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8044 service manual

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1. S In POWER WHICH IS AN IP66 EQUIVALENT LAT LED Y 7 CONNECTOR PINOUTS PING DESCRIPTION p 1 OT AVAILABLE 4 LN 2 OT AVAILABLE 5 PUSHBUTTON TILT RIGHT 7 Cp ose 4 PUSHBUTTON 22 GROUND TO PUSHBUTTONS BL 6 5VDC TO PUSHBUTTONS PIN 14 7 PUSHBUTTON TILT DOWN 8 PUSHBUTTON TILT UP 9 OT AVAILABLE 10 OT AVAILABLE 11 VALVE 12V SUPPLY SWITCHED 12 VALVE 12V SUPPLY SWITCHED 15 NOT AVAILABLE 14 NOT AVAILABLE a 5 FORK TILT UP VALVE 6 AUX 2 PUMP Tz 7 AUX 1 NOT U
2. a g FORK UP 5 SOLENOID RH JOY N BUTTON JOYSTICKS 2 AXIS DRIVER EX 1690 BLU FORK DN SOLENOID 2 11 BLK T 8 GRY 23 YEL zi H JOY 7 YEL 22 GRN BUTTON 5 RED 21 BLU T690 GRNTB a 5 BLK Ic 20 BLK gt 4 GRN 19 RED 1696 BLK 07 Orar 12 mo 15 GRY 1690 Y 8 59 16 MODA o 4 PON ee gt 5 AUX CN JOY 5 SOLENOID A amp BUTTON 8 45 AUX CCW E SOLENOID B voy 2 BUTTON g 8 ks E of 5 01 8 lt lt D1 A 14 16 DK GRN 16 RED TRANS TEMP GUAGE TRANSMISSION TEMP SENDER 22 pru M 1690 8L ENGINE COOLANT TEMP GUAGE 37 3 C ENGINE COOLANT TEMP SENDER O OIL PRESS WARNING LIGHT 17 4 lt lt TO3 16 8LU SS 85 16 800 z ENGINE OIL PRESS SWITCH 83 16 GRY 11 14 REDAWHT 12 14 REDAWHT 13 16 PNK 116 16 6RY T 82 16 GRY B3 16 GRY 17 16 RED PULSE f ALARM BUZZER 13 16 PNK d Bl CONSTANT z WATER TEMP ENGINE COOLANT WARNING LIGHT OPTIONAL 5 TEMP SWITCH OPTIONAL 107 16 YEL lt lt 78 16 YEL D 16go YEL FUEL LEVEL GUAGE FUEL LEVEL SENDER 47 6 2 C2 B 104 16 046 lt lt 80 16 08G ENGIN
3. 16 REMOTE CONTROLLED MAIN DIRECTIONAL VALVE 18 REMOVAL OF MAIN na chaste ace aerate ti dose a a 20 INSTALLATION OF MAIN VALVE a ee i deu Mt 20 MAIN DIRECTIONAL VALVE TROUBLESHOOTING 2 21 HYDRAULIC REMOTE CONTROL VALVE JOYSTICK 1 rennen nennen 22 REMOVAL OF REMOTE CONTROL VALVES se ee re ee re ee rere e rere e re ree rere eas 22 INSTALLATION OF REMOTE CONTROL VALVE 24 REMOTE CONTROL JOYSTICK TROUBLESHOOTING 35353 ota Eee one 25 FORK AND AUXILIARY HYDRAULIC JOYSTICK WITH 2 Axis DRIVE CARD 2 2 02 26 JoYSTICKSP VVINI TROUBLESHOOTING 0 31 STEERING Brizio TETTE TETTE DS 33 34
4. BMC 38 PAM SUD LS MI IM eae sles Fe dat LE p MEA LA 38 POR NS UTR Mle Seana haar abs a a nee UICE M 38 NAIVE T UIT 39 STEERING SELECTOR stars t doceat EE eda eR ie Ml 40 STEERING SELECTOR VALVE REMOVAL 2 1 40 STEERING SELECTOR TROUBLESHOOTING coetu oe tue Debe e DI E Wee ups e cu er Meo dd 41 CG YUINDERS LA M MI ELI NEUE DD 43 DISASSEMBLY OF CYLINDER GENERIC aa 44 ASSEMBIY OF C YUNDER GENERIC 5 44 CYLINDER COMPONENTS Satire conte eae nan ua 46 eod 47 INSTAVEATION OF LIFT CYLINDER FUE LC M A EAM ILIA 48 TORQUE SPECIFICATIONS mete ier a EE bU 48 la Ey CYENDER LROUBEBSHOOTING D DR pL 49 REMOVAL OF FRAME
5. E UI DEUS P 154 PETTIBONE TRAVERSE Lirr LLC PAGE 3 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL NOTES PETTIBONE T RAVERSE LLC PAGE 4 HYDRAULIC SYSTEM FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL E yu 0 L EAT SS gt PETTIBONE TRAVERSE Lirr LLC PAGE 5 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL GENERAL This section consists of service instructions and troubleshooting charts for serviceable components of the hydraulic system Follow ing this information are hydraulic schematics luid escaping from a small hole can be almost invisible Use a piece of cardboard or ood rather than hands to search for sus oected leaks Fluid under pressure Never attempt to disconnect any hydraulic lines unless boom and hydraulic operated components are secured without possibility of movement in any direction Relieve hydraulic system pressure by working control levers A circuit may be completely depressurized by remov ing a pin from either rod end or base end of cylinder s High pressure fluid and falling components may cause injury or death Escaping fluid under pressure can have sufficient force to penetrate the skin causing serious personal injury Before disconnecting lines relieve all pressure Before applying pressure to the system be sure all conne
6. 124 BOOM DISAS SENE noe o Deere cci cea 124 8 000 10 000 44 BOOM 125 BOOM MN 126 BoOOM IJISASSEMBEY 137 FORK CYLINDER INSTALLATION 1 sese p seres snis 138 FORK CYLINDER TROUBLESHOOTING 140 BooMANSTAEEATION 2 de 141 BOOM REMOVALS 145 10 000 POUND 56 FIXED BOOM ieee 147 ARE NNMERO 148 COMPLETE DISASSEMBLY 1 5 DL 149 amp amp ae oT Pe 153 BOOM IREMOVALTING TALDATION gute UE 153 TORQUE VALUES
7. A red PCTM fuel control solenoid plug If absent replace PCTM Verify resistance continuity between blk and pin A red If open replace fuel control solenoid Short low oil pressure switch leads together If alarms operate replace switch Disconnect gry lead on low oil pressure switch If alarms stop replace pressure switch Replace bulb FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL ENGINE TROUBLESHOOTING SYMPTOM PROBABLE CAUSE REMEDY Low oil pressure light on pulse alarm silent engine Defective alarm sonalert alarm not running NOTE TO PROTECT THE ENGINE VERIFY PROPER ENGINE FUNCTION OIL PRESSURE AND TEMPERATURE BEFORE SUSPECTING A WARNING MALFUNCTION solenoid hammering troubleshooting Use a 3 VDC scale voltmeter to Defective starter read voltage drop across starter solenoid High contact solenoid B and M posts Voltage resistance drop should not exceed 0 2VDC Repair or replace solenoid positive Use a 3 VDC scale voltmeter to read positive side voltage drop between battery post Excessive cranking and starter solenoid B terminal circuit resistance post Voltage drop should not exceed 0 4 VDC Repair or replace dirty corroded or loose battery cables negative ground Read negative side voltage drop between battery post and starter motor ground term
8. Pressure Checks Valve in Back Brake manifold Pilot adjust screw PETTIBONE TRAVERSE Lirr LLC PAGE 7 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 3 Set Pressure Compensator on hydraulic pump Locate the load sense relief adjustment on the main valve and turn the adjustment clockwise until it bottoms out This sets the main load sense relief at its maximum setting Valve in Back Style Machines PETTIBONE T RAVERSE LLC PAGE 8 Locate pressure compensa tor setting on the hydraulic pump With a 5000 psi gauge on the System Pres sure diagnostic point retract the boom and hold the func tion in the retract mode to deadhead the system Adjust the pressure compensator on the pump to 3450 psi or 25 psi This adjustment is located on the lower quarter of the pump on the side closest to the operator com partment m TOWARDS ENGINE np Shaft End PRESSURE COMPENSATOR ADJUSTMENT Mes nv WA 1 Ld din Pressure Compensator adjustment PRESSURE DIFFERENTIAL ADJUSTMENT a Once the pressure compen sator has been set the load sense pressure relief on the main control valve must be adjusted Set load sense pressure initial conditions for this procedure are with the engine running anda 5000 psi gauge connected to the load sense pressure test port FIXED AND TRAVERSING FORKLIFT ADVANCED
9. FRONT AXLE BRAKE AND STEERING LINES PETTIBONE T RAVERSE LLC PAGE 86 n m9 wn 4 ee BRAKE wmm b el SERVICE BRAKE REAR AXLE BRAKE AND STEERING LINES 5 Lastly put the tires back onto the axles AXLE REMOVAL For the removal steps just follow the installa tion steps in the reverse order INDEPTH SERVICE Please refer to the correct Carraro axle manual that was shipped with your machine for further disassembly and troubleshooting PAGE 87 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL REAR AXLE STABILIZATION MANIFOLD HYDRAULIC SCHEMATIC SYMBOL PETTIBONE TRAVERSE Lirr LLC FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL REAR AXLE STABILIZATION MopEs 5505 v O O 9 T gt d a U D U c ae Lg 9 Fully Locked Mode Boom Up P Brake restricted Mode Boom Up P Brake Off PETTIBONE T RAVERSE LLC 88 REAR AXLE STABILIZATION TROUBLESHOOTING SYMPTOM PROBABLE CAUSE REMEDY Rear axle not free with boom down park brake Defective oscillation limit switch OFF lock light fuse OFF restrict light OFF Defective oscillation limit relay Defective solenoid s coil FIXED AND TRAVERSING FO
10. 1 With the boom on appropriate stands remove bulkhead fittings and hoses and extension cylinder bracket from back of boom 4 Remove tubes from boom manifold and then remove manifold from underside of boom and cap manifold fittings Do not remove hoses at this time Pull hoses and chain from boom 1 as boom is being pulled apart top of boom 1 PETTIBONE TRAVERSE Lirr LLC 149 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 5 Remove bolt from boom 1 bottom roller 8 Remove top rollers from back of boom 2 With boom still connected attach hoist to then remove 4 bolts from extension boom 2 and start pulling boom 2 from cylinder and manually pull from boom 2 boom 1 Once boom 2 is partly removed Attach hoist at midpoint of extension from boom 1 remove pin and bottom cylinder and remove completely from rollers from boom 1 boom 2 D E 6 If necessary use a wood blockother means against back of exrtension cylinder to help push boom 2 from boom 1 7 Once boom 2 is almost out of boom 1 attach another hoist to boom 4 and adjust boom 2 hoist to help balance boom 2 once it is completely removed from boom 1 Place boom on appropri ate stands PETTIBONE T RAVERSE LLC 150 E c 3 fm MC d 10 Remove hose sheaves mcm 11 Remove side and top wear pads near the front of boom 2 then remove the chain sheave
11. g ACCY FUSES R4 4 32 16 RED 86 5 85 S 14go RED BLK 87 E Z6 14 RED WHT 87A x AO La 5 99 16 YEL RED 2 M a E 1690 BLK 5 5 5 gt 1 5 d 38015 gt SA F1 FS M 10A WIPER 98152 re ORG GRN A 5 FSS park 4705 WIPER SWITCH ORG B K 2 16ga RED WHT DEFROSTER DEFROSTER SWITCH 5 18 BRN BLU a 8 8 169 2 9 6 E pe HEATER 5 1 98 nion FAN z 5 2555 0 0 16 10A HEATER z BUD 5 4 16g0 BRN YEL 5 8 START LOCKOUT R8 HEATER SWITCH 86 Izd 85 1 58 16 BRN WHT 87 57 18 0RG WHT 30 87h 4 39 16 PINK 8LK PARK BRAKE PARK BRAKE SWITCH F8 10A PARK BRAKE SOLENOID E4 A t4 B 10 16 RED BLK 35 16 gt lt lt 52 25 12 RED VIO 56 16 0RG 16g0 0RG WHT 62 16 WHT F12 5A BRAKE INST LIGHTS DASH LIGHT 11 12 1 4 RED NHT 13 16 9NK 39 16 P INK BL 44 16 LT GRN 49 18 BRN 17 16 RED 44 16 LT ORN 25 12 RED V10 OSCILLATIO AND DASH LIGHTS NOT SHIFTE
12. 3 65 16 PUR 4 16 sei CHARGE 5001625 z PRESS SWITCH 7 ACCUM CHARGE x es a SOLENOID z 87A sauwit ESS 24 5 x 61 16 16 8LK e 8 WH AUX LOAD SENSE R9 5 P DE CLUTCH 2 5 7 2 gt 5 2 73 2 D 5 6 525 2 4 8 STEERING STEERING SOLENOID B x SWITCH ER 415 gt STEERING 2 gt 9 trey 9 Es 6 1 6 2 5 MEE ee 87 16 8 0 lt lt UK Ez 5 g Ed STEERING a ste SOLENOID A 3 T6 18 0RG7RED CRAB LOCK AND LIMIT RELAYS INCLUDED ON THE 6056 TURN SIGNAL SWITCH SHOWN IN NEUTRAL 2 amp m 5 amp 8 515 8 zs Shy ac z rO AM e E 5 5 24 as 512 8 G2 cese 25 gt 3 EL RED i E 2300 v i 18 16 5 X 3 PNK AAT 8 1916 E 19 16 WHT BLU 4 d FLASHER 50 PSIG 5 e F13 BRAKE PRESS lt lt SWITCH 6 t 38 6 PNK WHT 15 DE CLUTCH 8 TURNING SIGNAL 6 50 lt lt Wz 5 7 L lt pH JE o RR STOP TAIL OIRECTIONAL LIGHT fg B C6 C CGE E e LR STOP TAIL DIRECT IONAL LIGHT 558 0 amp
13. For accumulators having gas valve 1 Remove gas valve guard and cap 2 Back gas check T handle all the way out counter clockwise before attaching charging assembly to accumulator gas valve 3 Close bleed valve 4 Attach swivel nut to gas valve and tighten 10 15 in Ib 11 5 17 cm kg PETTIBONE T RAVERSE LLC 5 Turn gas chuck handle all the way down This will depress core in gas valve and check pressure 6 To remove gauging assembly turn handle all the way out on gas check Figure 1 then open bleed valve 7 Hold gas valve from turning loosen swivel nut remove assembly 8 Replace gas valve cap 10 15 in Ibs 11 5 17 kg and valve guard Remove from Hydraulic System Shut equipment down and make certain that hydraulic pressure at the accumulator 15 at zero At this point the piston will be bottomed at the hydraulic end For accumulators having gas valve attach gauging assembly then follow steps 1 through 5 Open bleed valve until all gas precharge is relieved from accumulator Next remove gauging assembly and gas valve Remove accumulator from hydraulic system Threaded holes in hydraulic cap may be used as a means of attachment for lifting or use a sling around the body 68 DISASSEMBLY OF ACCUMULATOR Lay the accumulator horizontally and hold down with a strap wrench or in a vise Some accumulators may have both end caps threaded into
14. Load larger than capacity 56 REMEDY Replace hose or tighten loose connections Add oil to FULL mark on reservoir GAUGE Check pilot pressure with a 600 psi pressure gauge Correct pressure should be 300 25 psi Replace defective spool seal s Replace defective wiper Replace defective piston seal Repair or replace pump Reduce to rated load capac ity at rated load center Replace defective spool seal s Replace defective piston seal Replace defective cartridge seal s Replace spool centering springs Clean cartridge or replace Reduce to rated load capac ity at rated load center FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL REMOVAL INSTALLATION OF STEERING CYLINDER HEAVY COMPONENTS BEFORE REMOVING NSTALLING CYLINDER CHECK ITS WEIGHT AND MAKE PROVISIONS FOR ATTACHING AND LIFTING SIDER WHAT REMOVAL OF THE COMPONENT WILL DO TO THE STABILITY OF THE MACHINE UsE A HOIST CAPABLE OF SUPPORTING THE WEIGHT SLIPPING OR FALLING COMPONENT MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL Refer to your Carraro Axle Manual for steering cylinder removal and installation NOTE THIS CYLINDER IS DESIGNED TO BE REPLACED WHEN THERE IS A PROB LEM WITH IT RATHER THAN BEING RE BUILT FOR REPLACEMENT PART NUM BERS REFER TO THE PARTS MANUAL PETTIBONE TRAVERSE Lirr LLC PAGE 57 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL
15. as etude et 69 NEUEN 69 ACCUMULATOR ED REDI RM UL 70 DRIVESHAFTS e DET Du 71 DISASSEMBLY OF DRIVESHAFT Lente ed eee Destra stre d ED E 72 ASSEMD OF DRIVESHAFT a iride n np id do unn bete UNE MeL i oS n 72 INSTALLATION OF DRIVESHAFT SM 73 DRIVE SHAFT TROUBLESHOOTING 15 77 ENGINE TRANSMISSION ASSEMBLY 78 IJI SAS SEMBLE eaaa awe Ld M e ETRE NPE 19 Te 123 eres sina a ed ee a 19 CARRARO TRANSMISSION CONTROL 1 80 TRANSMISSION TROUBLESHOOTING du rA te Ede Ge alta AG 80 PIES 83 ALE
16. DRIVESHAFT TROUBLESHOOTING Lack of lubricant Driveshaft assembly is out of balance Backlash due to worn cross or bearing Off center rotation due to worn slip joint Yokes are not in line Driveshaft out of balance Driveshaft sprung from contact with obstruction Excessive run out or dis torted yokes Loose flange nut on trans mission or differential flange Parking brake drum warped Off center rotation due to worn slip joint PAGE 75 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL REMEDY Check bearing cap grease seals for wear Replace if worn Lubricate with correct grade of grease specified Check for proper alignment Clean dirt from driveshaft Check for missing balance weights Replace cross and bearing assembly as a complete unit Replace slip joint or driveshaft assembly Check for proper driveshaft alignment See Assembly of Driveshaft Replace driveshaft assem bly Replace driveshaft assem bly Disassemble and correct or replace damaged parts Tighten nut and check splines If worn replace driveshaft assembly Replace parking brake Replace slip joint or drive shaft assembly PETTIBONE TRAVERSE Lirr LLC FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL NOTES PETTIBONE T RAVERSE LLC PAGE 76 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL NOISSINSNV PETTIB
17. FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 25 Next install sheave assembly and tighten 26 Now you re ready to install the mid tip boom into the main section of the boom Attach a hoist to the mid tip section of the boom and feed the hoses through the opening in the main boom as you col lapse the boom sections together Hal PETTIBONE TRAVERSE Lirr LLC PAGE 133 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL Lu 27 Temporarily install a block into main boomto prevent damaging retract chain and readjust your hoist and continue to collapse the boom sections PETTIBONE T RAVERSE LLC 28 Install the hoses onto the boom manifold tighten and install manifold onto underside of main boom PAGE 134 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 29 Install retract chain bolt through retract 30 Attach extend chains to boom chain plate and bottom wear pad onto main section of the boom r x j 4 4 5 i L M NOTE APPLY ANTISEIZE TOALL CHAIN ANCHOR BOLTS PETTIBONE TRAVERSE Lirr LLC PAGE 135 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 31 Install the top and side wear pads and 32 Attach a come along to tip end of boom shims to the main section of the boom and end of main boom with a spacer NOTE WE TAPE THE SHIMS
18. REMEDY Replace hose or tighten loose connections Add oil to FULL mark on reservoir dipstick Clean strainer Check pilot pressure with a 600 psi pressure gauge Correct pressure should be 300 25 psi Replace defective spool seal s Replace defective wiper Replace defective piston seal Repair or replace pump Reduce to rated load capac ity at rated load center Replace defective spool seal s Replace defective cartridge seal s Replace defective piston seal Replace spool centering springs Reduce to rated load capacity at rated load center PETTIBONE TRAVERSE Lirr LLC FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL REMOVAL OF FRAME TILT CYLINDER HEAVY COMPONENTS BEFORE REMOVING CYLINDER CHECK ITS WEIGHT AND MAKE PROVI SIONS FOR ATTACHING AND LIFTING CONSIDER WHAT REMOVAL OF THE COMPONENT WILL DO TO THE STABILITY OF THE MACHINE USE A HOIST CAPABLE OF SUPPORTING THE WEIGHT A SLIP PING OR FALLING COMPONENT MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL 1 Park machine on firm level surface Engage parking brake 2 Install blocking to prevent unit from tipping when cylinder is removed 3 Clean hydraulic connections at cylinder with a cleaning solvent 4 Match mark the hydraulic lines and cylinder ports to ensure correct connections during installation 5 Disconnect hydraulic lines from cylinder Cap the lines and cylinder ports to preven
