ARDCO/Traverse Lift, L.L.C. OWNER/OPERATOR MANUAL Rev. 05 ... · page 1 ardco/traverse lift, l.l.c. owner/operator manual rev. 05/00-5 model tl-6035 rough terrain variable reach forklift

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ARDCO/Traverse Lift, L.L.C. OWNER/OPERATOR MANUAL Rev. 05/00-5 MODEL TL-6035

ROUGH TERRAINVARIABLE REACHFORKLIFT

OWNER/OPERATOR MANUAL

MODEL TL 6035

THIS MANUAL MUST REMAIN WITH THE UNIT AT ALL TIMES

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ARDCO/TRAVERSE LIFT L.L.C.ARDCO/Traverse Lift, L.L.C. OWNER/OPERATOR MANUAL Rev. 05/00-5 MODEL TL-6035

TL 6035 OWNER/OPERATOR MANUALRevision 05/00-5

Copyright May 3, 2000ARDCO/Traverse Lift, L.L.C.

Technical PublicationsP.O. 451960

Houston, TX 77245-1960

• The information and illustrations in this manual have been approved as accurateby Technical Publications at the time of printing. However, the manual may containinformation on options not present on your machine. ARDCO/Traverse Lift, L.L.C.reserves the right to make changes and improvements in its product at anytime withoutnotice or obligation.

• This manual is to remain with the unit at all times. The storage compartment forthis manual is located in the operator’s cab behind the seat.

• Contact ARDCO/Traverse Lift, L.L.C. or an authorized dealer for replacementmanuals.

WARNING

Only operators trained in the use of this specific machinemodel AND trained according to the requirements set forthby the Occupational Safety and Health Administration(OSHA) Rule 29CFR 1910.178(1) are allowed to operatethis unit.

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TL 6035 Table of Contents Rev. 11/99-4b

PREFACE .................................................................................................................................................. 8CALIFORNIAPROPOSITION 65 WARNING ...................................................................................... 9

HYDRAULIC PRESSURE WARNING SHEET MODEL TL 6035.................................................... 10

SAFETY ................................................................................................................................................... 11 SAFETY RULES ...................................................................................................................................................12

EXPLANATION OF “WARNINGS” ................................................................................................. 12EXPLANATION OF “CAUTIONS” .................................................................................................. 12 EXPLANATION OF “NOTES ” ........................................................................................................ 12

BEFORE OPERATION...........................................................................................................................................13MACHINE OPERATION.......................................................................................................................................14TRANSPORTING SAFELY ...................................................................................................................................15PARKING THE MACHINE ...................................................................................................................................15BURN PREVENTION............................................................................................................................................15FIRE OR EXPLOSION PREVENTION ................................................................................................................16MAINTENANCE ....................................................................................................................................................18

SAFETY WHILE SERVICING THE MACHINE............................................................................... 18MAINTENANCE PROCEDURES..................................................................................................... 18

DECALS .................................................................................................................................................. 21SAFETY ...................................................................................................................................................................22DECAL LOCATIONS .............................................................................................................................................22TABLE I. ..................................................................................................................................................................24MATERIAL SAFETY DATA SHEETS (MSDS) ...................................................................................................44

EQUIPMENT .......................................................................................................................................... 45IDENTIFICATION NUMBERS .............................................................................................................................46MACHINE INSPECTION AND DELIVERY REPORT ......................................................................................47RIGHT, LEFT, FRONT AND REAR OF MACHINE ...........................................................................................48SAFETY ...................................................................................................................................................................49

EXPLANATION OF “WARNINGS” ................................................................................................ 49EXPLANATION OF “ CAUTIONS” .................................................................................................. 49 EXPLANATION OF “NOTES ” ........................................................................................................ 49SAFETY PRECAUTIONS.................................................................................................................. 49

INTRODUCTION .................................................................................................................................... 51IDENTIFICATION ..................................................................................................................................................51

FORKLIFT IDENTIFICATION PLATE ............................................................................................. 51ENGINE IDENTIFICATION PLATE.................................................................................................. 51TRANSMISSION IDENTIFICATION PLATE................................................................................... 51AXLE IDENTIFICATION PLATE LOCATION ................................................................................. 51

EQUIPMENT DESCRIPTION .............................................................................................................................53FORKLIFT DESCRIPTION ............................................................................................................... 53STANDARD ENGINE DESCRIPTION............................................................................................. 53

(Continued on next page)

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OPTIONAL ENGINETRANSMISSION DESCRIPTION ................................................................................................... 53AXLE DESCRIPTIONOPTIONSSPECIFICATIONS ............................................................................................................................. 53

TABLE I. SPECIFICATIONS .................................................................................................................................54

OPERATION ........................................................................................................................................... 57SAFETY ...................................................................................................................................................................58CONTROLS AND INDICATORS .........................................................................................................................58TABLE II. CONTROLS & INDICATORS ............................................................................................................59PREOPERATIONAL CHECKS AND SERVICES ...............................................................................................61

CHECK ENGINE OIL LEVEL ........................................................................................................... 61CHECK ENGINE COOLANT LEVEL .............................................................................................. 62CHECK TRANSMISSION OIL .........................................................................................................62TIRES AND RIMS.............................................................................................................................. 63CHECK FUEL LEVEL ....................................................................................................................... 63CHECK HYDRAULIC FLUID LEVEL .............................................................................................. 63

TABLE IIa. TIRE PRESSURES ............................................................................................................................63INSPECTION FOR LEAKS............................................................................................................... 64GENERAL INSPECTION.................................................................................................................. 64

OPERATIONAL CHECKS & SERVICES ............................................................................................................65GAUGES AND INDICATORS........................................................................................................... 65HYDRAULIC FLUID LEVEL ............................................................................................................. 65CHANGES IN PERFORMANCE ...................................................................................................... 65

OPERATING INSTRUCTIONS .............................................................................................................................65STARTUP AND DRIVING................................................................................................................. 65QUICK DISCONNECT FEATURE.................................................................................................... 68RAISING THE LOAD ........................................................................................................................ 69TRANSPORTING THE LOAD........................................................................................................... 70LANDING THE LOAD ...................................................................................................................... 70 SHUTDOWN..................................................................................................................................... 71

MAINTENANCE .................................................................................................................................... 73INTRODUCTION...................................................................................................................................................74TABLE III. SCHEDULED MAINTENANCE .....................................................................................................74TABLE IV. FLUIDS AND LUBRICANTS ..........................................................................................................76 LUBRICATION ......................................................................................................................................................78TROUBLESHOOTING...........................................................................................................................................80

HOW TO USE TROUBLESHOOTING TABLES.............................................................................. 80TABLE V. CUMMINS ENGINE TROUBLESHOOTING ..................................................................................80TABLE VI. JOHN DEERE ENGINE TROUBLESHOOTING ...........................................................................89TABLE VII. ENGINE ELECTRICAL TROUBLESHOOTING ...........................................................................93TABLE VIII. TRANSMISSION TROUBLESHOOTING ...................................................................................94TABLE IX. HYDRAULIC SYSTEM TROUBLESHOOTING ............................................................................95REPLACE FUEL FILTER ELEMENT (CUMMINS ENGINE) ...........................................................................96REPLACE FUEL FILTER ELEMENT (JOHN DEERE ENGINE) ......................................................................96BLEEDING THE FUEL SYSTEM (CUMMINS ENGINE) ..................................................................................97

(Continued on next page)

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BLEEDING THE FUEL SYSTEM (JOHN DEERE ENGINE) ............................................................................98SERVICE AIR CLEANER ................................................................................................................................... 100DRAIN AND REFILL COOLING SYSTEM (CUMMINS ENGINE) ............................................................... 101THERMOSTAT REPLACEMENT (CUMMINS ENGINE) ................................................................................ 103THERMOSTAT REMOVAL (JOHN DEERE ENGINE) .................................................................................... 104THERMOSTAT TEST ........................................................................................................................................... 105THERMOSTAT INSTALLATION (JOHN DEERE ENGINE) ........................................................................... 106DRIVE BELT TENSION ADJUSTMENT (CUMMINS ENGINE) ................................................................... 106DRIVE BELT TENSION ADJUSTMENT (JOHN DEERE ENGINE).............................................................. 106ALTERNATOR REPLACEMENT (CUMMINS ENGINE)................................................................................ 107ENGINE OIL CHANGE (JOHN DEERE ENGINE) ..........................................................................................111CLEAN CRANKCASE VENT TUBE ................................................................................................................. 112TRANSMISSION OIL CHANGE ........................................................................................................................ 113TRANSMISSION FILTER ELEMENT REPLACEMENT ................................................................................. 114AXLE LUBRICANT CHANGE ........................................................................................................................... 114HYDRAULIC STRAINER ELEMENT REPLACEMENT ................................................................................ 115SUMMARY ........................................................................................................................................................... 116

(Maintenance Procedures - continued)

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NOTES

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Intro

duct

ion

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PREFACEThis manual instructs the owner/operator in the correct operation of the ARDCO/Traverse Lift L.L.C.Model TL-6035 forklift. The location and operation of all controls are explained in this manual. It alsocontains lubrication tables, which indicate the recommended servicing intervals for all fluids and greasedcomponents.

