strap, necessary
starter or alternator

Defective battery Test battery and replace as

required

Battery uses too much water Cracked battery case Test battery and replace if
necessary

Battery charging rate too high Test charging system; replace

faulty component

Battery will not charge Loose or corroded connections Clean and tighten connections
Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODELS 6036/6044/8036/8044
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 TABLE IX. ENGINE ELECTRICAL TROUBLESHOOTING (Continued)

SYMPTOM PROBLEM SOLUTION

Battery will not charge (con’t) Sulfated or worn-out See authorized servicing
battery dealer or engine distributor

Loose or defective Adjust belt tension or

alternator belt replace belts

Starter cranks slowly Low battery output See authorized servicing

dealer or engine distributor

Crankcase oil too heavy Use proper viscosity oil

Loose or corroded Clean and tighten loose

connections connections

Starter and hourmeter Blown fuse on magnetic Replace fuse (14 amp)
functions; rest of electrical switch
system does not function

Entire electrical system Faulty battery connection Clean and tighten

does not function connections

Sulfated or worn-out See authorized servicing

battery dealer or engine distributor

Blown fuse (MDL-25) Replace fuse

TABLE X. TRANSMISSION TROUBLESHOOTING

SYMPTOM PROBLEM SOLUTION

Transmission slips Low transmission oil level Fill transmission with

proper oil to proper level

Worn clutches See authorized dealer

Contaminated transmission Drain transmission, replace

oil filter element, and refill with
clean oil. If problem persists,
see authorized dealer

Transmission will not Linkage loose or out of Connect and/or adjust

change into selected gear adjustment linkage
Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODEL 6036/6044/8036/8044
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 TRAVERSE LIFT

TABLE X. TRANSMISSION TROUBLESHOOTING (Continued)

SYMPTOM PROBLEM SOLUTION

Internal damage to See authorized dealer for

transmission valve service

Low transmission oil level Fill transmission with

proper oil to proper level

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

Page 82
TABLE XI. HYDRAULIC SYSTEM TROUBLESHOOTING
SYMPTOM PROBABLE CAUSE REMEDY
Pump not delivering oil Plugged sump strainer. Clean strainer.

Pump driveshaft coupling Remove pump and

sheared (direct drive). determine damage. Replace
defective parts.

Oil suction port in reservoir Remove contamination and

blocked. flush suction line with clean
hydraulic oil. Check sump
strainer for dirt and sludge.

Oil viscosity too heavy to pick Drain system and replace

up prime. with new oil of correct
viscosity (ASTM ISO VG 32).

Air leaks on suction line, (1) Inspect suction line for

pump not priming. leaks by pouring oil over
fittings. Tighten loose
connections.

(2) Check reservoir oil level.

The oil level must be
above the suction port.

(3) Check minimum speed of

pump driveshaft which
may be too slow to prime
the pump.

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

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 TRAVERSE LIFT

SYMPTOM PROBABLE CAUSE REMEDY

Pump makes excessive Partially blocked suction line Remove contamination and
noise or sump strainer. flush suction line with clean
hydraulic oil. Check for
loose lining in suction hose.
Clean sump strainer.

Low oil level in reservoir. Add oil to ‘FULL’ mark on

filler cap/dipstick.

Air leak at pump suction hose Pour oil over fittings and
joint or pump shaft seal. around driveshaft to check
for air leaks. Replace
defective pump seal.

Collapsed suction hose. Test at full rpm as hose may

be normal at low speed, but
collapses at high speed.

Pump never stops pumping, Improper DP setting between Adjust DP pressure setting
oil is excessively hot, or main pump and main directional using the pressure adjustment
directional valve makes valve procedures outlined on page 1-
excessive noise. 46.

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

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MAIN DIRECTIONAL VALVE TROUBLESHOOTING
SYMPTOM PROBABLE CAUSE REMEDY
Oil leaks at either end of Defective O-ring(s) in spool Replace O-ring(s).
spool control.

Oil leaks between Pinched or blown seal(s). Replace seal(s).

sections
Tie rod fasteners not cor- Torque fasteners to 44 ft.
rectly torqued. lbs.
(60 Nm).

Spool does not return to Broken centering spring(s)

neutral position in spool control. Replace spring(s).

Bent spool.
Replace section.
Foreign particles in valve.
Clean valve.

Solenoid for fork frame Defective fuse, switch or

side tilt fails to energize solenoid. Ensure that 12 vdc is
available to solenoid coil. If
no voltage available, replace
fuse or switch. If voltage is
available, replace solenoid.
Defective electrical wire
from switch to solenoid. Repair wiring defects or
replace wiring.
Electrical plug disconnected
from solenoid. Connect plug to solenoid.