19. Follow the procedure in the reverse order to remove the boom from the machine 7 Align frame tilt cylinder into quick discon nect and fasten with pin and bolt with locktight PETTIBONE TRAVERSE Lirr LLC PAGE 145 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL NOTES PETTIBONE T RAVERSE LLC PAGE 146 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 3 14 9g aNnod 000 PETTIBONE TRAVERSE Lirr LLC PAGE 147 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL DISASSEMBLY The fork frame quick disconnect and tilt cylinder can be removed from the boom without the boom being removed from the machine 1 Remove forkframe lower tilt cylinder pin quick disconnect pin and with a hoist lift the quick disconnect from boom 4 NOTE Place a bar into the cylinder hole where the pin used to connect to ease in tilt cylinder removal B ub i 2 Remove plate from front of boom 4 mr B 1 az 4 gt d 7 1 i Y PETTIBONE T RAVERSE LLC PAGE 148 Remove hoses from valve and pin from the top of the tilt cylinder Using a hoist remove the tilt cylinder from the machine and place onto a pallet or blocks FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL COMPLETE DISASSEMBLY 3 Remove side wear pads from boom 1 near the front of the boom
20. PAGE 14 1 Thoroughly clean the pump and hydraulic connections with a cleaning solvent 2 Match mark the hydraulic lines and pump ports to ensure correct connections during installation 3 Disconnect hydraulic lines from pump Cap the lines and pump ports to prevent con tamination 4 Attach a suitable lifting strap from hoist to pump 5 Remove the 2 capscrews and 2 lock washers which secure the pump to the torque converter Lift pump from machine Pump SERVICE INFORMATION For complete pump service information refer to the service guide included at the end of this manual INSTALLATION OF PUMP WARNING Heavy components Before installing the pump check its weight and make provisions for attaching and lifting Use a hoist capable of supporting the weight A slipping or falling com ponent may result in injury or death to personnel 1 Secure a suitable lifting strap from hoist to pump Lift the pump into position on torque converter 2 Install a new gasket between the torque converter and the pump Hold the gasket in place with a light coating of grease 3 Insert pump driveshaft into torque converter drive being certain to properly engage splines Secure pump to converter with the 2 capscrews and 2 lockwashers Remove lifting strap 4 Fill pump ports with clean hydraulic oil to provide initial lubrication 5 Connect hydraulic lines to pump and bleed air from system 6 Start
21. es 94 D IM helt ta sn d 97 RU UU I MM CAE D EAE ELE 97 REAR AXLE S TABILIZATIONUNIODES 98 REAR AXLE STABILIZATION TROUBLESHOOTING IH e mee he 99 93 ENGINE INSTALEATION eM M eet A 94 S 94 ENON 96 INDEPTH O ERVICE 96 ENGINE TROUBLESHOOTING deitate ee 97 ELECTRICAL SYSTEM uiis dta clic ee untae DM SOLUS 101 PETTIBONE T RAVERSE LLC FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL RSE NERS ucc 102 BATTERY MAINTENANCE RR Gaver dng ede 102 ELECTRICAL CHENG sa ono tb or
22. ADVANCED MAINTENANCE MANUAL Boom INSTALLATION 1 Lift completed boom with hoist and guide between lift cylinders to back of frame Install shaft with shims and torque bolt to proper specifications PETTIBONE TRAVERSE Lirr LLC PAGE 141 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 2 Start machine up and extend lift cylinder between mounts on shaft Turn machine off Apply antiseize to lift cylinder pin install shim s between frame and cylin der and install pin Fasten pin with locktight on bolt and torque to 80 foot pounds Follow the same procedure on other side of boom PETTIBONE T RAVERSE LLC PAGE 142 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 3 Install clamps and tubes onto underside of boom and attach tubes to boom manifold 7 4 Install hoses onto tubes and attach hoses to bukhead fittings andtighten PETTIBONE TRAVERSE Lirr LLC PAGE 143 FixED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 5 Lift quick disconnect with hoist and align with boom tip Install pin and shim and bolt into place with locktight Torque to proper specifications PETTIBONE T RAVERSE LLC 6 Assemble pin assembly together and install PAGE 144 into quick disconnect Attach other weldments and plates to quick disconnect and disconnect from hoist LN FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL Boom REMOVAL
23. 103 CHARGING SYSTEM TROUBLESHOOTING tae carta 104 BATTERY TROUBLESHOOTING ai uut Senat tte deuda Senece Ete dedu shania dide ue 105 GAUGES ROUBLESHOOTING TE RE 107 PARK BRAKE En 108 CurT OFF CCO TROUBLESHOOTING d seien ev Ene era etes e nte t e t ted es 109 AUDIBLE WARNINGS TROUBLESHOOTING I emen he eme e ee innere reme e e 110 REAR FLOODLIGAT TROUBLESHOOTING denn ib Ie Era ia 111 EIEAD AND TAL EIGHT TROUBLESHOOTING dut Mu Mi diu tcu terme deep 111 BRAKE STOP LIGHT TROUBLESHOOTING cre 53290 9 d ened E Desi edat 112 DIRECTIONAL HAZARD LIGHTS 5 113 ACCESSORIES TROUBLESHOOTING EM Lei ane geet 114 lel CETTE TTE 117 000 117 118 BOOM INSTALLATION REMOVA a
24. 20 21 2p 23 ILI OWN lt OWWA FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL GILMORE GLOBAL INSTRUMEN T3 CO INC ECS59801 HOUSTON T 77017 6 26 00 wan aimoredist com SU0 999 665 2 BATTERY RELAYS me 14 PIDE 11 ELE TE dud 12 16 acey IGH IGHN BATT FUSES 10 SPARE RELAYS 1 PIPER 104 11 SPARE 10 REFNO LOCKOUT 2 DEFROSTER 5A 12 KS TPAHEL LIGHTS 5 4 REREV LOCKOUT amp REV ALARM SALT SA I SIG ADECLUTCH RELAY R FULL Oc LOCK i HEATER 104 15 4 RA ACCY FUSE BLOCE 5 FUEL CTRL SOLOMOID 54 154 REVOLT LT amp HOURMETER S CSC LIMIT ACCUM CHARGE FLOOD amp BEACON LTS 204 RE OSC LIMIT SUT 104 16 BOOM amp 5 20 4 RI HORH 7 TRANS SHIFTER 10 4 REST ARTER LOCKOUT BRAKE I CIRCUIT BREAKER REALE LOAD SEHE OR 0 FORE SHIFT A LF UEL SOLEHUID 204 JOYSTICKS 2 AXIS DRIVER 5 11 BLK 8 GRY JOY 16go BLK 16 YEL ScHEMATIC SYMBOL PETTIBONE T RAVERSE LLC PAGE 30 JOYSTICK PWM TROUBLESHOOTING PROBABLE SYMPTOM CAUSE REMEDY No power to PWM Module Check fuse F9 15A Replace if necessary Power LED on Diagnostic LED on Operates in One direction only Loose connec
25. CAUSE REMEDY Verify 12 VDC present wht blk No rear floodlights Defective fuse center wire of rear flood light switch If absent replace fuse 15 ON headlights Verify 12 VDC present on wht blk end wire of rear floodlight switch with switch ON If absent replace NOTE FLOODLAMP ASSYS USE QUARTZ HALOGEN TYPE H3 BULBS USE CARE NOT TO TOUCH QUARTZ ENVELOPE TO PREVENT EARLY BURN OUT PETTIBONE TRAVERSE Lirr LLC PAGE 111 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL BRAKE Stop LIGHT TROUBLESHOOTING SYMPTOM PROBABLE CAUSE REMEDY No brake lights CCO foot operation does Defective fuse work Defective brake light switch No brake lights CCO foot operation normal w o directional lights option Defective isolation diodes in directional No brake lights CCO foot operation normal Defective directional with directional lights lever assy option 1 light OUT Defective bulb PETTIBONE T RAVERSE LLC PAGE 112 lever optional harness Verify 12 VDC present to pnk wht wire at brake light switch If absent replace fuse 13 place jumper across brake light switch terminals If brake lights light replace brake light switch Verify 12 VDC present on pin 6 pnk of directional lever plug jumper absent replace diodes Unplug directional lever Jump pins 6 pnk 5 gry amp 8 blk wht together on harness plug If brake lights operate
26. CIRCUIT In our brake system oil comes from the hydraulic pump and flows through the main directional valve to the steering brake pres sure reducing valve The pressure readings that can be obtained from the the main pressure test port will should be 3450 psi all others are load sense at 3250 psi Here are some conditions and corresponding pressures that could be ob tained at this location e At machine startup with no functions being actuated 500 1000 psi until the accumulator is charged then system pressure of 500 psi Machine running with no functions being actuated 500 psi Brakes only 500 psi until the accumulator pressure drops below 1000 psi then 500 1000 psi This is only until the Low Limit Pressure Switch reads accumulator pres sure of 1000 psi or more then the reading will be 500 psi Machine operating normally 500 3450 psi Machine sitting idle initially reading 500 psi and then turning the steering wheel 500 2500 psi Deadheading any function 3000 3450 psi Pressures read at this port may be between 500 3450 psi depending upon which functions are being actuated if any at all BRAKE PRESSURE CHECK The brake pressure test port and the steering pressure test port are the same so they will have the same pressure reading For doing an adjustment refer to the steering pressure PRESSURE LEST PoRTS ETTIBONE T RAvERSE LLC PowER BRAKE VALVE The power brake valve appl
27. CYLINDER 50 INSTALLATION OF FRAME Sway CYLINDER 50 FRAME CYLINDER TROUBLESHOOTING 52 FRREMOVAL FORK Tilt CYLINDER Mie eter nae 53 PETTIBONE TRAVERSE Lirr LLC PAGE 1 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL INSTALLATION OF TRAVERSE CYLINDER 1 54 REMOVAL OF TRAVERSE CYLINDER cccececcececeececeeeecececaecececaececeeaeceeeeaeaeceeaeaeeusaeaeeeeaeaeeeeneaeeesneatenaneaes 54 TRAVERSE CYLINDER TROUBLESHOOTING oan ottime eta eod 56 REMOVAL INSTALLATION OF STEERING CYLINDER 57 REMOVAL OF FORK FRAME SIDE TILT CYLINDER 58 EXTENSION CYLINDER INSTALLATION REMOVAL IH eem he eene ee he ei 58 E 59 ERREICHEN TEN 60 DRAKE PRESSURE MSto xxi dust gru mated ue EE 60 IPOUWERIBEAKE VAVE net
28. E p 60 Removal POWER BRAKE VALVE D ED EE MI 60 POWER BRAKE VALVE SERVICE INFORMATION IHR Ie emen 61 INSTALLATION OF POWER BRAKE VALVE 1 61 SERVICE CHECKS FOR BRAKE SYSTEM det 62 ty aetna access 64 65 SETUP AND 65 nasan 67 MAINTENANCE ranh E MITAD 68 PRECHARGE CHECKING PROCEDURE 1 1 1 sese sese e sese e essem serere ens 68 69 CLEANING 69 INSPECTION REIP MEME M CIMA ELE ME 69 REPAIR AND REPLACEMENT 20 1 e ense etse se sese ee p eese seme e ee et sees 69 ACCUMULATOR CHARGING E eso Ec teste ex
29. HYDRAULIC Pump LINES PETTIBONE TRAVERSE Lirr LLC PAGE 13 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL Pump Cavitation occurs when an insufficient supply of oil reaches the pump suction chamber Since the pump does not receive enough oil it begins sucking in air instead This condition is indicated by a high noise level in the pump IF THE PUMP EMITS A HIGH PITCHED NOISE SHUT OFF ENGINE IMMEDIATELY CONTINUED OPERATION OF A CAVITATING PUMP WILL CAUSE SEVERE DAMAGE TO ITS WORKING PARTS To prevent cavitation 1 Keep hydraulic oil level up to FULL mark on reservoir dipstick 2 Allow oil to warm up in cold weather 3 Keep suction line free of obstructions REMOVAL OF PUMP Should you find it necessary to service the hydraulic pump during its life expectancy you will see a noticeable drop in performance occur It is advisable to make an inspection and replace parts or components which may have become worn Expendable parts such as o rings seals washers and gaskets should never be reused even though inspec tion may show these items as being service able Alternately the complete unit may be replaced Heavy components Before removing the pump check its weight and make provisions for attaching and lifting Use a hoist capable of supporting the weight A slipping or falling com ponent may result in injury or death to personnel PETTIBONE T RAVERSE LLC
30. If open or high replace coil or valve EE Defective valve If electric check ok replace valve PETTIBONE TRAVERSE Lirr LLC PAGE 41 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL NOTES PETTIBONE T RAVERSE LLC PAGE 42 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL SYAGNIIAD PETTIBONE TRAVERSE Lirr LLC PAGE 43 FixED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL All hydraulic cylinders on this machine are double acting Oil entering the base end port of the cylinder extends the rod Oil entering the rod end port retracts the rod DISASSEMBLY OF CYLINDER GENERIC 1 Place a suitable container below the cylinder to catch the oil when the rod assembly is pulled out dispose of the oll removed from cylinder Do not pour oil on the ground into sewers or into bodies of water 3 Using a strap or chain wrench unscrew the collar 4 Use a suitable puller to remove the piston rod assembly from the barrel PETTIBONE T RAVERSE LLC PAGE 44 5 Remove cotter pin from piston lock nut Unfasten lock nut Slide piston spacer and head from rod CoTTER PIN Remove all software from head and piston Discard software Wash all metal parts in an approved cleaning solvent and dry thoroughly with a clean lint free cloth Inspect barrel rod and piston for nicks scratches and scoring 9 Replace any damaged parts and seals
31. MAINTENANCE MANUAL a Locate the load sense pres wise until it bottoms sure relief adjustment on the b With the gauge on the Sys main control valve With the tem Pressure check point engine running at approxi Adjust the Differential Pres mately 2000 RPM retract sure adjustment on the pump boom and deadhead the to 625 psi initially then adjust system by holding the joystick the Valve differential pressure in the retract mode Adjust the to 600 psi Finally set the load sense relief adjustment pump Differential Pressure on the valve to the following back down to 500 psi DO settings NOT TAKE MORE THAN 2 3 MINUTES TO MAKE THIS On6044 F 644 ADJUSTMENT 10056 F 1056 and 10044 F 1044 load sense pressure should read 3250 psi or 25 psi ii On 6036 F 636 8044 F 844 or 8036 F 836 load sense pressure EUM should read 2800 Ed psi or 25 psi 5 Set Pressure Differential Standby Pressure CAUTION Do not run with the pump pressure differential set ting higher than the main valve setting for more than 2 3 min utes Pump overheating will occur Note The following measurements are taken while the engine is idling and no hydraulic functions are being operated Valve in Back Style Machines a Locate pressure differential adjustment on main control valve Bottom out the differen tial pressure adjustment on the main control valve by loosening the jam nut and turning the adjustment clock PE
32. PAGE 27 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL PWM Module SPECIFICATIONS 4KBYTES OF IN CIRCUIT PROGRAMMABLE FLASH INPUTS 4 ANALOG 0 5VDC OUTPUTS 4 2AMP CURRENT COMPENSATED PROPORTIONAL 2 2AMP ON OFF 2 AXIS DRIVER POWER INPUT 10 30VD TEMP 20C TO 70C CONNECTOR AMPSEAL PLUG 770680 1 AMPSEAL SOCKET PIN 770854 1 ENVIRONMENTAL RATING TO AMP SPEC 109 74 5
33. TO THE temporarlily inserted between the tip and WEAR PADS WITH ELECTRICAL TAPE SO middle boom and collapse boom sections WEAR PADS SHIMS STAY TOGETHER together DURING INSTALLATION m Ya TOP WEAR PADS BOLTS PETTIBONE T RAVERSE LLC PAGE 136 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 33 Install extend cylinder pin through main 34 Cut plastic tie on counterbalnce hose and boom through valve and attach with pin attach to bulkhead fittings on boom and bolt NOTE FIXED MACHINES USE STRAIGHT n WU FITTINGS AND T MACHINESUSE 90 FIT TINGS BULKHEAD FITTINGS FIXED MACHINE BULKHEAD FITTINGS Boom DISASSEMBLY Follow the procedure in the reverse order for disassembly PETTIBONE TRAVERSE Lirr LLC PAGE 137 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL TILT CYLINDER INSTALLATION 3 Tap the pin through the frame and mounts 4 the boom 1 Lift the cylinder with a hoist being careful not to damage the hydraulic j tube and hoses 4 Install the bolt through the frame and into the pin and fasten with the nylock nut 2 Align the cylinder using a pry bar on one side as you install the pin on the other ce 5 Connect the hose to the j tube on cylinder PETTIBONE T RAVERSE LLC PAGE 138 FixED AND TRAVERSING FORKLIFT ADVA
34. TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL PETTIBONE TRAVERSE Lirr LLC PAGE 83 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL AXLE INSTALLATION 1 Using some type of overhead sling lift the front axle up near the mounts on the frame Be careful to align the 4 four dowels on the axle with the holes on the frame mounts If the dowels do not line up check the rubber gasket between the axle housing and the trunnions where the dowels are attached ALIGNING AXLE ATTACHING SLING AND CHAINS LIFTING AXLE PETTIBONE T RAVERSE LLC PAGE 84 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL ALIGNING AXLE 2 Once the axle is set in place attach it with the 4 four capscrews that secure it to the frame Apply light coating of thread lock snug them and then torque them to 360 470 ft lbs wet with a torque wrench TORQUING BOLTS 3 Follow the same steps to attach the rear axle and torque them to the same 300 ft lbs wet being sure to apply a thin coating of STARTING BOLTS thread lock prior to installing the capscrews PETTIBONE TRAVERSE Lirr LLC PAGE 85 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL MOVING REAR AXLE INTO PLACE ba 4 When axles are attached and secured connect the brake and steering hydraulic lines STEERING LINES ATTACHING SLING AND CHAINS LIFTING AXLE