This manual should be considered a permanent part of your vehicle. It should stay with the vehicle,if sold, to provide the next owner with required operating instructions.

All instructions, illustrations and specifications contained herein are based upon the latest productinformation available at the time of printing. ARDCO/Traverse Lift L.L.C. reserves the right to changespecifications without prior notice in order to follow its policy of constantly striving to manufacturea better product without incurring any liability to provide these new features on any units previouslymanufactured.

Be sure your dealer has returned the Warranty Registration Form for your machine to ARDCO/TraverseLift L.L.C.. This form must be filled out properly in initiate warranty coverage on the machine. In addition,your dealer will fill out a Machine Inspection Report, which the owner should sign. Also, a 30-daycheck up is recommended as defined in this manual. If a problem occurs with your machine duringthe warranty period, contact your dealer immediately. Do not continue to operate the machine untilauthorized.

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CALIFORNIA

PROPOSITION 65 WARNING

Diesel engine exhaust and some of itsconstituents are known to the State of

California to cause cancer, birthdefects, and other reproductive harm

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HYDRAULIC PRESSURE WARNING SHEETMODEL TL 6035

MAXIMUM HYDRAULIC SYSTEM PRESSURE FOR THIS MACHINEIS 3,000 PSI.

SETTINGS HIGHER THAN THIS MAY RESULT IN DEATH,SEVERE INJURY OR PROPERTY DAMAGE.

In many instances we have learned that the hydraulic relief valves of this equipment have been reset,thereby increasing the maximum pressures and, with this, the load the unit will lift before the relief valveopens. In some instances, the consequences of increasing this setting have been serious. The functionof the relief valve is to provide a fuse action to protect the machine and the operator from overloading.When overloaded, different portions of the machine can become stressed to a level at which partsfracture, possibly resulting in death, severe injury or property damage. Resetting hydraulicpressures above factory settings is an extremely dangerous practice.

Accordingly, you are advised that the settings of these valves are limited to the maximum listed above.Pressure settings in excess of this level render each and all ARDCO/Traverse Lift warranties null andvoid, and constitute an obvious misuse and abuse of our product.

ARDCO/Traverse Lift, L.L.C.

WARNING

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SA

FE

TY

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SAFETY RULES

Most accidents involving machine operation and maintenance can be avoided by following basic rules andprecautions. Read and understand all the safety messages in this manual, and the safety signs on the machinebefore operating or servicing the machine. See the dealer for any questions. Failure to read and follow theseinstructions could result in death, serious injury or property damage, including damage to the ma-chine.

READ THIS MANUAL COMPLETELY and be sure to understand the characteristics of speed, stability,and steering of this machine. Do not remove this manual from the machine. This manual must remain withthe machine at all times. The manual storage box is located inside the operator’s compartment, behind theoperator’s seat. See your dealer or contact ARDCO/Traverse Lift, L.L.C. for additional manuals.

The safety information given in this manual does not replace safety codes, insurance regulations, or federal, stateand local laws. Be sure the machine has the correct equipment according to these rules or laws.

IMPORTANT: Safety messages in this section point out situations that can be encountered during thenormal operation and maintenance of your machine. These safety messages also give possible ways ofdealing with these conditions.

Additional safety messages are used in the text of the manual to show specific safety hazards.

EXPLANA TION OF “ WARNINGS”

A warning is a statement that informs the reader of a condition that is unsafe to personnel. Failure to heed awarning may result in DEATH or INJURY to personnel.

EXPLANA TION OF “ CAUTIONS”

Cautions are provided as statements, which identify conditions and/or practices that could result in propertydamage or damage to the equipment.

EXPLANA TION OF “ NOTES ”

Notes are statements that simply provide additional information.

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BEFORE OPERATION

• Avoid loose fitting clothing, loose or uncovered long hair, jewelry or loose personal articles.

• Different jobs will require different protective equipment. Items such as hard hats, protective shoes, heavygloves, reflector type vests, respirators, and ear protection may be required. Know and use the equipmentthat is required before starting the job.

• Be prepared for emergencies. Always have a first aid kit and a functional (fully charged) fire extinguisher.Know how to use both.

• Know the hand signals used on the job. Follow the instructions of the flag man, signs, etc.

• Check that all guards and covers are installed correctly.

• Foreign material or grease on the step or grab handle can cause an accident. Keep the step and grabhandle clean.

• Before operating at night, check that all lamps illuminate.

• Know the rules, laws and safety equipment necessary for transporting this machine on road or highway.

• Before starting the engine, walk around the machine and check for oil or fluid leaks. Replace all broken ormissing parts and perform the required lubrication and maintenance as shown in this manual. Clean all trashand debris from the machine.

• Always face the machine and use the grab handle and step when climbing aboard. Do not rush.

• Remove all loose objects from the operator’s compartment and from the machine. Loose objects can jamcontrols and cause accidents.

• Before starting the engine, always properly fasten and securely tighten the seat belt, and always keep theseat belt fastened while operating the machine. Failure to do so can result in death or serious injury.

• Engine exhaust fumes can cause death. If you operate this machine in an enclosed area, make sure the areacontains a source of good ventilation (open doorways, windows, etc.) to replace the exhaust fumes withfresh air.

• Make sure all persons are away from the machine and give a warning before starting the engine.

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MACHINE OPERATION

� Perform a walk-around inspection of the machine prior to starting. Repair all discrepancies beforeoperating. If unable to make repairs, tag machine with a “DO NOT OPERATE” tag.

� Check all controls in a clear area and make sure the machine is operating correctly.

� Do not allow other persons to ride on the machine. Other persons can fall or can cause an accident.

� Do not use the machine to lift personnel or to lift any type of personnel carrier, including manlifts andpersonnel lifting platforms, that operate independently of the forklift and over which the forklift operatordoes not have control. Using the machine to lift equipment that is not under the forklift operator’sdirect control could result in serious injury or death.

• Dust, fog, smoke, etc., can decrease your vision and cause an accident. Stop the machine or decrease thespeed until everything can be seen.

• Contact with high voltage power lines, underground cables, etc., can cause serious injury or death fromelectrocution.

NOTEBefore driving or operating in an area with high voltage lines or cables, HAVE THEPOWER DISCONNECTED OR KEEP A SAFE WORKING DISTANCE from the lines orcables. Know the safe working distance from the high voltage power equipment andobserve federal, state/provincial, or local safety codes or regulations that apply to thejob site.

• Electrical cables, gas pipes, water pipes, sewers, or other underground objects can cause serious injuryor death. Learn the location of underground hazards before operating the machine in a new area.

• If this machine rolls over, death or injury may occur. Determine if weather, road, or earth conditionswill permit safe operation on a hill, ramp, or rough ground.

• Stay away from hazardous areas such as ditches, overhangs, etc. Walk around the work area beforestarting the forklift and look for hazards.

• Be alert and always know the location of all workers in the area. Keep all other persons completely awayfrom the machine. Injury or death can result if these instructions are not followed.

• Operate the machine controls from the operator’s seat only.

• Keep the forks low when moving around the work area and be careful when raising the load.

• Before operating the equipment where visibility is reduced, such as next to a building, install safety markersto warn others of possible danger.

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TRANSPORTING SAFELY

NOTEWhen properly loaded on the flatbed of a tractor trailer, this machine isdesigned to be transported between local work sites.

• Know which warnings must be placed on machine for highway travel and whether an escort is needed.

• Flag attachment or furthest projection of machine with proper warning flag (i.e., red flag) to alert othermotorists who may be traveling behind.

• Know measurements of machine when mounted on truck. Be sure machine is within proper limits forhighway transporting.

• Become familiar with public laws and ordinances affecting driving on public roads with a machine mountedon a flatbed trailer or other transporting vehicle. Check route for clearance. Check bridges for weightlimits.