No motion, slow or jerky Low oil level in reservoir.

action of hydraulic system Add oil to ‘FULL’ mark on
filler cap/dipstick.
Plugged sump strainer.
Clean strainer.
Valve body cracked inside.
Replace valve section.
Spool not moved to full
stroke. Check spool travel.

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

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 TRAVERSE LIFT

SYMPTOM PROBABLE CAUSE REMEDY

Main valve makes exces- Improper DP setting be- Refer to page 1-46 for
sive noise, oil excessively tween pump and valve. adjustment procedure of
hot, or pump does not stop main valve and pump.
pumping

Load drops when spool Load larger than capacity. Reduce to rated load capac-
moved to a working posi- ity at rated load center.
tion

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

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 REMOTE CONTROL (JOYSTICK) VALVE
SYMPTOM
TROUBLESHOOTINGPROBABLE CAUSE REMEDY
Pilot-operated spools in Improper stand-by pressure. Adjust the pressure compen-
main valve do not shift sator using the instructions
when joystick is actuated on page 1-xx.

Not enough pilot pressure Pilot pressure should be

supplied to main valve. within the range of 500 psi
(±25 psi). If it is not, clean
filter and clean or replace
pilot spool.
Leak(s) in pilot lines from
remote control valve. Tighten pilot hose couplings
or replace defective hoses.

Blocked pilot lines.

Remove contamination and
flush pilot lines with clean
hydraulic oil.

Joystick chatters Pilot pressure too high.

Check pilot pressure using a
600 psi pressure gauge.
Correct pressure should be
within the range of 500 psi
(±25 psi). If pressure is too
high, clean or replace pilot
spool in main directional
valve. (Refer to page 1-12).

Wrong response to Pilot lines connected to

joystick movement wrong valve ports. Reconnect lines to correct
ports.

Joystick does not center Broken centering springs.

Replace springs.

0il leaks between sections Defective section O-ring.

of remote control valve Replace O-ring.

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

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 TRAVERSE LIFT

ACCUMULATOR CHARGING VALVE TROUBLESHOOTING

SYMPTOM PROBABLE CAUSE REMEDY
Accumulator fails to Hi-Low limit switch not Replace Limit switch.
charge working

Solenoid valve not energiz- Check wiring between

ing switch and solenoid. If
wiring is good, replace
solenoid.

Spool in solenoid valve Clean spool and valve.

dirty

Replace spool or whole

Spool in solenoid valve valve as needed.
damaged

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

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 FRAME TILT CYLINDER TROUBLESHOOTING
SYMPTOM PROBABLE CAUSE REMEDY
Cylinder will not Failed hose or hose Replace hose or tighten
operate when toggle switch is connections leaking. loose connections.
actuated

Low oil level in reservoir. Add oil to ‘FULL’ mark on

reservoir dipstick.

Plugged sump strainer. Clean strainer.

Oil bypassing spool in main Replace defective spool

valve. seal(s).

Rod wiper leaking exces- Replace defective wiper.

sively.
Replace defective piston
Oil bypassing cylinder seal.
piston.
Repair or replace pump.
Cylinder drifts (will not
remain in position) Faulty pump operation.
Replace defective piston
seal.
Oil bypassing cylinder
piston.
Replace defective check
valve ball(s) or spring(s).
Oil bypassing dual pilot
check valve on cylinder. Replace defective spool
seal (s).
Oil bypassing spool in main
valve. Replace spool centering
springs.
Spool not centered in main
valve.

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

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 TRAVERSE LIFT

FORK TILT CYLINDER TROUBLESHOOTING

SYMPTOM PROBABLE CAUSE REMEDY
Cylinder will not Failed hose or hose connec- Replace hose or tighten
operate when rocker switch tions. loose connections.
is actuated
Low oil level in reservoir. Add oil to ‘FULL’ mark on
reservoir dipstick.

Plugged sump strainer. Clean strainer.

Oil bypassing spool in main Replace defective spool

valve. seal(s).

Rod wiper leaking exces- Replace defective wiper.

sively.
Replace defective piston
Oil bypassing cylinder seal.
piston.
Repair or replace pump.

Faulty pump operation. Reduce to rated load capac-

ity at rated load center.
Cylinder drifts (will not Load larger than capacity.
remain in position)
Replace defective piston
seal.
Oil bypassing cylinder
piston. Replace defective cartridge
seal(s).

Oil bypassing counterbal- Replace defective spool

ance valve cartridge. seal (s).

Oil bypassing spool in main Replace spool centering

valve. springs.