35. VALVE Joystick The remote control joystick valves supply pressure to the main directional valve This pilot pressure shifts the main valve spools which direct oil to the cylinders The remote control valves are mounted in front of the arm rest in the operator s com partment REMOVAL OF REMOTE CONTROL VALVES Joystick s 1 Disconnect the battery ground cable 2 Remove the console cover by taking off the two wing nuts that hold on the arm rest and lift the cover off 3 Thoroughly clean the valves and hydraulic connections with an approved cleaning solvent 4 Match mark the hydraulic lines and valve ports to ensure correct connections during installation 5 Disconnect hydraulic lines from joystick Cap the lines and valve ports to prevent contamination 6 Disconnect the joystick electrical wire underneath the mounting bracket 7 Remove the four 4 socket head fasteners on each of the joysticks and remove the joysticks PETTIBONE T RAVERSE LLC PAGE 22 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL MouwriNG BRACKET CAPSCREWS PETTIBONE TRAVERSE Lirr LLC PAGE 23 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL INSTALLATION OF REMOTE CONTROL VALVE 1 Install the valves onto the mounting bracket with the four 4 socket head fasteners for each joystick 2 Connect the joystick wires to the terminal 3 Connect the hydraulic lines to the valve
36. as necessary ASSEMBLY OF CYLINDER GENERIC The collar end of the head is referred to as the large end The opposite end is the small end Lise new software for assembly Refer to parts manual for part numbers of cylinder components 1 Coat new software with clean hydraulic oil 2 Install head o ring and head back up ring in groove on outside diameter of head O ring must be closest to small end of head 3 Install head wear ring in large groove on inside diameter of head LARGE FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 9 Carefully slide collar on rod then the head Use caution to prevent cutting the wiper on the rod 4 Install rod seal and modular back up ring in second largest groove inside head Lips of rod seal must face small end of head Modular back up ring must be closest to large end of head 5 Install rod wiper in groove on large end of head with wiper lips facing large end 6 Install piston seal in center groove on outside diameter of piston 7 Install the piston wear rings 2 in remain ing grooves on outside diameter of piston SEAL Wear RINGS 8 Install stub o ring in groove on inside diameter of piston STUB O RING 10 Slide spacer on rod then the piston 11 Fasten piston lock nut on end of rod Insert new cotter pin through nut 12 Insert piston rod assembly into cylinder barrel Lubricate threads with anti seize before
37. i t lo 16 8LK RF DIRECTIONAL LIGHT 10 9 0 16 LF DIRECTIONAL LIGHT 10 8 10 0 16 8LK 95 16 0RN RED 7 8 1690 8LK 4 LF HEAD LIGHT 10 0 1 dia E10 A 2 13 94 16 WHT BLU gt F16 gt RF HEAD LIGHT M 4 a 4 19 0 20 BOOM 24 16 ORG GRN 5 7 95 16 0RN RED Rm PARK LTS LIGHTS SWITCH 16 7 8 5 M 8 5 L LIGHT 23 16 BRN GRN 2 Re 4 3 8f 16388708G BOOM LIGHTS SWITCH BOON LIGHT 7 8 16g0 BLK 6 16 8LK T 22 16 WHT BLK 2 4 RR FLOOR LIGHT e 4 pooled 3 100 16 WHT BLK 0 R FLOOD LIGHTS SWITCH LR FLOOD LIGHT 4 7 8 E 16g0 BLK 4 c BEACON LIGHT OPTION o 21 16 WHT RED 2 e 3 93 16 WHT RED z Q 8 BEACON LIGHT SWITCH F14 HORN RELAY R7 8 HORN SWITCH 20 16 YEL 86 15 e T 54 16 YEL BLK E 30 5 5 55 16 WHT7ORG HORE 5 49 16 8RN er 85 HOUR METER 47 13 47 8 2 ssec m C uses 17 18 RED H YEL RE x LON VOLTAGE H VOLT LT HOUR METER R5 yg WARNING LIGHT jj e esce E 5 8 s 8 8082 SOLENIODS 11 14 REDAWHT 12 14 RED WHT 13 16 PNK
38. not run in PETTIBONE TRAVERSE Lirr LLC PAGE 115 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL NOTES PETTIBONE T RAVERSE LLC PAGE 116 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL Booms 0009 PETTIBONE TRAVERSE Lirr LLC PAGE 117 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL ASSEMBLY 4 Install clamps and hoses onto the tip end of tubes and then clamp and attach the 1 Install bottom and one side wear pad into tubes to the other end of the boom rear of boom 1 2 Install tubes into boom and attach fittings onto tubes in the front of boom 1 NOTE The outside tubes for the tilt cylinder have 10 10 fittings and the inside tubes for the extra circuit use 10 8 fittings PETTIBONE T RAVERSE LLC PAGE 118 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL Install middle clamps through the access 7 Install grease lines onto top of boom 1 and hole in each side tuck hoses and extension chain into boom for easier assembly into boom 2 6 Install retract chain onto top of boom 1 and set into place with pin and cotter On rear of boom 1 attach extension chain and set into place with pin and cotter PETTIBONE TRAVERSE Lirr LLC 119 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 9 Install 2nd rear side wear pad onto boom 1 10 Install front bottom wearpad onto boom 2 af
39. pins 151 FixED AND TRAvERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 9 Remove hoses from manifold on rear of 12 Remove bottom roller pin bolt and then boom 2 and cap fittings to prevent con tamination start pulling boom 3 from boom 2 Once boom 3 is partially removed remove the complete bottom roller assembly from boom 2 Place boom on appropriate stands PETTIBONE TRAVERSE Lirr LLC FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 13 Remove top rollers from back of boom 3 15 Remove screw pin and pin roller 14 Place a drain pan underneath back of boom 3 and remove tubes from manifold Cap manifold fittings and tubes to prevent contamination D 1 16 Remove side and top wear pads and top roller from boom 3 PETTIBONE T RAVERSE LLC PAGE 152 17 Attach a hoist to boom 4 and remove from boom 3 Place boom onto tip and appropriate n re al H gt A 18 Remove top rollers amd roller pin bracket and pin FixED AND TRAvERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 19 Remove clamps from bottom of boom 4 and bolts from top mount inside the tip to remove the gore trak Pull the gore trak assembly out through the tip of boom 4 NOTE Bottom wear pads should be installed before assembling booms together and removed after booms are separated Boom ASSEMBLY 1 Reverse order for assembly Boom REMOVALI INSTALLATION Use the 8 000
40. pound boom instructions for removal and installation PETTIBONE TRAVERSE Lirr LLC 153 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL Bott T ORQUE VALUES Size SAE Grade Dry Lube 1 4 20 5 8 Ft Lbs 75 In Lbs 1 4 28 5 10 Ft Lbs 86 In Lbs 5 16 18 5 17 Ft Lbs 13 Ft Lbs 5 16 24 5 19 Ft Lbs 14 Ft Lbs 3 8 16 5 30 Ft Lbs 23 Ft Lbs 3 8 24 5 35 Ft Lbs 25 PL Lbs 7 16 14 5 50 Ft Lbs 35 Ft Lbs 7 16 20 5 55 Ft Lbs 40 Ft Lbs 1 2 13 5 75 Ft Lbs 55 Ft Lbs 1 2 20 3 90 Ft Lbs 65 Ft Lbs 5 8 11 5 150 Ft Lbs 110 Ft Lbs 5 8 18 3 180 Ft Lbs 130 Ft Lbs 3 4 10 3 260 Ft Lbs 200 Ft Lbs 3 4 16 5 300 Ft Lbs 220 Ft Lbs 7 8 9 3 400 Ft Lbs 300 Ft Lbs 7 8 9 Ferry Bearing Bolts 808 Ft Lbs 606 Ft Lbs 7 8 14 3 440 Ft Lbs 320 Ft Lbs 1 8 5 580 Ft Lbs 440 Ft Lbs 1 8 Ferry Bearing Bolts 1212 Ft Lbs 909 Ft Lbs 1 12 5 640 Ft Lbs 480 Ft Lbs 1 1 8 7 Ferry Bearing Bolts 1702 Ft Lbs 1276 Ft Lbs 1 1 4 7 5 1120 Ft Lbs 940 Ft Lbs 1 1 4 7 Ferry Bearing Bolts 2162 Ft Lbs 1621 Ft Lbs PETTIBONE T RAVERSE LLC PAGE 154
41. spool centering springs FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL REMOVAL OF TILT CYLINDER HEAVY COMPONENTS BEFORE REMOVING FORK CARRIAGE AND CYLINDER CHECK THEIR WEIGHT AND MAKE PROVISIONS FOR ATTACHING AND LIFTING CONSIDER WHAT REMOVAL OF THESE COMPONENTS WILL DO TO THE STABILITY OF THE MACHINE USE A HOIST CAPABLE OF SUPPORTING THE WEIGHT A SLIPPING OR FALLING COMPONENT MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL Refer to 8 000 pound boom section further in this group for removal and installation PETTIBONE TRAVERSE Lirr LLC PAGE 53 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL REMOVAL OF TRAVERSE CYLINDER To remove the traverse cylinder perform the installation in reverse order INSTALLATION OF TRAVERSE CYLINDER 1 Using a suitable lifting device lift the cylinder to the appropriate height for installation b rn TIGHTENING REAR 4 Swing cylinder toward frame and place on stand This will allow for repositioning of the lifting strap LIFTING THE CYLINDER INTO POSITION 2 Line the cylinder in position above the rear mounting cone Insert bolt with washer at head of bolt PLACING CYLINDER ON STAND 5 Pull or push the carriage to a position that lines up the rod end of the cylinder with the front mount LINING UP THE CYLINDER MOUNTING CONE AND BOLT RE LOCATION OF LIFTING STRA
42. the body and some units may only have the gas cap threaded into the body IN BOTH CASES ALWAYS REMOVE THE GAS CAP FIRST end cap which contained gas valve To remove cap or caps install three 3 pins into the holes in the cap then using a long bar working against the pins unthread the cap from the body Remove o rings and back up rings from end cap Remove piston by pushing from hydraulic end with a bar NEVER TRY TO REMOVE PIS TON BY APPLYING COMPRESSED AIR AT OPPOSITE END To remove v o ring from piston lift seal with small smooth screw driver or similar tool moving the tool around the piston several times while using the other hand to work ring off the piston CLEANING Thoroughly clean metal parts in solvent and dry with compressed air Clean bore of body With a clean lint free cloth soaked in clean solvent Bore must be clean of any visible particles or particles detectable to touch INSPECTION Inspect piston for cracks burrs around o ring grooves or damage Examine body bore using a light for scratches or scoring Inspect end caps for damaged threads of burrs on o ring grooves REPAIR AND REPLACEMENT Minor nicks scratches or light scoring of the body bore can be removed by using crocus cloth Dress bore until all apparent imperfec tions have been removed Replace teflon wear rings v o rings O rings and their respec tive back up washers if the original assembly contained them FixED AND TRAvERSING
43. the hydraulic end cap The piston could bottom at minimum system pressure to reduce output and eventually cause damage to the piston and the piston seal The bottom ing of the piston often can be heard the sound serves as a warning of impending problems Excessively low precharge Excessively low precharge pressure or an increase in system pressure without a com pensating increase in precharge pressure also can cause operating problems and may promote accumulator damage With no precharge in a piston accumulator the piston likely will be driven into the gas end cap and probably will remain there Most likely no damage will occur with this single contact SG j LOCATION OF ACCUMULATOR PETTIBONE T RAVERSE LLC PAGE 66 The schematic representation of accumu lator is shown here PNAS h AUI PH a A 4 o o 4 PN A ita N 5 5 PRE CHARGING Use an inert gas such as nitrogen for precharging accumulators If water pumped nitrogen is not available oil pumped nitrogen may be used stan dards Nitrogen gas bottles for water pumped nitrogen has a right hand valve thread which requires charging and gauging assembly LL 1803 490 for units up to 3000 psi If equipment o
44. to drain from reservoir walls PROPERLY DISPOSE OF USED OIL DO NOT POUR OIL ON THE GROUND INTO SEWERS OR INTO BODIES OF WATER 5 Remove the 8 capscrews and 8 lock washers which secure the access cover to the reservoir Remove cover PETTIBONE T RAVERSE LLC PAGE 12 6 Clean out sludge and sediment from bottom of reservoir Clean tank magnet and replace on tank floor DO NOT FLUSH HYDRAULIC SYSTEM WITH KEROSENE OR ANY OTHER SOLVENTS 7 Apply a thin layer of silicone gasket sealant to reservoir access cover Install cover on reservoir and secure with the 8 capscrews and 8 lockwashers 8 Apply thread sealant to drain plug and install 9 Add hydraulic oil by pumping it from storage drum through a 10 micron filter into reser voir filler opening Fill reservoir to FULL mark on sight gauge 10 Prior to starting engine the system must be bled of air This is accomplished by removing the pump outlet hose and push ing air into hydraulic tank until oil exits pump pressure port Connect hose and start unit 11 Start engine and let engine idle If there is no hydraulic pressure in 30 seconds turn off engine and bleed air from the hydraulic system Restart engine to check for hydraulic pressure It is important that all functions be operated to ensure that new oil flows through all circuits 12 Shut off engine Add some more oil to maintain proper level This is necessary to replace oil drawn in
45. 62 HARNESS RK TILT SOLENOIDS PACKARD CONNECTOR 12010974 6987 16 18184588 L PI F 10 698 6 gt 12010293 SEAL UX CIRCUI 6987 19 _ i PACKARD C 25 2015797 6987 11 5 2124580 Y 6987 3 D BLACK BLUE 2010293 SEA 55 M 7WH W W E W C UJ C1 lt W Q CO PU e Y W 2 D2 6 68 PLUG 6987 19 2 0 LEADS I 0 10 0 1 01 16141 PETTIBONE TRAVERSE Lirr LLC PAGE 29 Sou ALD O lt AWOW z Se AYN gt IEI OUO MX UO CO 202 gt gt gt gt Ge O lt Pw MODULE AMP CONNECTOR 770681 1 5 26897 54 0678 1 SOCKET E 16987 22 2 770678 1 SEA 6987 23 2 0 LEADS 9 0 1 2 3 4 5 6 8 9
46. Connect hydraulic lines to cylinder 4 Start engine and apply down pressure to fill cylinder with oil 5 Extend cylinder to align rod end between cylinder mounts on boom 6 Drive pin through rod end and secure with capscrew lockwasher and nut 7 Add oil to FULL mark on reservoir dipstick 8 Check hydraulic connections at cylinder for leakage Inspect for excessive leakage at rod wiper It is normal for a light film of oil to adhere to the rod TORQUE SPECIFICATIONS Base Pin 80 foot pounds PETTIBONE T RAVERSE LLC PAGE 48 h CYLINDER ON HOIST ES TORQUE CAPSCREW TO PROPER SPECIFICATION SYMPTOM ylinder will not operate hen joystick is actuated ylinder drifts will not remain in position ylinder drifts will not remain in position CYLINDER TROUBLESHOOTING 5 Failed hose or hose nections leaking Low oil level in reservoir Plugged sump strainer Insufficient pilot pressure supplied to main valve Oil bypassing spool in main valve Rod wiper leaking exces sively Oil bypassing cylinder piston Faulty pump operation Load larger than capacity Oil bypassing spool in main valve Oil bypassing counterbal ance valve cartridge Oil bypassing cylinder piston Spool not centered in main valve Load larger than capacity PAGE 49 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL
47. E OIL PRESS GUAGE OPTIONAL ENGINE OIL PRESSURE SENDER OPTIONAL J7 14 77 18 PUR WHT 650 PSIG ACCUM OIL BRAKE OIL PRESS WARNING LIGHT 47 1 PRESS SWITCH DASH LIGHT TRANS PRESSURE GUAGE esf gt gt B4 16 BRN 25 26 9 16 8LK TRANSMISSION PRESSURE SENDER us C 06 702 16 GRN SS OLDOUT PETTIBONE TRAVERSE Lirr LLC 103 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL CHARGING SYSTEM TROUBLESHOOTING SYMPTOM PROBABLE CAUSE REMEDY power on ACE fuse P 2 Troubleshooting Check belt and tighten replace belt if necessary Defective alternator or Replace alternator or voltage voltage regulator regulator BATT light o Defective bulb Replace bulb engine not running Temporarily replace relay 5 with relay 6 If charge light glows replace relay 5 Defective charge light relay BATT light does not go nut when alternator charging Hour meter does not begin counting Verty XX YOC at alternator vv Defective alternator terminal with engine running If absent replace alternator Verity 12 VOC present to Defective haurmeter hourmeter terminal with charge light out Replace hourmeter Haurrneter does not count BATT light out Low charge rate alternator output voltage Laase ar worn alternator doesnot ri
48. E TRAVERSE Lirr LLC 113 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL ACCESSORIES T ROUBLESHOOTING SYMPTOM PROBABLE CAUSE REMEDY Verify 12 VDC present on ACC ICCY terminal in IGN and ACC positions If one or both absent replace key switch No power on ACC fuses with key in ACC or IGN Defective key switch Temporarily replace relay 4 with relay 7 If ACC fueses now powered replace relay 4 Defective ACC power relay Verify 12 VDC present on wiper Defective fuse switch yel blk wire If absent replace fuse 1 Wiper does not operate in any mode Wiper runs on HIGH only Parks randomly in low Defective wiper motor Replace motor OFF Verify 12 VDC present to wiper motor red lead in high If absent replace switch If 12 VDC present when testing Defective wiper motor wiper switch replace motor Wiper park is random Unplug wiper motor Verify 12 VDC with switch OFF low and Defective switch present on plug blk wire with switch high normal in park If absent replace switch If 12 VDC present when testing Defective motor switch replace motor Unplug wiper motor verify 12 VDC Wiper runs continuously RAISER ewe present on wire only when in park switch in park If present grn or blu wires replace switch EN Defective motor If Switch tests ok replace motor Verify 12 VDC present at heater Defective fuse switch brn yel wire If ab
49. FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL TABLE OF CONTENTS HYDRAULIC SYSTEM NT TTE TETTE T EP PENES 5 MMC TPePT POO 6 hino 6 HYDRAULIC PRESSURE CHECKS AND ADJUSTMENTS 1 1 6 CHECKING amp ADDING HYDRAULIC OIL 00 12 CHANGING HYDRAULIC lL 12 FIV DRA WIIG OIE FILTERS A 13 RETURN FILTERS na da M D nM E EU eat 13 HYDRAULIC PONP s 13 PUn CAVITATION ects ce gee icc aaa sas IDA ERR 14 miss MES ae ccd TTE 14 PUMP SERVICE INFORMATION m Ie nemen he nece en re eere errare ir reser reser reser reser rens 14 INS TAUEATION OP PUMP cR Lo A EE 14 HYDRAULIC PUMP TROUBLESHOOTING CHART AND SERVICE REPAIR 1 rene 15 FYDRAULICIPUMP DROUBUESHOOTING