• Always shut down machine engine when transporting, even over short distances, and never ride on machinewhile transporting. Serious death or injury can result if these instructions are not followed.

• Do not put chains over or against hydraulic lines or hoses.

• Always use tape or cap exhaust pipe to prevent air from spinning turbocharger while vehicle is transportedat highway speeds. The turbochargers depend upon engine oil pressure to lubricate shaft bearings and maybe damaged if spun dry. BE SURE TO REMOVE TAPE AFTER TRANSPORTING OR BEFORESTARTING ENGINE.

PARKING THE MACHINE

• When parking the machine and before leaving the operator’s seat, engage the parking brake by flippingtoggle switch (located on the left side of the dashboard) into “UP” position.

• Always face the machine and use the grab handles and step when getting on or off. Do not rush and do notjump from the machine.

BURN PREVENTION

• Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing.Antidote- EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Follow withmilk of magnesia, beaten egg or vegetable oil. Call a doctor immediately. EYE: Flush with water for 15minutes and get prompt medical attention.

(continued on following page)

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• If the battery electrolyte freezes, the battery may explode if, (1) battery charge is attempted, or (2) trying tojump start the engine. To prevent the battery electrolyte from freezing, keep the battery at full charge.

• Hot coolant can spray out when the radiator cap is removed. To remove the radiator cap, let the coolingsystem cool, turn to the first notch, wait until the pressure is released, then remove the radiator cap.

FIRE OR EXPLOSION PREVENTION

CAUTIONBatteries can be dangerous because (1) they contain acid that can burn a person, (2) theycontain gas that can explode or ignite, (3) they contain enough electricity to burn a person.Failure to follow the following instructions could cause personal injury or damage to theequipment.

CAUTIONSparks or flame near a battery can cause the hydrogen gas in a battery to explode. Do notuse a match or any type of open flame when working around a battery; use a flashlight if youneed more light.

• When replacing the battery, while disconnecting the battery cables disconnect the negative (-) cable first.When connecting battery cables, connect the negative (-) cable last.

CAUTIONWhen using jumper cables, make sure that the cables do not have loose or missing insula-tion. Cables with loose or missing insulation can cause a shock, causing injury to personnelor damage to the equipment.

• When jumping the battery, follow the procedure below:

1. Connect the red positive (+) cable to the positive (+) terminal of the machine withthe dead battery.

2. Do not let the other end of the cable touch metal; connect it to the positive (+)terminal of the good battery being used for the jump.

3. Connect the black (-) cable to the good battery’s negative (-) cable, making sure notto let the other negative (-) end of the cable to touch anything.

4. Attach the negative (-) end of the cable to a metal frame member, at least 18 inchesaway from the dead battery and away from moving engine parts.

(continued from previous page)


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5. Now start the vehicle with the good battery and run the engine for awhile.

6. Try to start the forklift with the charged battery. If it won’t start after a few tries, itprobably needs service or replacement.

• Do not short circuit the battery posts with metal items.

• Do not weld, grind, or smoke near a battery.

• Sparks from the electrical system or engine exhaust can cause an explosion and fire. Before you operate thismachine in an area with flammable dust or vapors, use good ventilation to remove the flammable dust orvapors.

• Engine fuel can cause an explosion or fire. Do not fill the fuel tank with the engine running or near openflames or sparks.

• Use nonflammable cleaning solvent to clean parts.

• Fire can cause injury or death. Always have a fire extinguisher near or on the machine. Make certain the fireextinguisher is serviced according to the manufacturer’s instructions.

• If a fire extinguisher has been used, always recharge or replace the fire extinguisher before operating themachine.

• Remove all trash or debris from the machine each day. Especially check the engine area and exhaust system.

• Starting fluid (ether) can cause death or serious injury. Do not inhale starting fluid vapors. Wear faceprotection when removing or installing a starting fluid container or when using aerosol spray starting fluid.Use starting fluid according to the instructions in this manual.

• If the machine has an oil, fuel, or hydraulic leak, always repair the leak and clean the area before operating.

• Keep the cooling system clean and maintain the correct coolant level.

• Check the electrical system for loose connections or frayed insulation. Repair or replace the loose ordamaged parts.

• Before welding or using a torch on the machine, clean the entire machine to reduce risk of fire hazard.

WARNINGDo not weld on any structural member unless specifically authorized by ARDCO/TraverseLift, L.L.C. Any unauthorized welding will void the warranty and may cause death,severe injury or damage to the equipment.


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MAINTENANCE

SAFETY WHILE SER VICING THE MACHINE

The following section gives suggested guidelines for operational maintenance on your machine. It is not intendedfor use as a service manual.

Check the Hour Meter regularly to determine when the machine needs periodic maintenance. In severeconditions (extreme dust, heat, cold, humidity, etc.) you will need to service your machine more often. Yourexperience may dictate a more severe servicing program.

Safety while servicing machine is the owner’s responsibility. Only qualified and authorized personnel should bepermitted to maintain, repair, adjust and inspect the machine.

Read and understand warnings and safety precautions in the “SAFETY” section and elsewhere in this manualbefore doing any service on machine. The following precautions (MAINTENANCE PROCEDURES) shouldbe used as a reminder to safe servicing.

WARNINGImproper service or repair can cause death, serious injury and/ or damage to theequipment. Refer to the service manual for proper maintenance procedures, includingany supplied component manuals.

MAINTENANCE PROCEDURES

• Before servicing the machine, put a DO NOT OPERATE tag in clear view on the instrument panel.

• Lower boom to ground, shut down machine to a zero energy state, remove key from ignition and allowmachine to cool before beginning work.

• Relieve all hydraulic pressure in the hydraulic reservoir before breaking any hydraulic connection or beforeopening the reservoir access cover.

• Disconnect battery.

WARNINGIf it is necessary to have the engine running while servicing the machine, have anotherperson assist with the procedure. Do not leave the operator’s seat with the enginerunning. Failure to follow these precautions could result in death, serious injuryor damage to the equipment.

• Do not support the machine, the boom, or any attachments on cinder blocks, hollow tiles, or props thatmay crumble under a load. Do not work under a machine that is supported solely by a jack.


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• Remove, block or guard against body contact with all other sources of hazardous pressure, temperature,electricity or machine motion.

• Make sure that boom and attachments are grounded to avoid electrical shock.

• Do not make any modifications to this machine or weld on any structural member unless specificallyauthorized by ARDCO/Traverse Lift, L.L.C. Any unauthorized modifications made or welding will void thewarranty and may cause death, serious injury or damage to the equipment.

WARNINGUnauthorized modifications to this machine can cause injury or death. Refer toyour authorized dealer or ARDCO/Traverse Lift, L.L.C. before modifying the machine.

• Metal chips or debris can cause eye injury. Always wear eye or face protection when using a hammer on thismachine. Use a hammer with a soft face, such as brass, to drive hardened pins.

• Hydraulic fluid or grease injected into skin can cause severe injury or death. Keep hands and body awayfrom any pressurized leak. If fluid is injected into skin, see a doctor immediately.

• When servicing this machine, always wear safety protection, including but not limited to hard hat, workshoesand safety glasses.

• Don’t leave loose tools and rags on the machine. Make sure that all walking and climbing surfaces areclean.

• Handle fuel carefully. Do not smoke while filling fuel tank or working near fuel. Refer to the “Lubricants”table when replacing oils, fluids or filling fuel tank.


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THIS PAGEINTENTIONALLY

LEFT BLANK

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DE

CA

LS

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SAFETYThe decals pictured in this section were verified as correct at this publication was printed. ARDCO/TraverseLift reserves the right to add additional safety decals to the machine as necessary to ensure operator safety. It isthe operator’s responsibility to follow the instruction decals on the particular machine being operated.

WARNINGInjury or death can result if safety decals are not followed. Immediatelyreplace any missing or damaged safety decal(s), and keep all safety decals cleanand legible. Contact an authorized dealer or ARDCO/Traverse Lift for newsafety decals.

• Be sure to read all safety decals and all instruction decals. Check these decals daily. Keep these decalsclean.

• To clean the decals, use only a cloth, water, and soap. Do not use solvents, gasoline, etc.

• Replace decals if damaged, missing, or unreadable. If a decal is on a part that is replaced, install a new decalon the replacement part.

DECAL LOCATIONS

Table I., “MACHINE DECALS” consists of a list of decals located on the TL 6035 forklift. The table isdivided into four columns:

• ITEM#: gives the number by which the particular decal is identified in Figures 1a. and 1b., “DecalLocations”.• PART#: gives number of that decal the ARDCO/Traverse Lift part number for reordering purposes.• DESCRIPTION: gives a description of the decal.• QTY. : lists the total number of that particular decal needed for the machine.