Spool not centering in main

valve.

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

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 EXTENSION CYLINDER TROUBLESHOOTING
SYMPTOM PROBABLE CAUSE REMEDY
Cylinder will not Failed hose or hose connec- Replace hose or tighten
operate when joystick is tions leaking. loose connections.
actuated
Low oil level in reservoir. Add oil to ‘FULL’ mark on
reservoir dipstick.

Plugged sump strainer. Clean strainer.

Insufficient pilot pressure Check pilot pressure with a

supplied to main valve. 600 psi pressure gauge.
Correct pressure should be
500(±25) psi.

Oil bypassing spool in main Replace defective spool

valve. seal (s).

Rod wiper leaking exces- Replace defective wiper.

sively.
Replace defective piston
Oil bypassing cylinder seal.
piston.
Repair or replace pump.
Faulty pump operation.
Reduce to rated load capac-
Load larger than capacity. ity at rated load center.
Cylinder drifts (will not
remain in position)
Replace defective spool
Oil bypassing spool in main seal(s).
valve.
Replace defective piston
Oil bypassing cylinder seal.
piston.

Replace defective cartridge

Oil bypassing counterbal- seal (s).
ance valve cartridge.
Replace spool centering
Spool not centered in main springs.
valve.
Clean cartridge or replace.
Main relief valve not hold-
ing. Reduce to rated load capac-
ity at rated load center.
Load larger than capacity.
Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODEL 6036/6044/8036/8044
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 TRAVERSE LIFT

MAINTENANCE PROCEDURES
Procedures included in the following paragraphs cover those that can normally be achieved by the
owner or operator, using common hand tools. For more complex maintenance, contact an authorized
dealer or service representative.
REPLACE FUEL FILTER ELEMENT
1. Working through the right side engine compartment opening, clean the filter heads to prevent fuel
contamination during filter element replacement.

2. Using a filter wrench, remove the two filter elements.

3. Apply a light film of engine oil to the inner and outer seal of each element. Make certain that the
inner seal is positioned in the center bore of each element.

4. Fill the first element with fuel and install it on the filter head. Hand tighten the element only. DO
NOT OVER TIGHTEN.

5. Fill the second element with fuel and install it on the filter head. Hand tighten the element. DO
NOT OVER TIGHTEN.

6. Start the engine and allow it to idle while check for leaks. Correct leaks if found.

INNER SEAL

OUTER SEAL

FILTER ELEMENT

Figure 19. Fuel Filter Replacement

BLEEDING THE FUEL SYSTEM

WARNING
Never attempt to bleed the fuel system of a hot engine. A fuel spill on a hot surface
could cause a fire, resulting in serious injury or death.

1. Bleed the low pressure lines and fuel filters as follows:

a. Open the vent screw, located on the side of the filter. (See Figure 20.)
Continued on following page
Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODELS 6036/6044/8036/8044
Page 92
continued from previous page

b. Operate the plunger lever, located on the fuel pump, until the fuel flow from the open vent screw
is a steady stream, free of air.

c. Tighten the vent screw.

2. Bleed the injection pump as follows:

a. Open the vent screw, located on the injection pump.

b. Energize the fuel solenoid.

c. Operate the plunger lever, located on the fuel pump, until the fuel flow from the injection pump
bleed port is free of air.

d. Close (tighten) the vent screw and de-energize the fuel solenoid.

3. Bleed the high pressure fuel lines as follows:

WARNING
The pressure of the fuel in these lines is great enough that the fuel escaping can penetrate
the skin, causing serious and possibly long-term injury.

a. Loosen one or more of the high pressure lines at the injectors.

b. Crank the engine while observing the fuel flow.

c. When the fuel flow is free of air, stop cranking the engine and tighten the high pressure lines.

d. Start the engine and allow to idle.

e. Bleed each high pressure line individually, with the engine idling, to remove any air that may yet
be in the lines.

VENT
SCREW

PRIMING
LEVER

Figure 20. Bleeding the Fuel System

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

SERVICE AIR CLEANER

1. Loosen the cup assembly retaining clamp and remove the cup assembly from the air
cleaner housing.

2. Remove the wing nut from the center post of the air filter housing and remove the primary
filter element.

CAUTION
Remove the safety element only if it is to be replaced. DO NOT attempt to clean the
safety element. If the safety element is to be replaced, immediately install a new
element in its place to prevent contaminants from entering the engine.