50. FORKLIFT ADVANCED MAINTENANCE MANUAL REASSEMBLY Coat all internal parts with clean hydraulic fluid before reassembly With new v o ring and Teflon rings on piston install piston hollow side toward gas end in bore of body Do not let v o ring drag on threads Piston must go into bore exactly square and very slowly V o ring will com press as it rides up the chamfer if done slowly but may be damaged if forced quickly Piston will fit snug Use hammer and wood block to tap piston into place until all of piston is 2 inches below beginning of honed bore Keep force against piston while tapping v o ring through the bore chamfer otherwise piston will bounce back damaging the o ring Cover port opening to keep dirt out Install new back up ring first then a new o ring on threaded end cap or caps and install into body bore Care should be exercised not to drag o ring over threads End cap will stop against chamfer leading into honed bore extreme tightness not required o ring sealing is not dependent upon cap tightness Cap should be flush with or above the end of accumulator body within 1 32 to 3 32 Install gas valve after replacing the o ring Remount accumulator and connect to hydrau lic system Precharge accumulator where space is a problem it may be necessary to precharge accumulator before connecting it to the hydraulic system ACCUMULATOR CHARGING VALVE The accumulator charging valve is nothing more than a so
51. ICE Please refer to the Carraro TLB2 manual that was shipped with your machine for further disassembly and troubleshooting PETTIBONE TRAVERSE Lirr LLC FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL TRANSMISSION T ROUBLESHOOTING SYMPTOM PROBABLE CAUSE REMEDY ransmission Low transmission oil level Fill transmission with proper oil to proper level Worn clutches authorized dealer Contaminated transmission Drain transmission filter element and refill with clean oil If problem persists see authorized dealer ransmission will not Linkage loose or out of Connect and or adjust hange into selected gear adjustment linkage Internal damage to see authorized dealer transmission valve for service Low transmission oil level Fill transmission with proper oil to proper level CARRARO TRANSMISSION CONTROL T ROUBLESHOOTING SYMPTOM PROBABLE CAUSE REMEDY No ist gear same Verify 12 VDC available between procedure for 2nd 3rd Defective shifter pin 1 and pin 2 of 1st gear solenoid and 4th plug If absent replace shifter Verify resistance 8 ohms Defective solenoid coil open or high replace If electric checks ok replace solenoid PETTIBONE T RAVERSE LLC 80 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL CARRARO TRANSMISSION CONTROL T ROUBLESHOOTING SYMPTOM PROBABLE CAUSE REMEDY Verify 12 VDC available to
52. INER AnD SEALS 6 Inspect stub yoke and slip yoke splines for excessive wear Check slip yoke and retainer cap for damaged threads 7 Inspect cross and bearing for side play If worn replace complete cross and bearing assembly NOTE OPPOSITE BEARINGS ARE HELD IN PLACE ON THE CROSS BY A WELD WIRE CUTTING THIS WIRE WILL ALLOW RE MOVAL OF BEARINGS FROM CROSS HOWEVER IF CROSS END BEARINGS ARE REPLACED AS AN ASSEMBLY CUT TING IS UNNECESSARY ASSEMLY OF DRIVESHAFT 1 Replace the 2 washers felt seal and retainer cap on end of slip yoke Felt seal goes between the washers 2 Install grease fitting in slip yoke FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 3 Slide slip yoke and stub yoke together 7 Secure opposite bearings of cross to being certain to properly engage splines driveshaft yoke with the 4 capscrews Make sure that yokes on both ends of the and 4 lockwashers Remove clamp driveshaft are in the same plane This alignment is necessary for correct timing 8 Repeat steps 6 7 for other cross bearing assembly 9 Check tightness of transmission yoke retaining nuts DRIVESHAFT ALIGNMENT 4 Tighten retainer cap on slip yoke 5 Install grease fittings in cross and bearing assemblies TRANSMISSION RETAINING NUT 6 Position a cross and bearing assembly on either end of driveshaft Insert opposite INSTALLATION OF DRIVESHAFT bearings of cros
53. If gauge drops to minimum replace sender If not defective sender see above Defective gauge and reading does not change replace gauge Defective sender or Replace sender or gauge gauge PETTIBONE TRAVERSE Lirr LLC 107 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL PARK BRAKE TROUBLESHOOTING SYMPTOM PROBABLE CAUSE REMEDY Verify 12 VDC absent on park Park brake does not Defective park brake brake switch It grn wire when park engage switch shorted brake ON If present replace Switch Verify 12 VDC present on park Park brake does not Defective park brake brake solenoid plug pin A It grn release switch open to pin B blk with park brake OFF If not present replace switch Verify coil resistance 9 2 ohms If Defective solenoid coil open or high replace coil or solenoid assembly f electrical check ok replace solenoid Park brake light does not Defective bulb or lamp anaes ip illuminate in PARK assembly P Place jumper between brn why blk ground on park brake switch If lamp lights replace switch Defective park brake switch CLUTCH CUT OFF NOTE CLUTCH CUT OFF 15 OPERATIONAL ONLY WHEN TRANSMISSION IS ENGAGED IN FWD OR REV PETTIBONE T RAVERSE LLC 108 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL CLurcH Cur Orr TROUBLESHOOTING SYMPTOM PROBABLE CAUSE REMEDY N
54. MAINTENANCE MANUAL ENGINE TROUBLESHOOTING SYMPTOM PROBABLE CAUSE REMEDY Engine does not run Fuel solenoid does not Engine does not run Fuel solenoid pulls in but does not hold approx 1 2 second Low oil light and pulse alarm do not operate with engine not running Low oil pressure light and pulse alarm stay on with engine running Low oil pressure light out pulse alarm on engine not running PETTIBONE T RAVERSE LLC Defective fuse Defective circuit breaker Defective fuel solenoid pull in coil Defective PC TM hold in circuit Defective fuel control solenoid Defective low oil pressure switch Defective low oil pressure switch Defective bulb PAGE 98 If either absent replace PC TM With key ON verify 12 vdc present between pin A grn and pin C blk ground on the pull coil timer module harness plug If absent replace fuse 5 Verify 12 VDC present between pin B wht and pin C blk ground on pull coil timer module harness plug IF absent replace circuit breaker 20A Verify 12 VDC present for approx 1 2 second between pin C blk and pin b wht on fuel control solenoid plug when key placed in IGN Verify 12 VDC constant between pin C and pin A red on fuel control solenoid with key ON Verify continuity between pin B wht and pin C blk on fuel control solenoid If open replace solenoid Verify 12 VDC constant between pin c blk
55. NCED MAINTENANCE MANUAL Tighten the clamp around the cylinder and hoses 6 Tighten the hoseto the j tube 7 Next connect the hose to the counterbal ance valve and tighten CLAMP 8 Readjust the hoist so you can slide the hose clamp around the cylinder PETTIBONE TRAVERSE Lirr LLC PAGE 139 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL Fork CYLINDER TROUBLESHOOTING SYMPTOM ylinder will not operate hen rocker switch 15 actuated ylinder drifts will not remain in position PETTIBONE T RAVERSE Lirr LLC PROBABLE CAUSE Failed hose or hose con nections Low oil level in reservoir Oil bypassing spool in main valve Rod wiper leaking exces sively Oil bypassing cylinder piston Faulty pump operation Load larger than capacity Oil bypassing cylinder piston Oil bypassing counterbal ance valve cartridge Oil bypassing spool in main valve Spool not centering in main valve 140 REMEDY Replace hose or tighten loose connections Add oil to FULL mark on reservoir gauge Replace defective spool seal s Replace defective wiper Replace defective piston seal Repair or replace pump Reduce to rated load capac ity at rated load center Replace defective piston seal Replace defective cartridge seal s Replace defective spool seal 5 Replace spool centering springs FIXED AND TRAVERSING FORKLIFT
56. ND WILL ALTER VALVE PERFORMANCE PAGE 32 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL JOYLIGUO ONINASLS PETTIBONE TRAVERSE Lirr LLC PAGE 33 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 2 Then remove the horn cover horn wire steering wheel and horn button cover and button from the steering column 4 3 steering orbitrol supplies oil pressure to the steering selector valve for distribution to the steering cylinders The pressure is cre ated by rotation of the steering wheel The orbitrol is mounted under the instrument panel ORBITROL REMOVAL 1 First remove the push screws from both sides of the dash by popping out witha pen light or small screwdriver These can be reused n Left Side oteering Wheel Right Side Horn Button Cover PETTIBONE T RAVERSE LLC PAGE 34 FixED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 4 Now remove the left hand panel from the dash and disconnect all wire connections Horn Button 3 Remove the shifter assembly from the column by removing the 2 allen head bolts NOTE WHEN REINSTALLING TAKE CARE NOT TO OVERTIGHTEN OVERTIGHTEN ING CAN STRESS THE PLASTIC AND IT COULD BREAK SEE TORQUE SPECS Left side panel wiring harness connections PETTIBONE TRAVERSE Lirr LLC PAGE 35 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 5 Remove the right side panel cover and all connecti
57. NG FORKLIFT ADVANCED MAINTENANCE MANUAL 4 Start engine and actuate brake pedal to ensure correct operation Inspect valve for leaks 5 Install the access cover under the operator s compartment and secure with the 5 capscrews 5 lockwashers and 5 flat washers BRAKE PEDAL SCHEMATIC SYMBOL BRAKES FROM BRAKE CHARGING MANIFOLD SCHEMATIC SYMBOL PSTIPS2 53 54 AC1 AC2 ACA PETTIBONE TRAVERSE Lirr LLC FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL ERVICE CHECKS FOR BRAKE SYSTEM SYMPTOM Accumulator charging cycle repeats frequently when accumulator is not normally being discharged in service Accumulator starts to charge but does not reach high limit Accumulator charging time too long Accumulator fails to start charging PETTIBONE T RAVERSE LLC PROBABLE CAUSE Leaking accumulator lines or fittings Incorrect setting of accumulator gas charge Line to accumulator plugged Defective pressure switch No oil or low oil level in tank Pump worn or inoperative and not delivering full flow or pressure Inoperative charging valve No oil or low oil level in tank Relief valve setting too low Pump worn or inoperative and not delivering full flow or pressure Inoperative charging valve No oil or low oi
58. ONE TRAVERSE Lirr LLC PAGE 77 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL ENGINE TRANSMISSION ASSEMBLY 3 Lift the transmission with two eye bolts attached on the side mounting holes of the 1 Install a dowel pin onto the torque converter transmission housing for aligning it to flywheel DOWEL ON TRANSMISSION LIFTING TRANSMISSION 4 Using the aligning dowels move the transmission up against the engine and start all of the mounting bolts While the transmission is still being supported by the lift tighten all of the mounting bolts 3 ALIGNMENT LOCATION ON ENGINE 2 Install two more dowels into the bell hous ing on the engine for aligning the transmis 444 ALIGNING TRANSMISSION um 2 DowELs ON ENGINE STARTING Borrs PETTIBONE T RAVERSE LLC PAGE 78 5 Open the access cover on the engine to insert and tighten the bolts to 35 Ft Lbs that mate the flywheel and the transmis sion torque converter Rotate the engine to each successive threaded hole until all of the 8 eight bolts are secured i 6 Remove the dowels from the housing and install the remaining bolts to secure the transmission to the engine Pace 79 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL DISASSEMBLY To disassemble do the previous steps in reverse order INDEPTH SERV
59. P AND LINING UP OF THE FRONT MOUNT PETTIBONE T RAVERSE LLC PAGE 54 FixED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 6 Hold the mounting cone in place while 8 Remove protective caps from valve block lining up the cylinder and inserting the front 22 bolt 3 PROTECTIVE CAPS ON VALVE BLOCK 9 Attach hoses to fittings on valve block hd MERE EY eet te Um tie SORDINDERSMODNTINGCONES ISOLE 10 Apply grease to using the fittings at each 7 Tighten bolt and nut to 800 ft Ibs end of the cylinder Ck TIGHTENING OF FRONT BOLT AND NUT PETTIBONE TRAVERSE Lirr LLC PAGE 55 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL SYMPTOM ylinder will not operate hen joystick is actuated ylinder drifts will not remain in position PETTIBONE T RAVERSE LLC TRAVERSE CYLINDER TROUBLESHOOTING PROBABLE CAUSE Failed hose or hose con nections leaking Low oil level in reservoir Insufficient pilot pressure supplied to main valve Oil bypassing spool in main valve Rod wiper leaking exces sively Oil bypassing cylinder piston Faulty pump operation Load larger than capacity Oil bypassing spool in main valve Oil bypassing cylinder piston Oil bypassing counterbal ance valve cartridge Spool not centered in main valve Main relief valve not holding
60. Pressure psi 6036 F636 3450 2800 2500 8036 F 836 6044 F 644 3450 3250 2500 T 6044 T 644 3450 2800 2500 8044 844 T 8044 T 844 300 3450 2800 2500 10044 3450 3250 2500 10056 F 1056 300 3450 3250 2500 PETTIBONE TRAVERSE Lirr LLC PAGE 11 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL CHECKING amp ADDING HYDRAULIC OIL You should inspect the hydraulic oil level every 8 hours of operation or daily by observing the reservoir sight gauge It is important to check the oil level daily to prevent air from entering the hydraulic system If the oil level drops below the suction port air can enter the pump causing cavitation pump starvation Return fluid entering the reservoir will also contain trapped air if it is discharged above the oil level CAUTION TANK UNDER PRESSURE REMOVE CAP SLOWLY USE CAUTION WHEN CHECKING HOT OIL CHANGING HYDRAULIC OIL The hydraulic oil should be changed every 1 000 hours of operation or once per year To drain the oil follow these instructions 1 Start engine and let hydraulic oil circulate through the system for several minutes Circulating oil should remove any dirt particles which may have settled in the system 2 Retract all hydraulic cylinders to force most of the oil back to the reservoir 3 Shut down engine and place a suitable container under reservoir drain plug to catch the 4 Remove drain plug to drain oil Allow time for oil
61. R SHOWN IN NEUTRAL 8 g amp 5 gt 5 3 zo a gt S8 r s H 54 E u z3 3 i 5 4 gt E G 8 8 E 7 5 14 2 E 16 YEL gt 7 6 1 cm gt er 5 142 TORG FIRST GEAR SOLENOID acs 2 1 FOURTH GEAR SOLENOID me 2 1 SECOND GEAR SOLENOID m 2 1 THIRD GEAR SOLENOID 1692 2 YT 2251 12 10 44 5 1690080 lt lt z5 gt lt gt FWD TRANS SOLENOID a 72 3 3 n al 1252 2 28 REV TRANS SOLENOID FE 12 8 ey az Ye o 1258 T 85 5 87 ele 30 i e 7 54 26 35 16 ORK BLU 27 12 47 8 FWD RELAY RI lt 6106 m PNKA IK 37 16 PNK BLK 86 s a DE CLUTCH DASH LICHT gt 6 87 3 el E 42 16 BRN REV RELAY R2 BACKUP ALARM ae 1 85 E13 A 13 lt lt 2 30 48 16 BLK YEL 18 8LK 87A E OSC LIMIT gt SOLENOIDS OSC LOCK RELAY 8 14 63 14 8 2 480880 V Tga 5 27 10 47 8 x 4 16 GRY RED 16 8LK AXLE RESTRICT OSC SWITCH DASH LIGHT CLOSES WHEN 27 8 BOOM ANGLE 25 TO8 16 PUR gt AND LESS OSC LIMIT RELAY R6 3 8 AXLE LOCK 5201678 DASH LIGHT GRY 85 87 11 E11 B 30 53 16 GRY BLK 9557 1690 RED 87A OSC LOCK m SOLENOIDS 3 12 12 E 18 GRY BLK 4 A
62. REMOVAL OF Fork FRAME SIDE TILT CYLINDER EXTENSION CYLINDER INSTALLATION REMOVAL Refer to boom section HEAVY COMPONENTS BEFORE REMOVING CYLINDER CHECK ITS WEIGHT AND MAKE PROVISIONS FOR ATTACHING AND LIFTING CON SIDER WHAT REMOVAL OF THE COMPONENT WILL DO TO THE STABILITY OF THE MACHINE USE A HOIST CAPABLE OF SUPPORTING THE WEIGHT SLIPPING OR FALLING COMPONENT MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL 1 Park machine on a firm level surface Engage parking brake 2 Lower fork frame to floor or ground to prevent tipping of the fork frame when cylinder is removed 3 Clean hydraulic connections at cylinder with a cleaning solvent 4 Match mark the hydraulic lines and cylinder ports to ensure correct connections during installation 5 Disconnect hydraulic lines from cylinder Cap the lines and cylinder ports to prevent contamination 6 Secure a suitable lifting strap from hoist to cylinder 7 Remove capscrew lockwasher and nut from cylinder rod pin Pull out pin with a suitable puller 8 Remove capscrew lockwasher and nut from cylinder base pin Pull out pin to disconnect cylinder from machine 9 Lift cylinder away from machine and place on suitable supports PETTIBONE T RAVERSE LLC PAGE 58 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL PETTIBONE TRAVERSE Lirr LLC PAGE 59 FixED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL BRAKE
63. RK No engine crank Park brake not engaged ON position Verify 12 VDC present on pin 1 Defective fuse blu on trans shifter If absent replace fuse 7 Place jumper between pin 1 blu Defective shifter switch and pin 7 yel If engine cranks replace shifter Place jumper between term 30 Defective start enable org grn and 87 org wht If circuit defective relay engine cranks check park control circuit Place jumper between brn wht and blk ground on park brake switch If engine cranks replace park brake switch If engine does not crank replace start enable relay 8 Transmission not in Place direction switch in neutral neutral position Dead battery Recharge battery oee BATTERY troubleshooting Defective start control Ensure that switch closes when circuit key switch actuated Ensure that magnetic switch contacts close when 12 VDC is applied to S terminal contacts do not close replace magnetic switch Defective start magnetic switch Ensure that starter solenoid throws Defective starter motor or motor rotates when 12 VDC is solenoid applied to solenoid S terminal Replace solenoid or motor Inspect wiring for loose corroded dirty connector or damaged wiring Repair or replace wiring Defective starter Repair or replace starter engage PETTIBONE T RAVERSE Lirr LLC Defective starter motor control wiring PAGE 97 FIXED AND TRAVERSING FORKLIFT ADVANCED