Full-size illustrations of these decals, along with expanded descriptions of each decal’s location, are shown onpages 24-44 following Table I. In cases where the decal is too large to be depicted at full-size, a representationof the decal is shown.

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13

13

1

1

2

25

42

30

37

32, 9, 10

9, 10

4

53

43

27

28

9, 10

11, 12

31

32, 9, 10

36

F, R

34

33

18

16

26, 23, 24

15

8

14

19, 20, 21, 22

17

40

7

35

39

39

38

Figure 1a. Decal Locations

Figure 1b. Decal Locations

43

43

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ITEM PART# DESCRIPTION QTY.

1 NLP01079 WARNING, No Riding 2 2 unassigned Boom Angle Indicator 1 3 LL-6463 WARNING, Machine Roll Away 1 4 LL-6458 WARNING, Safe Operation Checklist 1 5 LL-6457 CAUTION, Pre-start Maintenance Checklist 1 6 APP00463 Lift Capacity Chart (Rev. 1) 1 7 LLPXL6012-02 Boom Control Joystick 1 8 unassigned Pressure Test Ports (modified LPP00001Rev. 1) 1 9 LL-6480 DANGER, Pinch Point 410 DEC0048 Tire Ballast Not Required 411 LL-6455 CAUTION, Diesel Fuel Only 112 LL-6456 WARNING, Combustible and Flammable Fluids 113 LPP00078 Made in the U.S.A. 214 LL-6453 WARNING, Welding and Modification Hazard 115 LL-6477 CAUTION, No Step 116 DEC00010 CAUTION, Please Fasten Seat Belt 117 unassigned Do Not Operate When Low Brake Pressure Is Low 118 APP00454 WARNING, Steering Selector 119 LL-6465 DANGER, Electrocution Hazard 120 LL-6489 DANGER, Falling Boom or Load 121 LL-6474 WARNING, Backward Machine Tipover 122 LL-6470 WARNING, Machine Tipover or Structural Damage 123 LL-6472 WARNING, Personal Injury Hazards 124 LL-6490 WARNING, Carrying Personnel 125 LL-6464 DANGER, Falling Boom or Load, 12” x 12” 126 LL-6468 WARNING, No Riding 227 LL-6454 CAUTION, Hydraulic Fuel Only 128 LL-6494 WARNING, High Pressure Hydraulic Fluid 129 LL-6467 WARNING, Hot and Pressurized Fluid 130 LL-6492 WARNING, Carbon Monoxide 131 LL-6471 WARNING, Hot Exhaust Pipe 132 LL-6469 WARNING, Moving Belts and Spinning Blades 233 unassigned Frame Tilt 134 APPOO459 Owner/Operator Manual 135 LL-6493 WARNING, Inadequate Braking Ability 136 LPP29227 Frame Travel Location 137 LL-6466 WARNING, Explosion Hazard 138 DEC00011 Low Brake Pressure 139 DEC00012 Parking Brake 240 LPXL6012-01 Fork Tilt Control 141 unassigned Forward, Reverse 142 unassigned Traverse Lift Logo 443 unassigned 6035 Logo 244 LL-6476 CAUTION, Watch Your Step 1

TABLE I.

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

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

Page 26


#4: ONE (1)LOCATEDINSIDEOPERATOR’SCAB ONLEFT FRONTCAB FRAMEBY HANDGRIP, BELOW“MachineRoll Away”DECAL

#3: ONE (1)LOCATEDINSIDEOPERATOR’SCAB ONLEFT FRONTCAB FRAMEABOVEHANDGRIP

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#5: ONE (1) LOCATEDINSIDE OPERATOR’S CABON RIGHT FRONT CAB FRAME

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#8: ONE (1) LOCATED INSIDE OPERATOR CAB,BELOW OPERATOR SEAT ON MOUNTING

#6: ONE (1) LOCATED INSIDEOPERATOR’S CAB, RIGHT SIDEOF OPERATOR’S SEAT (Note: Decalshown is not to size; representationonly)

#7: ONE (1) LOCATED ONRIGHT SIDE OF DASHBOARD BELOWBOOM CONTROL JOYSTICK

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#9: FOUR (4) NEEDED:ONE ON FRAMEBEHIND EACH TIREABOVE AXLE

#10: FOUR (4) NEEDED: ONE ON FRAME BEHIND EACH TIRE ABOVE AXLE

#11: ONE (1) LO-CATEDON TOP OF FUELTANKNEAR INTAKE

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#12: ONE (1) LOCATED ONOUTSIDE OF FUEL TANK, NEAR TOP

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#13: TWO (2) NEEDED: ONE ON EACH SIDE OF REAR FRAMENEAR BOOM PIVOT

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WARNING#14: ONE (1) LOCATEDINSIDE CAB ON PANELBELOWBOOM CONTROLJOYSTICK

#16: ONE (1) LOCATED ON UNDERSIDEOF DASHBOARD

#15: ONE (1) LOCATED ONTOP OF HYDRAULIC TANK

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#17: ONE (1) LOCATED ON UNDERSIDE OF DASHBOARD,BELOW “Please Fasten Seat Belt” DECAL

#18: ONE (1) LOCATED ON UNDERSIDE OF DASHBOARD,BELOW “Low Brake Pressure” DECAL

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#21: ONE (1)LOCATEDINSIDE CAB ONRIGHT PANEL,BELOW “FallingBoom or Load”DECAL

#20: ONE (1)LOCATEDINSIDE CAB ONRIGHT PANEL,BELOW “ElectrocutionHazard” DECAL

#19: ONE (1)LOCATEDINSIDE CABONRIGHT PANEL

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#23: ONE (1) LOCATED ON LEFT OUTER SIDE OFDASHBOARD PANEL, BELOW “No Riding” DECAL

#22: ONE (1) LOCATEDINSIDE CAB ON RIGHT PANEL,BELOW “Backward TipoverHazard” DECAL

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#24: ONE (1)LOCATED ONLEFT OUTER SIDEOF DASHBOARDBELOW “PersonalInjury Hazard”DECAL

#25: ONE (1) LOCATED ONTHE UNDERSIDE OF FRONT BOOM, ACTUAL SIZE: 12” x 12”

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#26: TWO (2) TOTAL:ONE ON EACH SIDEOF FORK CARRIAGE

#27 ONE (1) LOCATEDON TOP OFHYDRAULIC TANK

Page 38


#28: ONE (1) LOCATEDBENEATH ENGINECOWLING ONPISTON ACCUMULATOR

#29 ONE (1) LOCATEDON TOP OFENGINE COWLINGNEAR RADIATOR CAP

Page 39


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

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

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#32: TWO (2) NEEDED: ONEON EACH SIDE OF FRAME

#34: ONE (1) LOCATED BEHIND OPERATOR’SSEAT ON COVER OF MANUALCOMPARTMENT

#33: ONE (1) LOCATED ONMOUNTING OFFRAME TILT LEVERUP FRAME DOWN

LEFT TILT RIGHT

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#35: ONE (1) LOCATED ONDASHBOARD, BELOWFRAME LEVEL INDICATOR

#37 (ONE) LOCATED ONREAR OF FRAME NEARBATTERY ACCESS

#36: ONE (1) LOCATED ALONGOUTSIDE OF FRAME, IN VIEW OFOPERATOR’S CAB (Note: decalshown is not to size; for representa-tion only)

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#39 (TWO) LOCATED ON LEFT SIDE OFDASHBOARD: ONE ABOVE BUZZER/LIGHT, ONE ABOVE TOGGLE SWITCH

#38 (ONE) LOCATED ON LEFT SIDEOF DASHBOARD ABOVE BUZZER/LIGHT:

#40: ONELOCATED INSIDEOPERATOR’SCAB, BELOWFORK TILTJOYSTICK

#41: ONE (1) LOCATED ON LEFT SIDEOF DASHBOARD, ABOVE BUZZERS/LIGHTS

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#42: TWO: ONE LOCATEDON EACH SIDE OF FRAMEAT REAR OF MACHINE

#43: FOUR (4), ONELOCATED ON EACHSIDE OF BOOM,ONE ON REAR OFMACHINE, ONE ONFRONT OFMACHINE (Note:Decal shown is not tosize; representationonly)

#44: ONE (1) LOCATED ON BOTTOMFRAME OF OPERATOR’S CAB

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MATERIAL SAFETY DATA SHEETS (MSDS)

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

Upon written request, ARDCO/Traverse Lift L.L.C. will provide the Material Safety Data Sheets appli-cable to our product line, at no extra cost. Write to:

ARDCO/Traverse Lift, L.L.C.P.O. Box 451960

Houston, TX 77245-1960or

ARDCO/Traverse Lift, L.L.C.322 Riley Road

Houston, Texas 77047

Tel (713) 433-6751(800) 909-0919

Fax (713) 433-3818

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

Page 45


EQ

UIP

ME

NT

Page 46


IDENTIFICATION NUMBERS

Write the machine’s model number, Product Identification Number and serial numbers on the linesprovided below. If necessary, give these numbers to the dealer when parts or information are neededfor the machine.