3. Remove the wing nut from the center post of the canister and remove the safety element.

4. Install the safety element immediately by positioning it in the air cleaner housing and
installing the wing nut.

5. Gently pat the sides of the primary element to loosen dirt. DO NOT tap the element
against a hard surface.

CAUTION
When using compressed air to clean the element, make certain the air pressure is less
than 30 psi. Clear the area of bystanders, guard against flying chips and wear proper
protective safety equipment, including eye protection.

6. Clean the primary element from the inside with compressed air. Hold the nozzle next to
the inner surface and move up and down pleats. Repeat as necessary until clean.

7. If necessary, wash the primary element, as follows:

a. If the element is coated with oil or soot, wash it in a solution of warm water and filter
element cleaner. Let the element soak at least 15 minutes, then agitate gently to flush
out dirt.

b. Rinse the element thoroughly from the inside with clean water. Keep the water pressure
under 40 psi to avoid damaging the filtering pleats.

c. Allow the element to dry completely before using. This usually takes from one to three
days. Do not oven dry or use drying agents. Protect the element from freezing until it is
dry.

8. Inspect the primary element as follows:

a. Hold a bright light inside the filter element and check it for holes. Discard the filter
element if holes are found.
Continued on next page
Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODELS 6036/6044/8036/8044
Page 94
 b. Inspect the outer screen for dents. Discard the element if dented.

c. Check the filter gasket for nicks and distortions. Replace the element if the gasket is
nicked, distorted or damaged.

WING ELEMENT HOUSING

NUT

Figure 21. Air Cleaner Service.

9. Install the primary filter element as follows:

a. Position the primary element over the safety element, inside the canister.

b. Install the wing nut to secure the element.

c. Position the cup assembly on the air cleaner housing.

d. Install the cup assembly retaining clamp and tighten.

DRAIN AND REFILL COOLING SYSTEM

1. Place a drain pan beneath the radiator drain valve.

2. Remove the radiator cap, open the drain valve and allow the radiator coolant to drain.

3. Position a drain pan beneath the engine coolant drain plug, located on the underside of the engine
water inlet.

4. While holding a long-spout funnel beneath the water inlet, remove the drain plug and allow
coolant to drain into the pan.

5. Install the drain plug after the coolant has drained.

continued on next page
Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODEL 6036/6044/8036/8044
Page 95
TRAVERSE LIFT

6. Close the radiator drain valve.

7. Fill the radiator with a mixture of 50% ethylene glycol antifreeze and 50% water.

8. Install the radiator cap and operate the engine until it reaches a temperature of 180oF and check for
leaks. Correct any leaks found.

ENGINE
WATER
INLET
LOCATED IN
LEFT REAR
OF ENGINE
COMPARTMENT RADIATOR
HOSE

Figure 22. Draining and Refill Cooling System

THERMOSTAT TEST

1. Place the thermostat in a pot of water and position a thermometer to indicate water
temperature.

2. Heat the water on a burner while observing the thermometer.

3. The thermostat should open when the thermometer indicates a water temperature of
180 degrees F. If not, replace the thermostat.

THERMOSTAT THERMOMETER

Figure 23. Thermostat Test. Continued on next page

Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODELS 6036/6044/8036/8044
Page 96
DRIVE BELT TENSION ADJUSTMENT
The Cummins engine is equipped with a spring-loaded tensioner and requires no drive belt adjustment.

BATTERY REPLACEMENT

WARNING
The Environmental Protection Agency has established guidelines for the disposal of
batteries. Make certain that EPA requirements are met when disposing of batteries.

1. Unlock and open door at rear of unit where battery box is located.
2. Unfasten the hold down strap and remove the lid from battery box. (See Figure 23.)
3. Remove the nut from each battery post.
4. Remove the battery ground cable from the negative (-) battery post, then remove the positive cable
from the positive (+) battery post.
5. Loosen the two battery clamp nuts and lift the hold-down clamp from the battery.
6. Remove the battery box from the from the forklift.
7. Position the new battery in the battery box.
8. Replace the battery box in rear of forklift.
9. Place the battery hold-down clamp on the battery with the threaded rods of the clamp hooked into the
slots provided.
10. Tighten the hold-down clamp nuts.
11. Position the battery cables on the posts in the following order, first the red cable to the positive (+)
post and then the black cable to the negative (-) post.
12. Install a nut on each battery post.
13. Replace the battery box lid and securely refasten hold down strap.
14. Dispose of the old battery in a manner approved by the EPA.

HOLD DOWN STRAP

(NOT SHOWN)

BATTERY
BATTERY BOX LID
BOX

Figure 24. Battery Replacement

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

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 TRAVERSE LIFT

FUSE REPLACEMENT

1. Using a phillips head screwdriver, remove the four screws on the fuse panel cover, which is located
below the operator’s panel on the left.