64. RKLIFT ADVANCED MAINTENANCE MANUAL Verify 12 VDC available to boom limit switch plug pin A If absent replace fuse 6 Temporarily replace relay 6 with relay 7 If axle releases replace relay 6 Verify solenoid continuity resistance 8 ohms 52 54 valves of oscillation manifold block If either or both open or high resistance replace solenoid s EE Defective solenoids Replace solenoids Rear axle in restricted mode boom down park Boom limit switch mis brake OFF Restrict light adjusted ON Rear axle in lock mode Park brake ON lock light ON Defective boom limit switch Defective osc limit relay Rear axle goes from free to lock 25 boom UP lock light ON park brake OFF Defective osc lock relay Rear axle does not lock when park brake switch ON boom above 25 in Defective osc lock relay restrict mode restrict light ON Rear axle does not go to restrict mode restrict light ON boom above 25 Defective solenoid coils PAGE 89 Readjust switch to open 257 boom UP Jump pin A to pin of boom limit switch harness plug If axle goes to free mode replace and readjust boom limit switch Temporarily replace relay 6 with relay 7 If axle release and mode lights go out replace relay 6 Temporarily replace relay 3 with relay 7 If axle reverts to limit mode limit light ON replace relay 3 Temporarily replace relay 3 with relay 7 If axle rever
65. RQUE SPECIFICATIONS Clamp 20 foot pounds steering Wheel Nut 32 37 foot pounds shifter Assy Bolts 18 inch pounds PETTIBONE T RAVERSE LLC PAGE 38 Horn 1 Remove the horn cover horn wire steering wheel and horn button cover and button from the steering column You will also need to unbolt the clamp from the upper column to remove the wire Use proper torque specifications when reassembling VALVES FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL cn X a JE Y i i 7 2 a PETTIBONE TRAVERSE Lirr LLC PAGE 39 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL STEERING SELECTOR VALVE The steering selector valve receives oil from the orbitrol and distributes it to the steering cylinders The distribution of oil is controlled by a switch mounted on the dash The switch provides the following steering functions 1 Two wheel steer 2 Four wheel steer 3 Oblique crab steer The selector valve is mounted in front of the battery box VALVE VALVE SCREWS STEERING SELECTOR VALVE REMOVAL 1 First remove figerglass cover and discon nect electrical connection on solenoid 2 Remove the four 4 screws that hold the valve body to the valve block 3 Remove hoses from valve block Match mark the four hydraulic lines that connect the selector valve to the orbitrol As they are disconnected cap
66. SED NE Iz E E EI C 8 VALVE 12V SUPPLY SWITCHED e 5 lu 19 BATTERY 12 24 VDC ad 20 BATTERY GROUND t qe we 21 FORK TILT RIGHT VALVE 22 FORK TILT LEFT VALVE 23 FORK TILT DOWN VALVE NOTES 1 E VALVE SUPPLY OUT IS A SWITCHED SUPPLY ONLY PRESENT WHEN THERE IS A SWITCH DEPRESSED 2 AUX 1 AND AUX 2 ARE HIGH SIDE DRIVE ON OFF OUTPUTS HE GROUND FOR THESE OUTPUT CAN BE ESTABLISHED EXTERNAL TO THE CARD 3 E DIAG LED INDICATES AN OPEN CIRCUIT CONDITION ON ANY OF THE SWITCH INPUTS VALVE OUTPUT IS DISABLED F ANY ERROR IS DETECTED PETTIBONE T RAVERSE LLC PAGE 28 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL WIRE SIZE TYPE BLU WHT MKR 6ga APL GRNZWHT 6ga APL BLK WHT MKR 6ga APL BLK GRN MKR 6ga APL BLK BLU MKR 6ga APL RED WHT MKR 6ga APL YEL WHT MKR 6ga APL GRY WHT MKR APL GRAY 6ga APL APL BLACK APL BLUE 6ga APL GREEN APL YEI LOW 6ga APL 6987 78 TO MAIN HARNESS lt RED POWER SUPPLY HITE LOAD SENSE SOLENOID PACKARD CONNECTOR BLACK gt GR 12010717 6987 15 12124582 1 PIN 6987 6 12010293 SEAL 6987 19 2 0 LEADS LUC WIRE YELLOW B GRAY D BLACK GREEN MKR FL 109
67. TTIBONE TRAVERSE Lirr LLC PAGE 9 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL Differential Pressure Adjustment on Main Control Valve n TOWARDS a PRESSURE COMPENSATOR A ADJUSTMENT E PRESSURE DIFFERENTIAL uei ADJUSTMENT E a 7 7 0 2 A m s i Zl PRESSURE DIFFERENTIAL ADJUSTMENT Pump Differential Pressure Adjustment 6 Set Steering Pressure These measurements must be taken with the gauge on the Load Sense diagnostic check point a Locate Steering Pressure adjustment screw on the brake manifold Steering Pressure Adjustment PETTIBONE T RAVERSE LLC PAGE 10 With the engine running bottom out steering by turning wheels all the way in one direction until it stops Hold wheel in this position With gauge on the Load Sense diagnostic point adjust the steering pressure adjustment screw on the brake manifold until steering pressure 15 set to 2500 psi or 25 psi FixED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 1 Final Checks Once the above procedure has been performed verify that all adjust ment screws on Pump Main Valve and Brake Manifold have been locked down with their associated jam nuts Final pressure measurements as follows Machine Pilot System Load Sense Steering Differential Model Pressure Pressure Pressure Pressure Pressure Standby psi psi psi psi
68. adual decrease in precharge pressure also can be measured repairs again can be made before total failure PETTIBONE T RAVERSE LLC PAGE 64 LLLLLLLLMM S 5 5 N Piston A TYPICAL PISTON ACCUMULATOR Precharge pressure psi No of cycles a Precharge pressure psi No of cycles 0 Precharge pressure psi No of cycles A bladder type failure is shown As fluid leaks past piston b gas side of piston accumulator fills with fluid to increase precharge pressure If precharge gas leaks past piston or vents through gas valve c accumulator gradually forces less fluid into system for lower efficiency FAILURE PREDICTION several methods can be used to monitor the precharge pressure of piston accumulators ewith the hydraulic system shut down A pressure transducer or gauge located in the gas end cap a indicates the true precharge pressure after a working hydraulic system has cooled and the accumulator does not contain fluid ewith the hydraulic system operating On request accumulator manufacturers will install a piston position sensor in an accumulator s hydraulic end cap b This sensor can be connected to a number of electronics packages With an accurate precharge and after enough system operation for thermal stability the electronics can be calibrated to provide continuous readout of pr
69. c ions are tight and that lines pipes and hoses are not damaged PETTIBONE T RAVERSE LLC PAGE 6 HYDRAULIC OIL The capacity of a hydraulic system to do work is a function of pressure and volume Pres sure is determined by resistance to flow and is normally limited by the relief valve setting Inability to perform normal circuit functions due to insufficient pressure below the setting of the relief valve indicates excessive leak age usually internal In such an event the leaking component should be repaired or replaced Working pressures with a cold system may be somewhat higher than normal due to higher oil viscosity and greater me chanical friction Fluctuating pressure may indicate dirty filters pump cavitation aerated oil damaged pump or varying resistance The arrangement of this hydraulic system includes five separate circuits boom lift boom extension fork tilt sway and steering The traversing machine hydraulic system includes a separate circuit for the traversing function The recommended hydraulic oil should have antiwear antifoam antirust and antioxidation properties for heavy duty use The following hydraulic oil viscosity is recommended for use in this machine at all ambient tempera tures RECOMMENDED ASTM VISCOSITY ISO VG 32 HYDRAULIC PRESSURE CHECKS AND ADJUSTMENTS Occasionally you should check the maximum operating pressures in the hydraulic system There is no specified
70. cover and short yel blk wire to ground If horn sounds repair or replace pickup assy column wiper ring and uplead Temporarily replace relay 7 with relay 8 If horn sounds replace relay 7 Verify 12 VDC present to horn wire wht org when button depressed If present replace horn Remove horn button If horn stops repair or replace horn button Remove column pickup assy cover Disconnect wire yel blk If horn stops repair or replace pickup assy wiper ring and uplead Temporarily replace relay 7 with relay 8 If horn works properly replace relay 7 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL HEAD AND TAIL LIGHT TROUBLESHOOTING SYMPTOM PROBABLE CAUSE REMEDY Verify 12 VDC present at headlight No head or tail lights Defective fuse switch org grn wire If absent replace fuse 16 1 light out head or tail Defective bulb Verify 12 VDC present to lamp assy If present replace bulb Verify 12 VDC present on org red wire of headlight switch with switch ON If absent replace switch Headlights ON taillights Defective headlight OUT switch Verify 12 VDC present on wht blu Defective switch of headlight switch with switch If absent replace switch d bulb in switch Defeciveswich Replace switch NOTE HEADLAMP ASSYS USE QUARTZHALOGEN TYPE H3 BULBS USE CARE NOT TO TOUCH QUARTZ ENVELOPE TO PREVENT EARLY BURN OUT REAR FLOODLIGHT TROUBLESHOOTING SYMPTOM PROBABLE
71. echarge pressure that corresponds accu rately to the true precharge and another alternative In applications where an accumulator is coupled to a gas bottle a Hall Effect sensor can be installed in the accumu lator gas end cap c to detect when the piston comes within 0 040 inches of the cap This warning indicates that precharge pres sure has dropped and the system should be shut down and checked SETUP AND MAINTENANCE Precharge Technique The fluid side should be empty during precharging so that gas side volume is at a maximum Little damage if any can take place during precharging Precharge pressure Excessively high precharge Excessive precharge pressure or a reduction in the minimum system pressure without a corresponding reduction in precharge pres sure may cause operating problems or dam age With excessive precharge pressure a piston accumulator will cycle between stages PAGE 65 Fluid Fluid Hall proximity CALABAR AI FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL Pressure transducer Pressure transducer NNNNNN TORY SS AAAAAAARARAN Sonar absolute position sensor b Pressure transducer al PETTIBONE TRAVERSE Lirr LLC FixED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL e and b and the piston will range to close to
72. engine Prime the pump by letting the engine idle with no load applied to the hydraulic system for at least two minutes Inspect pump for leaks HYDRAULIC Pump TROUBLESHOOTING CHART AND SERVICE REPAIR The following chart lists the common difficul ties experienced with the hydraulic pumps It also indicates the probable causes and remedies for each of the troubles listed This chart is organized to cover trouble that may occur due to improper service and mainte nance It should always be remembered that many apparent pump failures are actually the failures of other parts of the systems The causes of improper operation are best diag nosed with adequate testing equipment and a thorough understanding of the complete hydraulic system Please refer to your Parts Manual for pump parts breakdown PAGE 15 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL PETTIBONE TRAVERSE Lirr LLC FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL YDRAULIC PumP TROUBLESHOOTING SYMPTOM PROBABLE CAUSE REMEDY Pump not delivering oil 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 sucti
73. es into the boom tip Larger diameter boom tubes are both on the inside and the smaller diameter tubes are both on the outer sides 6 Install clamp onto tubes on tip end of boom NOTE USE LOCKTIGHT ON BOLT TO FASTENALL CLAMPS TOGETHER 4 Use a pry bar to raise the tubes in the middle to ease in installation PETTIBONE T RAVERSE LLC PAGE 126 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 7 Install clamps and hoses onto other end of 8 Install middle clamps through the access tubes and then attach the tubes to the hole in each side boom 9 Install large hoses to boom tip tubes 10 Attach front end of each extend chain with the pin and cotter pin PETTIBONE TRAVERSE Lirr LLC PAGE 127 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 11 Install seal into quick disconnect tip 14 Lift tip with hoist and guide into middle section of boom 12 Install bracket on tip and tighten side tilt hydraulics if equipped A 13 Attach one end of retract chain and tuck chain and hoses into boom tip PETTIBONE T RAVERSE LLC PAGE 128 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 15 Install bottom wear pad and keeper m 16 Install side and top wear pads Tighten all wear pads into place PETTIBONE TRAVERSE Lirr LLC PAGE 129 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 17 Install r
74. etract chain roller into place on 18 Insert pin and cotter pin onto retract chain back end of the middle boom and attach 4 6 2 19 Attach extend chain rollers with shim to top of boom NOTE THERE ISA GREASE FITTING EACH SIDE OF THE ROLLERS MAKE SURE TO GREASE BOTH PETTIBONE T RAVERSE LLC PAGE 130 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 22 Before the cylinder is completely into the boom place a drain pan underneath counterblance valve remove plugs install fittings Temporarily restrain hose on valve with plastic tie to ease in installa MS 20 Install the extend cylinder grease fitting tion and move hoses and chain to ease in installation 21 Lift the extend cylinder using the proper hoist and insert it into the boom Set down and readjust hoist as necessary PETTIBONE TRAVERSE Lirr LLC PAGE 131 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 24 The extend cyinder is fully into boom this point Before installing the pin shine a light through the tip end of the boom to check alignment of the cylinder Install pin through extend cylinder and attach with locktight and bolt Attach boom length decal to midddle boom PLASTIC TIE 23 Attach trunnion blocks to boom with bolts and locktight rj PETTIBONE T RAVERSE LLC PAGE 132
75. he fan guard with 4 four lockwashers and 4 nuts to the studs that are on the shroud 6 When the fan guard is mounted connect the upper and lower radiator hoses and also the oil cooler lines for the transmis sion 7 Fill the radiator up with a 50 50 mixture of antifreeze and water IMPORTANT When finished connecting engine run engine until at operating temperature and check coolant level Fill as needed PETTIBONE TRAVERSE Lirr LLC FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 8 Once the radiator is installed reconnect the throttle linkage mount and attach the throttle linkage to the fuel pump Also reconnect the fuel supply line to the fuel pump 9 Reconnect the electrical wiring and plugs to their previous locations NOTE electrical connections should be match marked during disassembly to ensure proper reassembly 10 Next connect the exhaust and intake components ENGINE REMOVAL For engine removal follow the engine installa tion steps in the reverse order NOTE Be sure to match mark all hydraulic lines and electrical wiring to ensure proper reassembly INDEPTH SERVICE Refer to the Cummins manuals shipped with the machine for further service and troubnleshooting information PETTIBONE T RAVERSE LLC PAGE 96 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL ENGINE TROUBLESHOOTING SYMPTOM PROBABLE CAUSE REMEDY Place park brake switch in PA
76. he electrolyte with a hydrometer Use a hydrometer with built in temperature correction or consult the hydrometer manufacturer s literature for its proper use 102 8ga RED 1290 8 0 10 14go RED 30 10 RED 29 6 RED 56 16 0RG 25 12 RED VIO STARTER RELAY 30 10 RED 63 10 GRN 57 16 ORG WAT FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL ELECTRICAL SCHEMATIC FL 11914 2 5 DEFROSTER 62 16 WHT PCTM MODULE FUEL SHUTOFF F5 5A FUEL VALVE Po SOLENOID HOLD IN lt re 6 14 YEL PULL 4999 790 APPROX 20A 0 5 2 4278 IGNITION e 4 7 8 PURER AU FUEL SOLENOID PULL IN COIL ORG _ 2 2 3 2 5 2 ALTERNATOR 28 8 RED 29 6 RED H F3 5A ALTERNATOR 2 8 6 14 9 03 49 16 8RN lt lt 16 68N IGNITION SWITCH 27 12 RED V1O 33 16 0RG GRN lt 15 16
77. hes the output of that function on supplying voltage to the appropriated control solenoid coil and regulating the control current to it at minimum value 5 At this point the driver locks out the oppo site motion output regardless of its input level If fork up has reached threshold fully depressing fork down will have no effect until fork up input is reduced below thresh old voltage This prevents the control valves from attempting to operate in both directions at one time 6 Further depressing the control button varies the input voltage to maximum and the driver increases the control current proportionally to maximum allowing smooth speed increase decrease by releasing the control button of the con trolled function The driver reaches maxi mum voltage output of approximately 3 6 VDC 7 Maximum current values for the control Solenoids Are Fork up Fork down 1 0A Fork cw Fork cow 1 75 prior to 8 1 00 2 0A after 8 1 00 NOTE 1 THAT MAXIMUM JOYSTICK REF ERENCE VOLTAGE OF 4 2 VDC IS ABOVE THE 3 6 V INPUT NECESSARY FOR MUM DRIVER CURRENT OUTPUT THIS ASSURES FULL SOLENOID SHIFT FOR MAXIMUM SPEED NOTE 2 THE DRIVER ALSO CONTROLS PUMP LOAD SENSING FOR THE FORK ROTATE FUNCTION BY ENERGIZING THE AUXILIARY LOAD SENSE RELAY COIL THE RELAY CONTACTS THEN OPENS DE ENERGIZING THE CHARGE VALVE SOLE NOID COIL ALLOWING THE PUMP TO SENSE THE FORK ROTATE VALVE OPERA TION PETTIBONE TRAVERSE Lirr LLC