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

MACHINE MODEL NUMBER _________________________________________

MACHINE SERIAL NUMBER _________________________________________

ENGINE SERIAL NUMBER _________________________________________

TRANSMISSION SERIAL NUMBER _________________________________________

FRONT AXLE SERIAL NUMBER _________________________________________

REAR AXLE SERIAL NUMBER _________________________________________

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MACHINE INSPECTION AND DELIVERY REPORT

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

NOTEThe customer’s cost for this inspection will be for filters, oil or otheraccessories. If the dealer comes to the machine, there may also be a costfor the time and travel.

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RIGHT, LEFT, FRONT AND REAR OF MACHINE

All directional references (right, left, front and rear) used in this manual are as seen from the operator’s seat.

FRONT

REAR

LEFT RIGHT

Figure 1. Directional Reference

STAMPED MACHINE SERIAL NUMBERTOP OF RAIL BEHIND OPERATOR’S CAB (SEE ALSO FIGURE 2.)

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SAFETY

EXPLANA TION OF “ WARNINGS”

A warning is a statement that informs the reader of a condition that is unsafe to personnel. Failure toheed a warning may result in DEATH or INJURY to personnel.

EXPLANATION OF “ CAUTIONS”

Cautions are provided as statements, which identify conditions and/or practices that could result indamage to the equipment.

EXPLANATION OF “ NOTES ”

Notes are statements that simply provide additional information. Notes are not safety related.

SAFETY PRECAUTIONS

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

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

3. Only trained, qualified personnel should operate the forklift.

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

5. Always wear the seatbelt when operating the forklift.

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

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

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

9. Do not use the forklift to lift personnel.

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

11. Make certain that the load is positioned squarely and evenly on both (or all) forks before raising.

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

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

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

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

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

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

18. Always be aware of the machine and load width and the width of the path in which it is operating.

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

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

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

22. Modifications to the forklift can result in death and/or serious injury to personnel, damage toequipment and/or poor equipment performance.

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

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

25. Always use the traverse feature to land a load rather than moving the forklift.

26. Do not operate a forklift that is in need of maintenance.

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

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INTRODUCTIONThe Model TL6035 rough-terrain, variable-reach forklift is manufactured by the ARDCO/Traverse Lift L.L.C., .The Model TL6035 is designed to provide years of reliable operation with minimal maintenance.

IDENTIFICATION

FORKLIFT IDENTIFICATION PLATE

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

Figure 2. Forklift Identification Plate Location

ENGINE IDENTIFICATION PLATE

The CUMMINS engine identification plate is located on the timing cover at the engine’s left front(right side of forklift). (See Figure 3.)

The JOHN DEERE engine identification plate is located on the engine block, above the starter. Itcontains the engine serial number. (See Figure 3a.)

TRANSMISSION IDENTIFICATION PLATE

The transmission identification plate is located atop the transmission housing, centered behind the engine.It contains the model, specification number and serial number. (See Figure 3.)

AXLE IDENTIFICATION PLATE LOCATION

The axle identification plate is located on the backside of the axle, to the right of the differential. The platecontains the axle part number, serial number and build date. The front axle is mounted with its backside towardthe front of the forklift. (See Figure 4.)

FORKLIFTIDENTIFICATIONPLATE(BOLTED ON UNITSEE ALSO FIGURE 1)

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TRANSMISSIONIDENTIFICATIONPLATE

ENGINEIDENTIFICATIONPLATE

TRANSMISSION RIGHT VIEW

Figure 3. Transmission and Cummins Engine Identification Plate Locations.

ENGINE LEFT VIEW

AXLE IDENTIFICATION PLATE(LOCATED BEHIND AXLE MOUNT)

Figure 4. Axle Identification Plate Location.

Figure 3a. John Deere Engine Identification Plate Location (left view)

ENGINEIDENTIFICATIONPLATE

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TRANSMISSION DESCRIPTION

The transmission is a Clark with three forward speeds and three reverse speeds. The transmission isequipped with a mechanical disc-type parking brake, located on the output shaft to the forward driveaxle.

AXLE DESCRIPTION

The forklift is equipped with two steerable drive axles. The front axle is equipped with a limited slipdifferential. Both axles are equipped with internal, wet-type disc brakes, located inside the planetaries.

OPTIONS

Your ARDCO/Traverse Lift L.L.C. dealer offers a wide assortment of options for the TL6035 forklift, includinga variety of forks, carriages, buckets and more. Contact your dealer for additional information and prices.

EQUIPMENT DESCRIPTION

FORKLIFT DESCRIPTION

The Model TL6035 is a low profile, rough-terrain, variable-reach forklift with an approximate gross vehicleweight of 23,200 pounds (depending on the options used) and a lifting capacity of 6,000 pounds with carriageand boom retracted (1,000 pounds with carriage forward and boom extended). The TL6035 is equipped withfour-wheel drive and a steering system that is capable of two-wheel steering, four-wheel steering and oblique(crab) steering as selected by the operator. The TL6035 has proven itself especially useful handling heavy loadsin environments in which a hard surface operating area is not available.

STANDARD ENGINE DESCRIPTION

The Model TL6035 is equipped with a Cummins Model 4BT3.9-CPL engine. This engine is a liquid-cooled,four cylinder, four stroke, diesel engine with a displacement of 239 cubic inches (3.9L). The engine is fuelinjected and turbocharged with a rated output of 100 horsepower at 2500 rpm. The compression ratio is17.5:1.

OPTIONAL ENGINE

As an option, ARDCO/Traverse Lift L.L.C. provides a naturally aspirated, four cylinder, four cycle, liquidcooled, Model 4039 D John Deere engine. This engine has a displacement of 239 cubic inches (2.9L), acompression ratio of 17.8:1 and an output rating of 80 HP.

SPECIFICATIONS

Table I. provides specifications for the various systems and major components of the Model TL6035forklift. All specifications reflect the equipment configurations and characteristics as they were at thetime of this publication.

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TABLE I. SPECIFICATIONSMODEL TL 6035 FORKLIFT

GENERAL

Lifting capacity 6,000 lbs. (2,722 kg) with boom & carriageretracted.1,000 lbs. (453.6 kg) with carriage fully forward& boom fully extended.

Maximum forward reach 29 ft. (8.84 m)

Maximum lift height 37 ft. (11.28m)

Gross Vehicle Weight (GVW) 23,200 lbs. (10,524 kg)

Maximum travel speed 20 mph (32 km/h)

Height 8 ft. 8 in. (2.64 m) with forks on ground

Length 24 ft. 7 in. (7.51 m) with carriage retracted and48 in. (1.09 m) forks

Width 8 ft. (2.44 m)

Ground Clearance 17 in. (0.43 m)

STANDARD ENGINE Cummins Model 4BT3.9-CPL liquid cooled,four cylinder, four stroke, turbocharged withfuel injection

Horsepower rating 100 hp at 2500 rpm

Displacement 239 cubic inches (3.9L)

Compression ratio 17.5:1

Oil capacity 17.5 quarts (10.4 liters)

OPTIONAL ENGINE John Deere Model 4039D, four cylinder, liquidcooled, naturally aspirated diesel w/fuel injection

Horsepower rating 80 hp

Displacement 239 cubic inches

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Compression ratio 17.8:1

Oil capacity 10 quarts (9.46 L)

TRANSMISSION Clark

Speeds 3 forward, 3 reverse

AXLES Clark steerable with internal wet disc brakes

TIRES 13:00 x 24 (14 ply), Interchangeable. NOTE:Specifications apply to machine tested inaccordance with ASME B56.6A-1994. Anyreplacement of tires must meet or exceed thesespecifications for sidewall stiffness.