2. Remove the panel cover to reveal the fuse panel at the lower left.

3. Using a fuse puller, remove the faulty fuse and replace.

4. Replace the panel cover and refasten the screws.

ENGINE OIL CHANGE

WARNING
Never dispose of engine oil by pouring it on the ground or down a drain.
Contact the local EPA or Cummins distributor for information.

1. Operate the engine until the engine water temperature reaches 140o F.

2. Position a drain pan beneath the engine oil pan drain plug.

3. Remove the oil pan drain plug and allow the oil to drain into the drain pan.

4. Using a filter wrench, remove the filter element.

5. Apply a light film of engine oil to the filter element gasket and fill the filter element with engine oil.
Install and hand tighten the element only. DO NOT OVER TIGHTEN.

6. Install and tighten the engine oil drain plug.

7. Fill the engine crankcase with oil to the proper level as indicated on the oil dipstick.

8. Start the engine and allow the oil pressure to come up to operating pressure. Check for, and correct,
any oil leaks.

FILTER
WRENCH
FILTER
ELEMENT

Figure 25. Engine Oil Filter

Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODELS 6036/6044/8036/8044
Page 98
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TRAVERSE LIFT

TRANSMISSION OIL CHANGE

NOTE
Transmission oil should be changed with the transmission warm.

WARNING
Never dispose of transmission oil by pouring it out on the ground or
pouring it down a drain. Contact the local Environmental Protection
Agency (EPA) office or the nearest Clark Distributor for proper disposal
information.

1. If this is the first transmission service, fill the transmission with four (4) gallons of C-3 type transmission oil. If
this is not the first time the transmission has been serviced, disregard this step and proceed to step two.

2. Position a container beneath the oil drain plug located on the lower front of the transmission.

3. Remove the plug and allow the oil to drain into the container. Install the drain plug.

4. Fill the transmission to the proper level shown on the dipstick.

5. Start the engine, put the transmission in neutral and check the oil level on the transmission joystick.

6. Dispose of transmission oil in a manner prescribed by the EPA.

FILTER
ELEMENT

DIPSTICK AND
FILL TUBE

IDENTIFICATION
PLATE

DRAIN
PLUG

Figure 26. Transmission Drain Plug Location.

Pettibone Michigan, L.L.C. OWNER/OPERATOR MANUAL MODELS 6036/6044/8036/8044/10044/10056

Page 99
 TRAVERSE LIFT

TRANSMISSION FILTER ELEMENT REPLACEMENT

1. With the engine shut off, place a container beneath the transmission filter, located at the right front of
the engine compartment.

2. Using a filter wrench, remove the filter element.

3. Apply a light coat of transmission fluid to the surface of the element’s gasket.

4. Install element onto filter base and hand tighten only.

5. Start engine and check for leaks. Tighten element if leaking.

AXLE LUBRICANT CHANGE

WARNING
The Environmental Protection Agency has established guidelines for
lubricant disposal. Contact the local office of the EPA or the nearest
axle manufacturer distributor for the proper disposal procedure.

1. Position a container beneath the differential drain plug, located on the underside, center of the axle.

2. Remove the drain plug and allow lubricant to drain into the container.

3. After the axle has drained, install the drain plug and remove the high lubricant level inspection plug.

4. Fill the axle through the high lubricant level plug opening until the lubricant level is even with the
bottom of the opening. Install the plug.

5. To drain a planetary, park the forklift so that the drain plug on the planetary is in the lowest position.
Remove the plug and allow the planetary to drain. After draining, park the forklift so that the arrow,
located on the face of the planetary hub, is pointed downward. Fill the planetary to a level even with
the bottom of the drain plug opening. Install the drain plug. Repeat this step for each planetary.

HIGH LUBRICANT LEVEL

INSPECTION PLUG

DRAIN PLUG

Figure 27. Axle Drain and Fill Plug Location.

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

Page 100
 SUMMARY
This manual has been furnished by Pettibone Michigan L.L.C. to be used as a guide for equipment
operation and routine maintenance. Remember, this machine can be extremely dangerous when operated
recklessly. The most important safety feature of a Pettibone machine is the operator.

The Extendo is designed to encourage daily, routine maintenance by locating maintenance points in
easily accessible locations. Constant adherence to the maintenance schedules listed herein will serve to
lengthen the usable life of this machine. Should a problem arise which you cannot resolve, contact your
servicing dealer immediately, or call us at (906) 353-6611; we’re here to ensure your satisfaction with
Pettibone Michigan products.

THANK YOU FOR CHOOSING PETTIBONE

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

Page 101