78. ht does not go Defective lo brake oil pressure Unplug pressure switch if light out switch goes out replace switch Lo brake oil light does not light Replace bulb on lamp assy Jump pin A bm to pin B blk Defective lo brake oil pressure on lo brake pressure switch Accumulator does not charge Defective pressure switch open switch If light glows replace pressure switch PETTIBONE T RAVERSE LLC PAGE 70 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL SLAVHSAAIYG PETTIBONE TRAVERSE Lirr LLC PAGE 71 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL DISASSEMBLY OF DRIVESHAFT 1 Remove the 4 capscrews and 4 lockwashers which secure the cross and bearing assembly to the stub yoke Re move cross and bearing assembly APSCREWS 2 Remove the 4 capscrews and 4 lock washers which secure the other cross and bearing assembly to the slip yoke Remove cross and bearing assembly 3 Unscrew grease fittings from cross and bearing assemblies 4 Separate the driveshaft assembly by loosening the retainer cap and sliding the slip yoke from the stub yoke Use caution to prevent damaging the splines Unscrew grease fitting from slip yoke Sup YORE RETAINER CAP STUB YOKE PETTIBONE T RAVERSE LLC PAGE 72 5 Remove retainer 2 washers and felt seal from end of slip yoke SLIP YORE WASHER PELT SRAL WASHER RETAINER RETA
79. ies oil pressure to the pistons in the disc brake calipers The pressure is created by actuation of the brake pedal The power brake valve is located under the floor of the operator s compartment REMOVAL POWER BRAKE VALVE 1 Remove the 5 capscrews 5 lockwashers and 5 flat washers from the access cover under the floor of the operator s compartment Remove the Access Cover LOCATION 2 Thoroughly clean the power brake valve and hydraulic connections with an approved cleaning solvent T pea 4 EE le mr j gt V AI ONE POWER BRAKE VALVE 60 3 Match mark the hydraulic lines and valve ports to ensure correct connections during installation 4 Disconnect hydraulic lines from valve Cap the lines and valve ports to prevent con tamination 5 Remove the 3 capscrews which secure the valve base to the floor Remove valve FASTENERS 3 TOTAL BRAKE VALVE BASE BRAKE VALVE MouNTING CAPSCREWS Power BRAKE VALVE SERVICE INFORMATION For complete service information on the power brake valve refer to the Mico Service Publica tion included in this manual INSTALLATION OF POWER BRAKE VALVE 1 Install the valve in the floor of the operator s compartment and secure with the 3 capscrews 2 Connect hydraulic lines to valve 3 Bleed the brake lines by following the procedure indicated in the Mico Service Publication PAGE 61 FixED AND TRAvERSI
80. inal post Voltage drop should not exceed 0 4 VDC Check all terminals and interfaces Use a 30 VDC scale voltmeter to read cranking voltage across starter solenoid B terminal post and Insufficient battery starter motor ground terminal post capacity low cranking while cranking Voltage should not voltage drop below 9 5 VDC Repace battery with one of sufficient capacity or add battery in parallel to increase output capacity PETTIBONE TRAVERSE Lirr LLC PAGE 99 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL ENGINE TROUBLESHOOTING SYMPTOM PROBABLE CAUSE REMEDY Ensure that 9 5 VDC minimum is available to S terminal on starter solenoid the starter solenoid hammers with proper voltage applied while cranking the hold in coil is open starter solenoid hammering Hold in coil open Slow cranking and or solenoid hammering Ensure that engine is free to turn Excessive engine load normally Locate and repair engine defects PETTIBONE T RAVERSE LLC Pace 100 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL IN3ISAG 1 21412314 PETTIBONE TRAVERSE Lirr LLC 101 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL GENERAL This chapter begins with safety information which you should be aware of before working on any component of the electrical system For your own safety please observe and practice these precautionary measures This chapter consis
81. installing collar 13 Fasten collar on barrel with strap or chain wrench 1 am 14 Install NEW set screw with nylatron tip on collar PETTIBONE TRAVERSE Lirr LLC PAGE 45 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL CYLINDER COMPONENTS Lube Fitting Protective Protective 2 ug U ag PETTIBONE T RAVERSE LLC PAGE 46 Rod Wiper ead ring Ring Spring Washer amp Packing Set Retainer Ring Tube Weldment Shaft Weldment Spacer Stub U ring Piston Piston Seal Kit Nylock Nut FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL REMOVAL or CYLINDER Heavy components Before removing cylinder check the weight and make provisions for attaching and lifting Consider what removal of the component will do to the stability of the machine Use a hoist capable of supporting the weight A slipping or falling component may result in serious injury or death to personnel 1 Park machine on fi
82. l level in tank Worn or inoperative pump Inoperative relief valve Air in accumulator line PAGE 62 REMEDY Check accumulator gas charge Replace line Replace switch Check oil level Check pump Replace charging valve Check oil level Check valve setting Check pump Replace charging valve Check oil level Check pump pressure and flow Check relief valve settings Bleed accumulator line SYMPTOM ery rapid cycling of charg Accumulator charges ontinously SERVICE CHECKS FOR BRAKE SYSTEM PROBABLE CAUSE Incorrect setting of accumu lator gas charge Inoperative charging valve Inoperative pump Blocked lines Inoperative charging valve Bad solenoid valve Defective or disconnected wire Defective pressure switch PAGE 63 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL REMEDY Check accumulator gas charge Replace charging valve Check pump pressure and delivery Replace lines Replace charging valve Check voltage at solenoid valve in manifold block If voltage is present replace solenoid valve If voltage is not present at solenoid check continuity with mico switch and replace wires If mico switch is not sending a signal to the solenoid valve replace switch PETTIBONE TRAVERSE Lirr LLC FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL ACCUMULATORS The type of accumulators that the machines use are Pa
83. lenoid valve that is controlled by a Hi Low limit switch This solenoid valve directs the oil to the accumulator when the charged pressure drops below 1000psi and returns the load sense signal back to tank Under normal operating conditions where the accumulator pressure is above 1000 system pressure is constantly applied to the accumulator and to the load sense signal This allows the accumulator to stay charged during normal operation PETTIBONE TRAVERSE Lirr LLC PAGE 69 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL ACCUMULATOR TROUBLESHOOTING SYMPTOM PROBABLE CAUSE REMEDY Verify 12VDC present between pin A wht and pin blk on Open diode in harness 51 solenoid valve on charging manifold If absent replace diode Accumulator charges during engine cranking Unplug charging pressure Charging pressure switch switch If charging begins shorted beg replace pressure switch Defective solenoid Replace solenoid Defective fuse Replace fuse 6 times pressure over 1000psi Unplug pressure swtch and and jump harness side plug pin Ato B If charging stops replace pressure switch Verify 12 VDC present between 2 A org and ground at charging pressure switch If absent replace diode Verify coil resistance 9 2 Defective solenoid coil ohms If open or high replace Coll pease ed If electrical check ok replace solenoid Lo brake oil lig
84. mbly J Replace gas valve cap 10 15 in Ibs 11 5 17 cm kg and valve guard Gas cap serves as a secondary seal o 3 m 2 E Z B BLEED VALVE HANDLE GAS CHUCK SWIVEL NUT PETTIBONE TRAVERSE Lirr LLC FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL MAINTENANCE Repair Kits see Parts Book are available for all accumulator models When ordering repair kits state complete model number from nameplate Also specify fluid and temperature at which used Occasional replacement of v o ring seal on the piston is generally the only maintenance required Replacement of other seals on end caps and gas valve is recommended see Kit Numbers Periodic checking of precharge pressure will detect whether v o ring wear is sufficient to begin reducing sealing performance If precharge is low also check for gas valve and or end seal leakage Allowing for tem perature difference if any from time of its pressure checking precharge pressure will rise if oil gathers in the gas side and will fall if gas leaks into the oil side or out past gas end seals It is suggested that a check be made week after installation and thereafter once a month PRECHARGE CHECKING PROCEDURE Using appropriate valve in the hydraulic system discharge all oil from accumulator and allow piston to bottom against hydraulic end cap For the accumulator used on the forklift use gauging assembly Part LL 1803 490
85. nd bolts through boom 3 into manifold on top of boom 2 Next install fittings onto manifold and connect the tubes to the fittings 23 Install back side wear pad into boom 2 and top wear pads into boom 3 uo E E PETTIBONE TRAVERSE Lirr LLC PAGE 123 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 24 Use a come along on top of boom3 and attached to boom 1to pull booms together so chain and extension cylinder can be attached into back of boom 3 25 Attach trunnion blocks to extension cylinder and attach blocks to boom 3 Attach chain to anchor PETTIBONE T RAVERSE LLC 26 Insert set screws and bushings into boom 3 and attach hoses and bulkhead fittings into back of boom 3 Boom DISASSEMBLY 1 Reverse order to disassemble Boom INSTALLATION REMOVAL 1 Attach boom onto machine using the proper hoists See 8 000 Pound Boom Installation procedure PAGE 124 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL WOO 000 OL 9 000 8 PETTIBONE TRAVERSE Lirr LLC PAGE 125 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL Boom ASSEMBLY 5 Attach fittings to all boom tubes at the tip u Also install small hoses to small tubes 1 Install the grease fitting and grease line to install into tip the boom tip NOTE LARGER HOSES WILL BE ADDED LATER 2 Install the bottom side and top wear pads 3 Insert boom tub
86. nect lines to correct ports Replace springs Replace o ring PETTIBONE TRAVERSE Lirr LLC FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL TILT AND AUXILIARY HYDRAULIC JOYSTICK 2 Axis CARD Overview 4 5 lt TAT X EU AX x The Fork Control Consist of four control buttons mounted in the joystick handle the 2 axis driver module the solenoid operated fork up down section of the main valve the auxil iary fork rotate solenoid operated valve the auxiliary charge relay and the charge solenoid valve on the brake charge manifold E ANS 7 3 4 P a ot Medes ya z BIR Mii D 2 7 n b Sf i ki Proportional Solenoid Valve pM a ee Ze Ake N L90 Tilt Section Solenoids 1 The fork up and down buttons supply an analog voltage reference to the 2 axis driver proportional to button depression varying approximately 5 VDC to 4 2 VDC to control the speed of operation Digital PWM Module 2 The 2 Axis driver is located under the arm rest bracket underneath the fiberglass console on the RH side of the operator compartment Fork Tilt and Auxiliary Function Joystick with Digital PWM Module PETTIBONE T RAVERSE LLC PAGE 26 3 2 axis driver is a Pulse Width Modu lated PWM curren
87. ns at cylinder for leakage Inspect for excessive leakage at rod wiper It is normal for a light film of oil to adhere to the rod 50 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL ALIGN BASE END OF CYLINDER BETWEEN FRAME MOUNTS FULLY INSTALLED Sway CYLINDER DRIVE PIN THROUGH AND SECRURE WITH CAPSCREW AND NUT USE LOCKTIGHT ON CAPSCREW BEFORE INSERTING AND TORQUE TO PROPER SPECS PETTIBONE TRAVERSE Lirr LLC PAGE 51 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL FRAME TILT CYLINDER TROUBLESHOOTING SYMPTOM PROBABLE CAUSE ylinder will not operate Failed hose or hose hen toggle switch is connections leaking actuated Low oil level in reservoir Oil bypassing spool in main valve Rod wiper leaking exces sively Oil bypassing cylinder piston Faulty pump operation Oil bypassing cylinder piston ylinder drifts will not Oil bypassing dual pilot remain in position check valve on cylinder Oil bypassing spool in main valve Spool not centered in main valve PETTIBONE T RAVERSE LLC PAGE 52 REMEDY Replace hose or tighten loose connections Add oil to FULL mark on reservoir gauge Replace defective spool seal s Replace defective wiper Replace defective piston seal Repair or replace pump Replace defective piston seal Replace defective check valve ball s or spring s Replace defective spool seal 5 Replace
88. nsmission down onto the mounts that are attached to the frame ENGINE T RANSMISSION IN PLACE 6 When the engine and transmission are in place install the radiator RADIATOR INSTALLATION 1 Attach a chain to the upper most bolts that secure the mounts to the radiator MOUNTS Torque Values Ft Lb Dry M12x1 75 93 70 1 2 UNC 110 80 Note 1 2 UNC through top of dome mount should not exceed 50 Ft Lb PETTIBONE T RAVERSE LLC PAGE 94 2 Move the radiator over the rear portion of the frame and carefully lower it down into place ym HET 177 f m LOWERING RADIATOR 3 When the radiator is aligned over the mounting holes in the frame start the four mounting bolts IMPORTANT Be sure that the radiator is as low in the mounts as possible This is to prevent the lift cylinders from hitting the top of the radiator when the boom is completely lowered If the radiator will not set all of the way down GENTLY tap it down with a dead blow hammer or the heel of your hand 4 Secure all 4 four of the radiator mounting bolts and also tighten the engine transmis sion mounting nuts mu 7 gly iy id AS Ex eee uy it a ra INSTALLING RIGHT RADIATOR MOUNT FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 2 INSTALLING LEFT RADIATOR MOUNT 5 Once the radiator is secured attach t
89. o FWD or no REV CCO light OFF No FWD and REV foot brake released CCO arm switch OFF No FWD and REV foot brake applied CCO arm switch ON No FWD and REV foot brake released CCO arm switch ON Transmission does not disengage when foot brake applied CCO light does not light arm switch Transmission does not disengage when park brake applied Defective CCO relay Park brake switch in PARK CCO light ON park brake light ON Defective park CCO control circuit CCO arm switch OFF Foot brake applied with CCO arm switch ON arm switch light ON CCO light ON Defective brake light switch Defective brake light fuse Defective brake light switch Defective CCO arm Switch FWD or REV only Defective CCO relay Defective isolation diode open in park brake switch lead pnk blk Defective park brake switch 109 Jump relay 30 to 874A of affected direction If transmission engages replace relay 1 for FWD or relay 2 for REV Release park brake switch to OFF Verify 12 VDC absent on park brake switch pnk blk wires when park brake OFF If present unplug switch If voltage now absent replace park brake switch Release foot brake or turn CCO arm switch OFF Unplug pnk wire on brake light switch If FWD and REV engages replace brake light switch Verify 12 VDC present on pnk wht wire lf absent replace fuse 13 Verify 12 VDC present on CCO arm switch
90. on line pump 1 Inspect suction line for 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 T RAVERSE LLC PAGE 16 SYMPTOM Pump makes excessive noise Pump never stops pumping oil is excessively hot or main directional valve makes exces Sive noise HYDRAULIC PumP TROUBLESHOOTING PROBABLE CAUSE Partially blocked suction line Low oil level in reservoir Air leak at pump suction hose joint or pump shaft seal Collapsed suction hose Improper DP setting between pump and main directional valve PAGE 17 FixED AND TRAvERSING FORKLIFT ADVANCED MAINTENANCE MANUAL REMEDY Remove contamination and flush suction line with clean hydraulic oil Check for loose lining in suction hose Add oil to FULL mark on sight gauge Pour oil over fittings and around driveshaft to check for air leaks Replace defective pump seal Test at full rom as hose may be normal at low speed but collapses at high speed Replace as necessary Adjust DP pressure setting using the pressure adjustment procedures PETTIBONE TRAVERSE Lirr LLC FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL REMOTE CONTROLLED MAIN DIRECTIONAL VALVE This machine is equipped with 19015 closed center p
91. ons next Dash cover with removed panels 7 Remove the lower dash panel by remov lighting switches ing the knob and all 6 screws Right panel with optional bn AM P b Right panel connections 6 Remove key switch nut and cover from dash Lower dash panel 3 Lower dash panel knob Key switch nut PETTIBONE T RAVERSE LLC PAGE 36 Dash panel screw Removing the panel 8 Unwrap wires from left side off of steering column to make access to column easier FixED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 9 Disconnect hoses and cap ports to prevent contamination zin x 93 ri 4 in A 10 Remove the four bolts with lockwashers from the frame NOTE If you need to replace the bolts that were removed at this point do not use bolts longer than 5 8 Longer bolts will damage the orbitrol 11 Loosen clamp assembly on upper cover of steering column and remove from machine PETTIBONE TRAVERSE Lirr LLC PAGE 37 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL REASSEMBLY For installation simply follow the steps in the reverse order When installation is complete start the machine and operate the steering from one extreme to the other several times to purge any air that may be trapped in the valve and lines Then check the fluid level in the hydraulic reservoir TO