Tire inflation pressure 40 psi with tires empty

WHEELS 9.00 x 24, Interchangeable

BRAKE SYSTEM Hydraulic, enclosed wet disc with mechanicalexternal disc parking brake

ELECTRICAL SYSTEM 12 volt, negative ground

Alternator Delco-Remy, 12 volt, 78 Amps withinternal voltage regulator

Battery 12 volt

Circuit Protection:

Instrument panel and horn Fuse, 15 amp Fuel injection pump Fuse, 10 amp Backup alarm and Hourmeter Fuse, 15 amp Parking brake & low brake press. alarm Fuse, 10 amp Joysticks Fuse, 10 amp

HYDRAULIC SYSTEM

Tank capacity 54 gal. (204.4L)

TABLE I. SPECIFICATIONS (Continued)

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Operating pressure 2800 psi (19306 kPa) main circuit1200 psi (8274 kPa) brake circuit 400 psi (2758 kPa) pilot circuit

Pump Double gear type, transmission mounted

Recommended hydraulic fluid:

-5o to 140oF (-21o to 60oC) ISO 225o to 170oF (-15o to 77oC) ISO 3215o to 190oF (-9o to 8oC) ISO 46

Filtration 25 micron return filter, pilot circuit filterand 100 micron suction screen

FUEL SYSTEM

Fuel type Temperatures above 32oF (0oC) use ATSM D 975Grade No. 2-DTemperatures below 32oF (0oC) use WinterizedNo. 2-D

Fuel tank capacity 43.5 U.S. gallons (164.6L)

TABLE I. SPECIFICATIONS (Continued)

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OP

ER

AT

ION

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SAFETY

WARNINGCarefully study and understand all the safety informationprovided in the Safety Summary, located at the front of thispublication prior to operating the forklift.

Prior to attempting to operate the forklift, read this publication and become familiar with all thesafety information (see warning), controls and indicators, daily checks and services and operatinginstructions provided.

CONTROLS AND INDICATORS

The following table consists of a list of all controls and indicators provided on the Model TL6035forklift. The table is divided into three columns: ITEM, DESCRIPTION and FUNCTION. TheITEM column gives the number by which the particular control or indicator is identified in Figure 5,“Controls and Indicators.” The DESCRIPTION column gives a description of the component andthe FUNCTION column describes the component’s function.

Figure 5. Controls and Indicators.

TRANSFERCARRIAGE

EXTEND

BOOMOUT

BOOMIN

TRANSFERCARRIAGERETRACT6

10

119

87

1

23

4

5

23

19

18

20

21

22

FORK TILT DOWN

BOOM UP

FORK TILT UPAUXILIARY

DECAL A

DECAL B

OPTIONAUXILIARY

(ROCKER LEFTROTATE LEFT)

(ROCKER RIGHTROTATE RIGHT)

BOOM DOWN

24

10

Page 59


TABLE II. CONTROLS & INDICATORS

ITEM NO. / DESCRIPTION FUNCTION

1. Steering selector 3-position lever used to select either2-WHEEL STEER (center position),4-WHEEL STEER (right position) orOBLIQUE STEER (left position.

2. Transmission selector Used to select the desired gear (speed) byrotating the end grip to either 1 for FIRSTgear, 2 for SECOND gear or 3 for THIRDgear and direction of travel by pushinglevel forward for FORWARD travel orpulling backward for REVERSE travel.

3. Frame level indicator Indicates angle of frame in relation tohorizontal.

4. Horn switch (button) Sounds horn when pressed.

5. Steering wheel Used to control direction of travel.

6. Water temperature gauge Indicates temperature of engine coolant.

7. Hourmeter Indicates total hours of operation.

8. Voltage gauge Indicates voltage produced by thealternator.

9. Transmission temperature gauge Indicates transmission fluid temperature

10. Parking brake toggle switch Push switch into “UP” position to apply theparking brake; push switch down to releasethe parking brake.

11. Oil pressure gauge Indicates engine oil pressure

Illustrated Decal A: Push forward to tilt down. Push back toFork tilt Joystick tilt up.

Illustrated Decal B: To ROTATE the FORKS in aFork tilt rotate switch COUNTERCLOCKWISE direction,

press down the left side of the rockerswitch. For CLOCKWISE ROTATION,press the right side of the rocker switch.

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TABLE II. CONTROLS & INDICATORS (Continued)

ITEM NO. / DESCRIPTION FUNCTION

Illustrated Decal B: Used to control movement of the boom.Boom control joystick Move the joystick forward to LOWER the

BOOM, backward to RAISE the BOOM,left to RETRACT the BOOM and right toEXTEND the BOOM.

Illustrated Decal A: Used to control carriage movement. ToCarriage transfer joystick TRAVERSE FORWARD, push the

joystick right, to TRAVERSEBACKWARD, pull the joystick left.

17. Neutral safety lock switch Locks transmission in neutral. To LOCK,put switch in the right position. ToUNLOCK, put switch in the left position.

18. Throttle pedal Used to control engine (and forklift)speed.

19. Brake pedal Used to slow or halt forklift travel.

20. Ignition switch Used to start or stop engine operation.

21. Low brake pressure warning light Glows to warn of pressure loss in thebrake system.

22. Parking brake “ON” warning light Glows to warn that the parking brake is onwhen the ignition switch is on.

23. Fuel gauge Indicates level of fuel in the fuel tank.

24. Frame Tilt Joystick To ROTATE the FRAME in aCOUNTERCLOCKWISE (LEFT) direction,pull down on joystick. For CLOCKWISE(RIGHT) ROTATION, push up on joystick.

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Figure 6b. John Deere Engine Oil Dipstick.

ENGINEOILDIPSTICK

PREOPERATIONAL CHECKS AND SERVICES

The following checks and services are to be performed before operating the forklift:

CHECK ENGINE OIL LEVEL

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

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

3. Check the level of the oil on the dipstick and add oil as required.

4. Insert the dipstick back into the engine.

ENGINEOILDIPSTICK

Figure 6a. Cummins Engine Oil Dipstick.

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CHECK ENGINE COOLANT LEVEL

WARNINGNever attempt to remove a radiator cap from a hot engine. Pressurizedsteam and hot coolant escaping from the system can cause serious burnsand injuries to the eyes and skin.

1. After making certain the engine is cool, remove the radiator cap by pressing down while turning itcounterclockwise. (See Figure 7.)

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

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

CHECK TRANSMISSION OIL

1. Start the engine and allow it to idle with the transmission in neutral until the transmission reachesoperating temperature. (See Figure 8.)

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

3. Add transmission oil as needed and insert the dipstick back into the transmission.

3/4 INCH

Figure 7. Radiator Coolant Level Check

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CHECK FUEL LEVEL

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

CHECK HYDRAULIC FLUID LEVEL

Check the hydraulic fluid level as indicated on the sightglass, located on the side of the hydraulic tank.Add hydraulic oil as needed.

TIRES AND RIMS

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

CAUTIONThe tire specifications of the TL6035 apply to the machine as it was tested inaccordance with ASME B56.6A-1994. Any replacement of tires must meetor exceed these specifications for sidewall stiffness.

Figure 8. Transmission Fluid Dipstick.

FILTER ELEMENT

DIPSTICK ANDFILL TUBE

DRAIN PLUG

IDENTIFICATION PLATE

SIZE PLY RATING FRONT REAR

WITH 13.00 - 24 14 60 psi 60 psiCALCIUM 14 60 psi 60 psi

14.00 - 24 14 65 psi 65 psi 14 65 psi 65 psi

WITHOUT 13.00 - 24 14 65 psi 65 psiCALCIUM 14 65 psi 65 psi

14.00 - 24 14 65 psi 65 psi 14 65 psi 65 psi

TABLE IIa. TIRE PRESSURES

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INSPECTION FOR LEAKS

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

GENERAL INSPECTION

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

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

GAUGES AND INDICATORS

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

HYDRAULIC FLUID LEVEL

Periodically check the hydraulic oil level and temperature as indicated on the sightglass, located on theside of the hydraulic tank. Add hydraulic oil if necessary.

CHANGES IN PERFORMANCE

Be constantly alert to changes in the equipment’s operating characteristics. Such changes in performanceare sometimes an indication of a malfunction.

OPERATING INSTRUCTIONS

STARTUP AND DRIVING

CAUTIONNever operate the starter for more than 20 seconds continuously. Allow 2minutes between starting efforts. If using starting fluid for a cold weatherstart, inject the starting fluid only while the engine is cranking.

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

WARNINGThe forklift must be standing still when selecting the steering mode. Death,serious injury and/or equipment damage could occur if the mode is selectedwhile the forklift is moving.