92. or plug the fittings and lines as they are disconnected to prevent contamination Also be sure to use a container to catch the hydraulic oil that will spill NOTE DISPOSE OF OIL PROPERLY DO NOT POUR ON THE GROUND INTO SEW ERS OR INTO BODIES OF WATER 4 Next remove the 2 screws that anchor the valve block to the mounting plate 5 Remove the fittings from the valve block and remove the valve block from the machine For installation simply follow the steps in the reverse order When installation is complete start the machine and operate the steering from one extreme to the other several times to purge any air that may be trapped in the valve and lines Then check the fluid level in the hydraulic reservoir and fill as necessary PETTIBONE T RAVERSE LLC 40 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL STEERING SELECTOR TROUBLESHOOTING SYMPTOM PROBABLE CAUSE REMEDY Verify 12 VDC present to steer Defective fuse switch on gry red lead If present replace fuse 10 Verify 12 VDC present between pin 1 org and pin 2 blk on solenoid B plug of steering valve If absent replace switch steering has 2 wheel steer only No 4 wheel steer Defective switch Verify 12 VDC present between pin crab steer 1 blu 2 blk of solenoid A plug of steering valve If absent replace switch Verify resistance of affected coil of Defective solenoid coil 4 8 ohms
93. pin 1 Defective fuse blu on shifter plug none replace fuse 7 Verify 12 VDC available to No FWD engage 4 FWD REV control module plug No REV engage CCIE REND Pur Wht wire in FWD not present replace shifter Verify 12 VDC available to FVVD REV control module plug on Org Wht wire in REV not present replace shifter No shifter power Machine does NOT start Verify approx 6 VDC available to FWD solenoid plug between pin 1 grn yel and 2 on FWD solenoid not present replace FWD REV Control module Defective FWD REV control module NOTE OUTPUT OF MODULE IS APPROX eVDC Verify approx 6 VDC available to REV solenoid plug between pin 1 gry and pin 2 wht on REV solenoid If not present replace FWD REV Control module Verify 12 VDC available to Defective wire no power FWD REV control module plug to control module between blu and brn If absent repair wire defect Verify coil resistance 3 2 ohms of affected coil If open or high Defective solenoid coil replace NOTE MAXIMUM FWD REV COIL VOLTAGE IS 6 VDC DO PLACE 12 VDC ACROSS COIL TERMINALS TO PREVENT BURNOUT If electric checks ok replace solenoid Defective CCO circuit See CCO troubleshoot PETTIBONE TRAVERSE Lirr LLC PAGE 81 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL NOTES PETTIBONE T RAVERSE LLC PAGE 82 FIXED AND
94. pnk wire when foot brake applied If absent replace brake light switch Verify 12 VDC present on pnk blk wire on CCO switch when foot brake applied with CCO switch ON If absent replace CCO switch Switch FWD and REV relays If direction of disengagement reverses replace defective relay Verify 12 VDC present on CCO arm switch pnk blk when park brake applied CCO switch OFF absent replace diode Verify 12 VDC present on park brake switch pnk blk wire with park brake applied If absent replace park brake switch PETTIBONE TRAVERSE Lirr LLC FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL AUDIBLE WARNINGS TROUBLESHOOTING SYMPTOM PROBABLE CAUSE REMEDY Backup alarm does not sound in REV Defective backup alarm transmission works properly Verify 12 VDC present between backup alarm brn and blk when REV CCO arm switch Off park brake OFF present replace backup alarm Horn does not sound Defective fuse Replace fuse 14 Defective relay control circuit Steering column pickup assy wiper ring horn button Defective horn relay Defective horn Defective relay control circuit steering column pickup assy wiper ring or horn button Horn sounds continuously Defective horn relay PETTIBONE T RAVERSE LLC 110 Remove horn button Short button lead to ground If horn sounds clean or replace horn button Remove column pickup assy
95. posite button control out If this is suspected switching the input wires of the affected circuit will cause the lockout switch i e up to down or left to right to opposite of the original fault Replace the joystick button if that appears to work PETTIBONE TRAVERSE Lirr LLC PAGE 31 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL PROBABLE SYMPTOM CAUSE Operates in Incorrect pilot one direction pressure or bad only solenoid No output Bad continuity or functions driver board Sluggish or slow Bad driver board or operation of aux load sense relay fork rotate Sluggish or slow operation of Fork Tilt PETTIBONE T RAVERSE LLC Jovsrick PWM TROUBLESHOOTING REMEDY Verify hydraulic solenoid valve operation by switching plugs on the valve and depressing control buttons If control switches direction replace solenoid coil and or check hydraulic pilot pressure Verify solenoid coil continuity and resistance with ohmmeter Proper coil resistance at 70 F is approx 5 2 ohm for main valve L90 coils and 6 ohm for aux solenoid valve D1VVV coils NOTE COIL RESISTANCEWILL VARY WITH TEMPERATURE VARIATION Verify line voltage present at pin D measured to ground Frame on Packard 4 pin output plug when control button is depressed If not present verify continuity of harness between pin D pin 110f the 23 pin amp plug for fork up down For fork rotate left right verify continuity bet
96. replace directional lever assy Verify 12 VDC presenton red leadof brake Tail lamp If present replace bulb FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL DIRECTIONAL HAZARD LIGHTS TROUBLESHOOTING SYMPTOM PROBABLE CAUSE REMEDY No directional lights no Verify 12 VDC present to wht blu brake lights no hazard Defective fuse lead of flasher plug If absent lights replace fuse 13 Remove flasher and jump wht blu lead to yel red lead in flasher socket If directionals light but do not flash replace flasher Directional lights do not light Brake lights normal Defective flasher Verify 12 VDC available to pin 3 yel red of directional lever plug If present replace directional lever assy NOTE VOLTAGE MAY PULSE AT SIGNAL RATE Defective directional lever assy EU Io GNS LONE OU Defective flasher Replace flasher do not flash 1 light OUT Defective bulb Replace bulb Unplug directional lever and jump harness plug as follows for affected lamp 3 yel red to pin 4 grn wht LF 3 yel red to pin 7 red blu RF pin 3 yel red to pin 5 gry LR pin 3 yel red to pin 8 blk wht RR If affected lamp lights replace directional lever assy Hazard lights will not Defective directional Replace lever assy engage lever assy Hazard lights will not Defective directional Replace lever assy disengage lever assy Defective directional lever PETTIBON
97. rker piston type Some useful information follows charge 750 psi of Nitrogen Failure prevention Accumulator failure generally is defined as its inability to accept and exhaust a specified amount of fluid when operating over a specific system pressure range Failure often results from an unwanted loss or gain of precharge pressure Piston accumulators normally fail in one of these gradual modes Fluid leaks to the gas side This failure sometimes called dynamic transfer normally takes place during rapid cycling operations after considerable time in service The worn piston seal wipes a small amount of fluid into the gas side with each stroke as the gas side slowly fills with fluid precharge pressure rises and the accumulator stores and ex hausts decreasing amounts of fluid The accumulator totally fails when precharge pressure equals maximum hydraulic system pressure At that point accumulator will accept no fluid Because the rise in precharge pressure can be measured failure can be predicted and repairs made before total failure occurs and gas escapes Precharge usually is lost as gas slowly bypasses deteriorated piston seals Seal deterioration occurs from the wear of millions of cycles from fluid contamination or from a combination of the two Gas also can directly vent through a defective gas valve core or end cap O ring Less precharge pressure forces less fluid into the system Because this gr
98. rm level surface Engage parking brake 2 Raise boom approximately two feet above carry position and support from shop floor or ground 3 Clean hydraulic connections at cylinder with a Cleaning solvent 4 Match mark hydraulic lines and cylinder ports to ensure correct connections during installation 5 Disconnect hydraulic lines from cylinder Cap the lines and cylinder ports to prevent contamination 6 Secure a suitable lifting strap from hoist to cylinder 7 Remove capscrew and nut from cylinder rod pin Pull out pin with a suitable puller to disconnect cylinder from boom 8 Remove capscrew and nut from cylinder base pin Pull out pin to disconnect cylinder from frame 9 Lift cylinder away from machine and place on suitable supports PETTIBONE TRAVERSE Lirr LLC PAGE 47 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL INSTALLATION OF LIFT CYLINDER WARNING HEAVY COMPONENTS BEFORE INSTALLING CYLINDER CHECK ITS WEIGHT AND MAKE PROVISIONS FOR ATTACHING AND LIFTING USE A HOIST CAPABLE OF SUPPORTING THE WEIGHT A SLIPPING OR FALLING COMPONENT MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL 1 Secure a suitable lifting strap from hoist to cylinder Lift the cylinder into position on machine and align base end between cylinder mounts 2 Drive pin through base end of cylinder and secure with capscrew and nut Remove lifting strap Note Capscrew MUST have locktight applied 3
99. roportional load sensing and pressure compensated system valve Oil from the pump enters the directional valve through the inlet port located on the far left section as shown Oil returns to the reservoir through the outlet port located on the section that is on the opposite side of the valve as shown also ORASE PACS SUA Ae rei ee SSE 41 P BLET 3 MAIN DIRECTIONAL VALVE No PLUMBING MAIN DIRECTIONAL VALVE INSTALLED FRONT OF MACHINE PETTIBONE T RAVERSE LLC All of the boom functions are pilot controlled at the main directional valve REAR OF MACHINE PAGE 18 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL The LS PX PL and LSP functions are shown below LS This is the Load Sense Pressure line that sends the load signal back to the hydraulic pump PX line sends oil to the system pressure test port PL This line sends oil to the load sense pressure test port LSP This line carries load sense pressure returning from the brake steering systems P2B This line sends oil to the brake charge manifold PETTIBONE TRAVERSE Lirr LLC PAGE 19 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL REMOVAL OF MAIN VALVE INSTALLATION OF MAIN VALVE 1 Install the valve onto the mount and secure with the 4 capscrews 4 lockwashers Heavy components Before removing and 4 nuts Remove lifting
100. rrent capacity Maximum allowable differential is 0 5VDC Check and repair all defective connections Recharge battery to full charge Check specific gravity of each cell Temperture corrected readings of each cell should not vary A oulphated battery variable of more than 0 50 points between cells indicate a bad battery The chart below indicates battery charge at different hydrometer readings 1 260 1 280 Full 1 230 1 250 3 4 Charge 1 200 1 220 1 2 Charge 1 170 1 190 1 4 Charge 1 140 1 160 Near dead 1 110 1 130 Dead If the battery cannot be recharged or corrected to 1 250 or above the battery is sulphated Replace PETTIBONE T RAVERSE LLC 106 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL GAUGES TROUBLESHOOTING SYMPTOM PROBABLE CAUSE REMEDY No power to any gauge gauge limit lights out or dim Defective fuse Replace fuse 12 Defective instrument Verify gauge ground terminal panel ground continuity to frame Repair Single gauge does not indicate gauge light ON Single gauge indicates max Single gauge indicates incorrectly Short gauge load to ground at Defective sender sender If gauge reads max replace sender If not defective sender see above Defective gauge and reading does not change replace gauge Defective gauge ground Verify good ground to gauge lead terminal Repair Disconnect sender lead at sender Defective sender
101. s 4 Connect the ground cable to the battery 5 Start engine and actuate joystick to ensure correct operation Be sure to check forl eaks as the joysticks are operated 6 Replace console cover and armrest with the two wing nuts PETTIBONE T RAVERSE LLC PAGE 24 REMOTE CONTROL JOYSTICK TROUBLESHOOTING SYMPTOM Pilot operated spools in main valve do not shift hen joystick is actuated oystick chatters rong response to joystick movement oystick does not center 011 leaks between sections of remote control valve PROBABLE CAUSE Improper stand by pressure Not enough pilot pressure supplied to main valve Leak s in pilot lines from remote control valve Blocked pilot lines Pilot pressure too high Pilot lines connected to wrong valve ports Broken centering springs Defective section o ring PAGE 25 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL REMEDY Adjust the pressure com pensator Pilot pressure should be within the range of 300 psi 25 psi If itis not clean filter and clean or replace pilot spool Tighten pilot hose couplings or replace defective hoses Remove contamination and flush pilot lines with clean hydraulic oil Check pilot pressure using a 600 psi pressure gauge Correct pressure should be within the range of 300 psi 25 psi If pressure is too high clean or replace pilot spool in main directional valve Recon
102. s into keyed portion of driveshaft yoke WARNING KEYWAY HEAVY COMPONENTS BEFORE INSTALLING DRIVESHAFT CHECK ITS WEIGHT AND MAKE PROVISIONS FOR ATTACHING AND LIFTING USE A HOIST CAPABLE OF SUPPORTING THE WEIGHT A SLIPPING OR FALLING COMPONENT MAY RESULT IN SERIOUS INJURY OR DEATH 1 Secure a suitable lifting strap from hoist to driveshaft Lift the driveshaft into position between transmission and axle BEARING 2 Bring one end of driveshaft up against drive yoke on axle or transmission Insert INSERT Cross BEARINGS INTO YOKE KEevwavs opposite bearings of cross into keyed portion of drive yoke Clamp opposite bearings with a clamp to compress seals and seat each bearing into Clamp opposite bearings with clamp to its keyway DO NOT INSTALL BEARING compress seals and seat each bearing into CAPSCREWS UNTIL BEARINGS ARE its keyway DO NOT INSTALL BEARING PROPERLY SEATED CAPSCREWS UNTIL BEARINGS ARE PROPERLY SEATED PETTIBONE TRAVERSE Lirr LLC PAGE 73 FixED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 3 Secure opposite bearings of cross to drive yoke with the 4 capscrews and 4 lockwashers Remove clamp 4 Repeat steps 2 and 3 for other end of driveshaft 5 Remove block and jack from axle 6 Lubricate the driveshaft and cross and bearing assemblies with the recom mended lubricant specified PETTIBONE T RAVERSE LLC PAGE 74 SYMPTOM Noise Vibration
103. s to lock mode lock light ON replace relay 3 Verify 51 amp 53 coil continuity resistance of 8 ohms If open high resistance replace coil s PETTIBONE TRAVERSE Lirr LLC FixED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL REAR AXLE STABILIZATION TROUBLESHOOTING SYMPTOM PROBABLE CAUSE REMEDY Restrict light does not light in restrict mode axle works properly ecc our camp Replace bulb or lamp assy assembly Lock light does not light in lock mode axle works properly Defective bulb or lamp assembly Replace bulb or lamp assy Temporarily replace relay 3 with Defective lock relay relay 7 If light glows replace relay 3 PETTIBONE T RAVERSE LLC PAGE 90 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL NOTES PETTIBONE TRAVERSE Lirr LLC PAGE 91 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL NOTES PETTIBONE T RAVERSE LLC PAGE 92 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL PETTIBONE TRAVERSE LLC PAGE 93 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL ENGINE INSTALLATION 3 Align the mounts and place the bolts through the holes Attach the washer and 1 Attach a chain with hooks to two lifting nuts but wait to tighten until after the points on the engine and transmission and radiator has been installed lift them over the frame ENGINE ON HOIST 2 Lower engine and tra
104. se above 13 2 Tighten or replace bett Verity that ll engine shut off circuit loads do nat exceed 75 of rated alternator capacity Defective alternator or Replace alternator or voltage voltage regulator regulator Defective battery Test Battery see BATTERY troubleshooting Load alternator to rated capacity Check voltage between alternator Excessive charge line output terminal case and battery resistance loose dirty terminals Charge voltage at the corroded charge line battery should be within USOC of connectors charge voltage atthe alternator Inspect and repair replace defective charge line PETTIBONE T RAVERSE LLC 104 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL CHARGING SYSTEM TROUBLESHOOTING SYMPTOM PROBABLE CAUSE REMEDY High charge rate output Defective alternator or Replace alternator or voltage voltage exceeds 15VDC voltage regulator regulator Excessive electrolyte temperature Electrolyte temperature must not exceed 125 F 51 C in combination of ambient and charge power dissapation Defective battery internal Test battery See BATTERY short troubleshooting BATTERY TROUBLESHOOTING SYMPTOM PROBABLE CAUSE REMEDY Battery goes dead ina short time overnight or nonuse week end Electrical accessories on when machine not In use Defective ignition key switch Defective charging alternator internal short Defec