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

a. OBLIQUE. Shown in Figure 10. In this position all four wheels will turn in the samedirection. This steering mode should not be used at speeds exceeding 2 MPH.

OPERATIONAL CHECKS & SERVICES

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Figure 10. OBLIQUE Steering Mode.

b. TWO-WHEEL STEER. Shown in Figure 11. In this position only the front wheels willsteer. Before selecting this mode, the rear wheels must be turned straight using the 4 WHEELSTEER mode. Use ONLY 2 -WHEEL STEER mode when travel speed exceeds 10 MPH.

12345678123456781234567812345678123456781234567812345678

12345678123456781234567812345678123456781234567812345678

12345678123456781234567812345678123456781234567812345678

12345678123456781234567812345678123456781234567812345678

12345678123456781234567812345678123456781234567812345678

12345678123456781234567812345678123456781234567812345678

123456781234567812345678

Figure 11. TWO-WHEEL STEER Mode.

123456789123456789123456789

c. FOUR-WHEEL STEER. Shown in Figure 12. In this mode the rear wheels will turn in theopposite direction from the front wheels, providing the shortest turn radius. Do not use 4wheel steer at speeds over 10 mph.

1234567123456712345671234567123456712345671234567

12345671234567123456712345671234567123456712345671234567

12345678123456781234567812345678123456781234567812345678

12345671234567123456712345671234567123456712345671234567

Figure 12. FOUR-WHEEL STEER Mode.

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

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

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

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

WARNINGThe Model TL6035 forklift is capable of a maximum speed of 20 mphregardless of direction. Make certain the intended direction has beenselected. Death, serious injury or damage could result from acceleration inan unintended direction.

3. Position the steering selector lever ( Figure 13) in the desired mode of steer, either OBLIQUE (left posi-tion) , TWO-WHEEL STEER (center position) or FOUR-WHEEL STEER (right position) .

FOUR-WHEEL STEEROBLIQUE

TWO-WHEEL STEER

Figure 13. Steering Selector.

Figure 14. Startup and Driving.

TRANSFERCARRIAGE

EXTEND

BOOMOUT

BOOMIN

TRANSFERCARRIAGERETRACT

FORK TILT DOWN

BOOM UP

FORK TILT UPAUXILIARY

OPTIONAUXILIARY

(ROCKER LEFTROTATE LEFT)

(ROCKER RIGHTROTATE RIGHT)

BOOM DOWN

IGNITIONSWITCH

PARKINGBRAKESWITCH

TRANSMISSIONSELECTOR

BRAKEPEDAL

STEERINGSELECTOR

FRAME TILT JOYSTICK

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QUICK DISCONNECT FEATURE

1. To change the fork carriage:

a. Disconnect all boom end auxiliary hydraulics.

b. Extend the inner boom 4 - 5 feet.

c. Lower the forks to the ground.

d. Rotate the quick disconnect lever 180 degrees, to the extreme right position.

e. Tilt the forks forward while retracting the inner boom.

2. To attach forks and carriage to forklift:

a. Extend the boom until the pin cradles are directly under the fork carriage rotation pins.

b. Raise the boom until the quick disconnect pin is aligned with the bore in the carriage.

c. Rotate the quick disconnect lever to the full left horizontal position.

d. Connect the hydraulic hoses if so equipped.

PIN

CRADLE

LEVER(IN LOCKEDPOSITION)

Figure 15. Quick Disconnect Feature.

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RAISING THE LOAD

NOTERefer to Figure 14, “Startup and Driving,” for identification ofcomponents mentioned in this procedure.

1. Inspect every load before attempting to lift. Make certain the loads are properly bound and willnot fall apart while lifting and transporting. Also, make sure the weight of the loads are within thesafe lifting range of the forklift.

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

3. Lower the boom by pushing the boom control joystick forward until the forks are at the necessarylevel to engage the load.

4. Level the forks by moving the Tilt/Traverse joystick forward (to tilt forward) or back (to tilt theforks back).

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

6. Traverse slowly forward by pushing the Tilt/Traverse joystick to the right until the load is fullyengaged and touching the backrest of the fork carriage.

7. To position the load for transport, tilt the forks back by pulling the Tilt/Traverse joystick back.Retract the boom by moving the Boom Control joystick to the left and retract the carriage bymoving the Tilt/Traverse joystick to the left.

WARNINGAlways level machine before raising the boom. Never tilt the frame with the boom raised.Machine may tip and cause serious personal injury or death.

8. Pull the Boom Control joystick back to lift the load only enough to clear obstacles. Keep the top of theload below eye level. The load is now ready to transport.

WARNINGDo not attempt to transport stacked loads. The top of a stacked load may not bevisible to the operator . If the load is too tall, it should be transported in two or moremoves. Failure to do so could result in death, serious injury or damage to theequipment.

Figure 16. Typical Lift Capacity Chart

Page 70


TRANSPORTING THE LOAD

NOTERefer to Figure 14, ”Startup and Driving,” for identificationof components mentioned in this procedure.

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

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

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

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

WARNINGNever attempt to drive across an excessively steep incline, regardlessof circumstances. Serious injury and/or death could otherwise result.EXERCISE GOOD JUDGEMENT.

5. Driving on inclines or unstable surfaces is unsafe but sometimes unavoidable. If driving onan incline cannot be avoided, level the forklift by using the rocker switch located on top ofthe Tilt/Traverse joystick as follows:

a. Press the left side of the rocker switch to tilt the forklift frame to the left.

b. Press the right side of the rocker switch to tilt the forklift frame to the right.

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

a. If transporting a load, approach the incline with the forks pointed uphill.

b. If empty, approach the incline with the forks pointed downhill.

c. Do not approach an incline at an angle. When necessary to travel on an incline, drive either straight up the incline or straight down.

Page 71


LANDING THE LOAD

WARNINGWhen landing a load, be constantly aware of all personnel in the area. Soundthe horn as a warning to others. Make certain that anyone in the area is farenough away to avoid injury should the load fall.

NOTERefer to Figure 14, “Startup and Driving,” for identification ofcomponents mentioned in this procedure.

1. Keeping the load low, position the forklift as close to the landing point as possible. DO NOTraise the load if the forks are tilted to one side. Level the machine, using the rocker switchlocated atop the Tilt/Traverse joystick before raising the load.

2. Raise the load to the proper height by pulling back on the Boom Control joystick.

3. Move the Tilt/Traverse joystick to the right to extend the carriage until the load is positioneddirectly over the landing location.

4. Carefully lower the load by slowly pushing the Boom Control joystick forward until the load testssolidly on the landing location. Continue to lower the boom until the forks have no weight on them.

5. By moving the Tilt/Traverse joystick forward or back as necessary, tilt the forks so that theyare not contacting the load or the landing area beneath them.

6. Move the Tilt/Traverse joystick to the left to traverse back, and move the forks away from the load.

SHUTDOWN

1. Bring the forklift to a complete stop.

2. Apply the parking brake.

3. Lower the forks to the ground by moving the Boom Control joystick forward.

4. Place the transmission in neutral.

5. Allow the engine to idle for 1-3 minutes.

6. Shut the engine off.

7. Cycle the hydraulic controls to relieve pressure.

8. Remove the ignition key from the switch.

9. Block wheels if on an incline.

Page 72


THIS PAGEINTENTIONALLY

LEFT BLANK

Page 73


MA

INT

EN

AN

CE

Page 74


INTRODUCTION

SERVICE Daily 20 hr 40 hr 50 hr 100 hr200 hr500 hr1000

hr2000

hr

Engine Oil C *CR CR

Engine Oil Filter *CR CR

Fuel Filter CR

Engine Vent Tube Clean

Alternator Belt Adjust

Transmission Fluid C *CR CR

Transmission Filter *CR CR

Hydraulic Fluid C CR

Hydraulic Filter CR

Air Cleaner Element Clean CR

Radiator Coolant C

Battery C

Parking Brake Adjust

The information provided on the following pages will allow the owner to establish an effectivepreventive maintenance plan. Close adherence to such a plan will add greatly to the equipment’sperformance and longevity. Always keep an accurate record of the maintenance performed.

The maintenance procedures included in the following are those that can be accomplished by the owner,using common hand tools. For more complex maintenance, contact an authorized dealer or servicerepresentative.