105. sent replace fuse 4 Verify 12 VDC present on heater Defective switch plug brn blu pin in LO position If absent replace switch Defective motor If switch tests ok replace motor PETTIBONE T RAVERSE LLC Wiper runs in low only Defective wiper switch parks normally Heater does not run either position Heater runs low speed only PAGE 114 FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL ACCESSORIES TROUBLESHOOTING SYMPTOM PROBABLE CAUSE REMEDY Verify 12 VDC present on heater Defective switch plug brn org pin B in HI position If absent replace switch Defective motor If switch tests ok replace motor Verify 12 VDC present to switch in Defective fuse fan base If absent replace fuse 2 Verify 12 VDC present to and LO switch terminal when switch Heater runs speed only Defroster fan does not run either HI or LO Defective switch actuated If absent replace switch or fan assy Verify 12 VDC present on LO Defroster fan does not Switch speed terminal of switch when run in LO actuated If absent replace switch or fan assy Defective fan assy motor switch tests ok replace fan assy Verify 12 VDC present on HI speed Defective switch terminal of switch when actuated If absent replace switch or fan assy Defective fan assy motor switch tests ok replace fan assy Defroster fan does
106. stem Main valve makes excessive noise oil excessively hot or pump does not stop pump ing Load drops when spool moved to a working position PROBABLE CAUSE Defective o ring s in spool control Pinched or blown seal s Tie rod fasteners not correctly torqued Broken centering spring s in spool control Bent spool Foreign particles in valve Defective fuse switch or solenoid Defective electrical wire from switch to solenoid Electrical plug disconnected from solenoid Low oil level in reservoir Valve body cracked inside Spool not moved to full stroke Improper DP setting be tween pump and valve Load larger than capacity PAGE 21 FixED AND TRAvERSING FORKLIFT ADVANCED MAINTENANCE MANUAL REMEDY Replace o ring s Replace seal s Torque fasteners to 44 ft Ibs 60 Nm Replace spring s Replace section Clean valve Ensure that 12 vdc is available to solenoid coil If no voltage available replace fuse or switch If voltage is available replace solenoid Repair wiring defects or replace wiring Connect plug to solenoid Add oil to FULL mark on sight gauge Replace valve section Check spool travel Adjust accroding to proce dure of main valve and pump Reduce to rated load capac ity at rated load center PETTIBONE TRAVERSE Lirr LLC FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL HYDRAULIC REMOTE CONTROL
107. strap the valve check its weight and make provisions for attaching and lifting 2 Connect hydraulic lines electrical plugs Use a hoist capable of supporting the and solenoids to valve weight A slipping or falling com ponent may result in injury or death to 3 Connect ground cable to battery personnel 4 Start engine and actuate all valve functions to ensure correct operation Inspect valve 1 Disconnect battery ground cable for leaks 2 Remove the access cover 5 Install access cover 3 Thoroughly clean the valve and hydraulic connections with a cleaning solvent 4 Match mark hydraulic lines and valve ports to ensure correct connections during installation 5 Disconnect all hydraulic lines from the valve bank and ensure that there is a container to catch any oil that will spill Cap the lines and valve ports to prevent con tamination 6 Match mark the electrical plugs and sole noids to ensure correct connections during installation 7 Secure a suitable lifting strap from hoist to valve 8 Remove the 4 capscrews 4 lockwashers and 4 nuts which secure the valve to the mount Lift valve from machine PETTIBONE T RAVERSE LLC 20 Main DIRECTIONAL VALVE TROUBLESHOOTING SYMPTOM Oil leaks at either end of Oil leaks between sections pool does not return to neutral position olenoid for fork frame side ilt fails to energize No motion slow or jerky action of hydraulic sy
108. t contamination 6 Secure a suitable lifting strap from hoist to cylinder 7 Remove capscrew and nut from cylinder rod pin Pull out pin with a suitable puller 8 Remove capscrew and nut from cylinder base pin Pull out pin to disconnect cylinder from machine 9 Lift cylinder away from machine and place on suitable supports PETTIBONE T RAVERSE LLC INSTALLATION OF FRAME TILT Sway CYLINDER ZNWARNING HEAVY COMPONENTS BEFORE INSTALLING CYLINDER CHECK ITS WEIGHT AND MAKE PROVI SIONS FOR ATTACHING AND LIFTING USE A HOIST CAPABLE OF SUPPORTING THE WEIGHT A SLIP PING OR FALLING COMPONENT MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL 1 Secure a suitable lifting strap from hoist to cylinder Lift the cylinder into position on main frame and align base end between cylinder mounts 2 Drive pin through base end of cylinder Apply locktight to capscrew and secure pin with capscrew and nut Remove lifting strap 3 Connect hydraulic lines to cylinder 4 Start engine and apply retract pressure to fill cylinder with oil 5 Extend cylinder to align rod end between cylinder mounts and cradle 6 Drive pin through rod end and secure with capscrew and nut NOTE APPLY LOCKTIGHT TO CAPSCREW 7 Operate cylinder several times to remove air from circuit Cylinder may initially operate jerky because of trapped air 8 Add oil to FULL mark on reservoir gauge 9 Check hydraulic connectio
109. t compensated output control which maintains a constant level of current to the solenoid coils proportional to an input signal from the joystick ensur ing constant hydraulic operation regard less of system temperature and voltage variations The driver is equipped with two monitor Leds power and diagnostic The power LED lights whenever power is applied to the unit by the key switch The diagnostic LED indicates an input circuit failure and should not be lit during normal operation An open circuit in any of the input circuits from the joystick fork up or down and fork rotate cw or ccw will cause the LED to light and the driver to lock out ALL output functions therefore and input failure in fork up down will also lock out fork cw ccw tion and vice versa The diagnostic LED can be tested by discon necting the connector from the grip assembly to the controller harness which will turn the LED on Operation 1 With no buttons pressed there should be no voltage at pins 11 and 12 2 With a button pressed depending on the axis Vbatt minus of about 1 volt will be present at either pin 11 or 12 3 Normal standby reference voltage of the four control input may range from 5 to 1 2 vdc approximately FixED AND TRAvERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 4 Depressing any control button causes its reference voltage to begin rising At 1 4 vdc the driver control threshold is reached which switc
110. ter boom 1 is partially inserted into boom 2 11 Install top rear wearpad after boom 1 is installed into boom 2 PETTIBONE T RAVERSE LLC 12 Install top rear wearpad bracket 13 Install side wearpad onto boom 2 14 Install top spacer block on the front of boom 2 between boom 2 amp 1 z J n 120 15 Install chain roller and roller bolts onto top of boom 2 FixED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 16 Install hose sheaves onto back of boom 2 and pull hoses and chain out of boom 1 cr dels IE umm PETTIBONE TRAVERSE Lirr LLC PAGE 121 FixED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 17 Attach hoses to boom manifold on top of boom 2 5 18 Attach chain anchor and insert through manifold and attach spring and nut NOTE Chain anchor must have anti seize applied PETTIBONE T RAVERSE LLC 19 Lift extension cylinder with proper hoist and insert into boom 2 Install 4 bolts on back of extension cylinder into rear of boom 2 Also install the fittings onto the extension cylinder WATCH YOUR STEP PAGE 122 FixED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL 22 Install side wear pads into front of boom 3 and install spacer onto top 20 Using the proper hoist lift boom1 amp 2 into boom 3 mi _ 1T V 21 Install washers a
111. ther than the above listed is used make sure it is compatible with the gas valve assembly Nitrogen source and all components must be rated for a pressure at least as high as the nitrogen source It is strongly recommended that the nitrogen bottle used have a high pressure regulator Make sure nitrogen supply is shut off Attach hose to nitrogen bottle A Remove gas valve guard and gas valve cap B Back gas chuck T handle all the way out counter clockwise before attaching charging assembly to accumulator gas valve C Close bleed valve D Making sure not to loop or twist the hose attach swivel nut to gas valve and tighten 10 15 in Ib 11 5 17 cm kg E Turn gas chuck T handle all the way down This will depress core in gas valve F Crack open nitrogen bottle valve and slowly fill accumulator Shut off when gauge indicates desired precharge G Let the precharge set for 10 to 15 minutes This will allow the gas tempera ture to stabilize If the desired precharge Is exceeded close nitrogen bottle valve then slowly open bleeed valve Do not reduce precharge by depressing valve core with a foreign object High pressure may rupture rubber valve seat PAGE 67 FixED AND TRAvERSING FORKLIFT ADVANCED MAINTENANCE MANUAL H When finished precharging accumulator turn handle all the way out on gas chuck then open bleed valve 1 Hold gas valve to keep from turning loosen swivel nut remove asse
112. time interval as to when these pressures should be checked Usually pressure checks are made if the system is unable to perform normal hydraulic functions The maximum operating pressure for the hydraulic system is measured by operating any hydraulic function to its maximum stroke and holding it there while taking the gauge reading This causes the hydraulic pump to provide maximum system pressure FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL NOTE ALL PRESSURES SHOULD BE a With engine off attach a 600 TESTED WITH THE NORMAL OPERATING psi gauge to the pilot pres TEMPERATURE OF THE HYDRAULIC OIL sure diagnostic check point FROM 80 120 F 27 49 C Start engine and read gauge E value while actuating a 1 To check hydraulic pilot pres function sure b Onunits equipped with Dana axles Clark transmission a Locate pilot pressure diag pilot pressure should be 500 nostic point on machine psi or 25 psi d SYSTEM PRESSURE Onunits equipped with Carraro axles transmission SENSE pilot pressure should be 300 psi or 25 psi 2 To adjust pilot pressure a Locate the brake manifold block Loosen jam nut on pilot adjustment cartridge and turn counter clockwise 2 fullturns Start the machine and move the joystick func tion Adjust pilot pressure to the desired pressure above Tighten the jam nut and operate functions to insure correct pressure setting
113. tions Incorrect system voltage Open circuit in joystick inputs Threshold minimum voltage lockout FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL Check harness for loose or mis aligned pins to driver board connection 3 way plug Verify that system voltage is available to driver board between pin 19 and pin 20 on the driver connector If voltage is present and LED does not light replace driver board Verify 5VDC to joystick pin 2 and pin 1 If no voltage check driver to joystick harness for continuity If continuity replace driver card Verify stand by reference voltage from joystick 5VDC 1 2VDC pin 3 to pin 1 pin 4 to pin 1 pin 5 to pin 1 and pin 6 to pin 1 If one or more not present check plug for bad or broken pins If no pins are bad replace joystick or joystick switch If stand by voltage is present at joystick plug check harness continuity at plug and driver on all 4 input wires If one or more fails continuity repair or replace harness NOTE STAND BY REFERENCE VOLTAGE MUST BE PRESENT ON ALL 4 DRIVER CONTROL INPUTS TO CANCEL INPUT FAILURE LED AND OUTPUT LOCKOUT FUNCTION EVEN WHEN UNIT 5 NOT EQUIPPED WITH AUX FORK ROTATE VALVE AND CIRCUIT If the input of one directional control button stand by voltage is slightly above 1 4 VDC but not high enough to allow the driver board to supply minimum current necessary to shift the hydraulic valve control spool thereby locking its op
114. tive battery shorted internally Defective wiring shorted Pace 105 Turn accessories off and recharge battery observing proper charging procedure charging circuit for correct operation Check that ignition key switch contacts are open when engine is stopped If contacts are closed replace switch Check that no current is flowing in alternator output line with the engine stopped If current is flowing replace alternator NOTE A VERY SMALL SPARK MAY BE NOTED IF THE OUTPUT WIRE IS DISCONNECTED WHEN THE BATTERY CABLES ARE DISCONNECTED THIS IS NORMAL Fully charge battery and disconnect for discharge timer period noted in machine failure Check charge state at end of test period Replace battery if it is discharged while disonnected Check all wiring visually and with meters Repair or replace defective wiring PETTIBONE TRAVERSE Lirr LLC FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL BATTERY T ROUBLESHOOTING SYMPTOM PROBABLE CAUSE REMEDY Battery at low charge Loose or worn alternator Check tension on alternator belt condition belt Tighten or replace belt Check that alternator output voltage maintains 13 14 5 VDC See CHARGING troubleshooting Defective charging alternator low voltage Check voltage differential between alternator BAT terminal and alternator case and and Excessive charge line battery posts at full alternator resistance voltage drop cu
115. to the system DO NOT OVER FILL 13 Inspect for leaks HYDRAULIC OIL FILTERS The hydraulic oil is filtered by a main return line filters The main return line filters strain the oil return ing to the reservoir from the main directional valve The hydraulic system depends on these filters to keep the oil clean Filters which are not cleaned or replaced at recommended inter vals can become plugged with debris and lose their ability to strain the oil After the first 40 hours of operation filters should be replaced This is necessary since the oil may contain a high concentration of metal particles from initial wear of the new valves and cylinders Refer to the owner s service guide to determine when the filters should be replaced IN TANK RETURN FILTERS After the first 50 hours of operation filters should be replaced Refer to the owner s service guide to determine when the filters should be replaced FIXED AND TRAVERSING FORKLIFT ADVANCED MAINTENANCE MANUAL HYDRAULIC PUMP Oil is circulated through the hydraulic system by a variable volume piston pump located on and driven by the torque converter It contains seven pistons that ride along a swash plate This swash plate when adjusted determines the stroke of the pistons which in turn deter mines the amount of flow The swash plate is adjusted according to the amount of flow required from the pump which is determined by the load on the hydraulics
116. ts of troubleshooting charts for electrical system components It also contains electrical schematics for stan dard and optional equipment ELECTRICAL SAFETY PRECAUTIONS Observe the following at all times 1 NEVER PERFORM MAINTENANCE ON LIVE ELECTRICAL EQUIPMENT STOP THE ENGINE AND DISCONNECT THE GROUND BATTERY CABLE BEFORE BEGINNING MAINTENANCE 2 NEVER DISCONNECT THE BATTERY OR INTERRUPT THE BATTERY CHARG ING OUTPUT WIRE FROM THE CHARG ING ALTERNATOR WHILE THE ENGINE IS RUNNING DANGEROUSLY HIGH DIRECT CURRENT VOLTAGES ARE PRODUCED WHICH MAY BE FATAL 3 DO NOT SMOKE OR ALLOW AN OPEN FLAME OR ELECTRIC SPARK NEAR THE BATTERY 4 WHEN REMOVING THE BATTERY DIS CONNECT THE GROUND BATTERY CABLE FIRST WHEN INSTALLING THE BATTERY CONNECT THE POSITIVE BATTERY CABLE FIRST THIS WILL REDUCE THE POSSIBILITY OF TOOL TO MACHINE SHORTS PETTIBONE T RAVERSE LLC BATTERY MAINTENANCE Every 160 hours of operation or monthly perform the following battery maintenance 1 Check the electrolyte level If level is low add distilled water to maintain fluid up to level indicator below cell caps DO NOT OVERFILL CELLS 2 Check tightness of battery terminals Clean corroded terminals with water baking soda solution DO NOT ALLOW BAKING SODA SOLUTION TO ENTER THE BATTERY 3 Inspect battery cables for damage and frayed ends If you experience battery failure check the specific gravity of t
117. wen pin D and pin 12 of the 23 pin amp plug If continuity is good replace driver board To verify pump load sense operation measure line voltage present on pin B of Packard 3 position plug when fork rotate button either is depressed If not present verify harness continuity between pin C and pin 16 of the 23 pin amp connector If continuity is good replace driver board If voltage is present verify aux load sense relay operation by checking that voltage is removed from charge valve solenoid coil pin A to ground when either fork rotate button is depressed If voltage remains constant replace aux load sense relay To verify actual full stroke operation of the valve control solenoids insert an ammeter in line with pin D on both output 4 position connectors pos toward driver board neg toward valve Full stroke current readings obtained with button fully depressed are Fork Up 1 0A Fork Down 1 0A Fork CW 1 75A Fork CCW 1 75 A See note1 2 and 3 below NOTE 1 FULL STROKE CURRENT READING OF AUX FORK WILL CHANGE FROM 1 75 TO2 0a 8 01 01 TO ACCOMODATE FULL FLOW TO AUX FUNCTION NOTE 2 BECAUSE THE DRIVER OPERATION IS CURRENT COMPENSATED VOLTAGE READINGS TAKEN ACROSS THE OPERATOR COILS WILL VARY WITH TEMPERATURE AND ARE THEREFORE NOT AN ACCURATE INDICATOR OF DRIVER PERFORMANCE NOTE 3 TEST LIGHTS ARE NOT RECOMMENDED SINCE THE LIGHT WILL DIVERT A SIGNIFICANT PORTION OF THE DRIVER OUTPUT CURRENT A

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