TABLE III. SCHEDULED MAINTENANCE

Page 75


Axle Differential *CR C CR

Planetary Hubs *CR C CR

Boom Pivot Lube

Front Tilt Cyl. Pivots Lube

Rear Tilt Cyl. Pivots Lube

Quick Attach Pivots Lube

Boom Rollers Lube

Frame Tilt Cylinder Lube

Fork Tilt Cylinder Lube

Attachments/Hyd. OptionsLube

Axle U-joints Lube

Steer Cyl. Pivots Lube

Steer Spindles Lube

Tie Rod End Pivots Lube

Drive Shaft U-joints Lube

TABLE III. SCHEDULED MAINTENANCE . . . (CONTINUED)

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

Page 76


TABLE IV. FLUIDS AND LUBRICANTSAPPLICATION DESCRIPTION

ENGINE OIL API Service Classification CE or CE

(SINGLE GRADE) CCMC Specification D5 or D4

At temperatures:

Below -4 degrees F (-20 degrees C) Arctic Oil

4 to 50 degrees F (-20 to 10 degrees C) SAE 10W

32 to 86 degrees F (0 to 30 degrees C) SAE 30W

50 to 104 degrees F (10 to 40 degrees C) SAE 40W

ENGINE OIL API Service Classification CE or CE

(MULTI-GRADE) CCMC Specification D5 or D4

At temperatures:

-22 to 68 degrees F (-30 to 20 degrees C) SAE 5W-30

-4 to 86 degrees F (-20 to 30 degrees C) SAE 10W-30

14 to 122 degrees F (-10 to 50 degrees C) SAE 15W-40

ENGINE COOLANT John Deere Low Silicate Antifreeze or equivalent

TRANSMISSION FLUID The following hydraulic transmission fluids, as ap

At temperatures:

Above -10 degree F (-23 degrees C) Type C-3 (except Grade 30)

Below -10 degree F (-23 degrees C) Type C-3 (except Grade 30) with auxiliary preheattemperature to above -10 degrees F (-23 degrees C

Above 32 degrees F (0 degrees C) Type C-3 or Type C-3 Grade 30

Page 77


APPLICATION DESCRIPTION

AXLE LUBRICANT Multi-purpose gear lubricants meeting MIL Spec

(SINGLE GRADE) L-2105 and suitable for API Service Classification

SAE 80W TRACTELF SF3

AXLE LUBRICANT Milti-purpose Libricants meeting MIL-Spec

(MULTI-GRADE) L-2105C and suitable for API Service Classificatio

At temperatures:

-15 to 100 degrees F (-26 to 38 degrees C) SAE 80W-90 FINA PONTONIC MPX

10 to 120 degrees F (-12 to 50 degrees C) SAE 85-140 FINA PONTONIC MPX

NOTE: FINA PONTONIC MPX Gear Oil is suitable forlimited Slip differentials (Front Axle). If excessive chatteroccurs, the axle must be drained and refilled with 9 oz. ofadditive Part No. APP866 and then filled with FINAPONTONIC MPX up to the normal level.

GREASE ZERKS NLGI-2

HYDRAULIC FLUID ISO-32

TABLE 4. FLUIDS AND LUBRICANTS . . . (CONTINUED)

Page 78


LUBRICATION

All grease fittings on the Model TL6035 are to be serviced with NLGI-2 grease at the intervals specifiedon Table III., “Scheduled Maintenance”. Locations of the various grease fittings may be determined byuse of the illustrations provided.

*ARDCO/TraverseLift L.L.C.

**

*

**

**

*

* *

*

One on each side of axle*

*

* Grease fitting

Figure 17. Lubrication Points (Left Side and Axles).

Figure 18. Lubrication Points (Right Side)

*

* * *

* * *

**

Grease fitting*

ARDCO/TraverseLift L.L.C.

Page 79


*

*

Grease fitting*

ARDCO/TraverseLift L.L.C.

*

Figure 20. Lubrication Points (Rear View)

*

*

*

Grease fitting*

Figure 19. Lubrication Points (Front View).

See Fig. 16for axle.

Page 80


TROUBLESHOOTING

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

HOW TO USE TROUBLESHOOTING TABLES

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

SYMPTOM PROBLEM SOLUTION

Engine will not crank or Loose or corroded starter Clean and tighten connectionscranks slowly electrical connections at starter and battery

Low charge in battery Test condition of battery andcharge if possible. Replacebattery if not usable

Solenoid or starter motor Replace startermalfunction

Broken or missing teeth on Replace starter if drive gear isstarter drive gear or on damaged. Contact Cumminsflywheel ring gear dealer if flywheel is damaged

Engine hard to start or will not Incorrect starting procedure Refer to “STARTUP”start (w/presence of exhaust smoke)

Air in the fuel lines Bleed the fuel system and checkfor leaks in the lines betweenthe fuel pump and the tank

Old or contaminated fuel Drain fuel system and refillwith clean fuel. Bleed fuelsystem.

Clogged air filter Replace air cleaner element

Incorrect injector pump Contact Cummins Dealertiming

TABLE V. CUMMINS ENGINE TROUBLESHOOTING

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Engine hard to start or will not Incorrect valve timing Contact Cummins Dealerstart (w/presence of exhaust smoke)

Faulty injector(s) Contact Cummins Dealer

Faulty injector pump Contact Cummins Dealer

Engine cranks but will not start Incorrect starting procedure Refer to “STARTUP”(with no smoke from the exhaust)

No fuel in fuel tank Fill tank and bleed air fromfuel system

Clogged fuel filter Replace fuel filter element

Incorrect injection pump Contact Cummins Dealertiming

Faulty injection pump Contact Cummins Dealer

Faulty fuel pump Replace fuel pump and bleedfuel system

Engine starts; will not keep running Idle speed too low Adjust idle speed

Faulty shutdown device Repair, replace shutdown device

Air in the fuel system Bleed the fuel system


Contaminated fuel Drain and refill system withclean fuel, bleed air fromsystem

Restricted fuel line Locate restriction and correct

Engine will not shut off Faulty shutoff valve Repair or replace valve

Fuel fumes being drawn Locate and remove source ofinto the air intake fumes

TABLE V. CUMMINS ENGINE TROUBLESHOOTING (Con’t)

Page 82



Engine will not shut off (con’t) Fuel leaking into manifold Check for porosity betweenfuel filter mounting andintake manifold. Correct iffound to be porous

Engine idles roughly at Idle speed set too low Adjust idle speedoperating temperature

Air in the fuel system Bleed system and check forleaks between the fuel pumpand the fuel tank

Incorrect injection pump Contact Cummins Dealertiming

Faulty or clogged injector Contact Cummins Dealernozzles

Broken engine mount(s) Replace engine mount(s)

Faulty injector pump Contact Cummins Dealer

Engine surges at idle Low fuel level in the tank Fill tank and bleed system

Idle speed set too low Adjust idle speed

Air in the fuel system Bleed the fuel system; check forand correct any leaks foundbetween fuel pump & fuel tank


Clogged fuel line Locate restriction and correct.Bleed system afterward


Low engine oil pressure Incorrect oil level Add oil or drain off excess oiluntil proper level is reached

Engine oil diluted with fuel Replace fuel pump

Stuck injector nozzle Contact Cummins Dealer


Page 83



Low engine oil pressure (con’t) Faulty injector pump Contact Cummins Dealer

Oil diluted with water Missing raincap, oil fill cap,dipstick, etc. Replace missingpart and change oil

Incorrect oil Change to proper type andgrade of oil

Loose or missing pipe plug Install and/or tighten plug

Engine operating Correct cooling systemtemperature too high problem

Oil pressure gauge fault Replace gauge

Faulty oil pressure Contact Cummins Dealerregulator valve

Clogged oil filter Change oil, replace filter element

Engine oil pressure too high Faulty oil pressure gauge Replace gauge

Engine operating Correct cooling systemtemperature too cold problem

Incorrect oil Perform oil and filter changeusing proper type, grade of oil

Faulty press. regulator valve Contact Cummins Dealer

Engine losing oil External leak(s) Locate and correct leak(s)

Crankcase overfilled Drain oil to proper level andcheck to make sure dipstick iscorrectly marked

Incorrect oil Change oil and filter usingproper type and grade of oil

Oil diluted with fuel, Contact Cummins Dealercausing a reduction inoil viscosity


Page 84



Engine losing oil (con’t) Oil changes not frequent Shorten the intervals betweenenough oil changes

Oil cooler leak Correct the leak

Engine crankcase pressure Contact Cummins Dealerblow-by

Turbocharger leaking oil Contact Cummins Dealerinto the air intake

Coolant temp. above normal Low coolant level Add coolant to proper level

Radiator fins obstructed or Repair or clean radiator finsdamaged

Faulty radiator hose Replace faulty hose

Incorrect oil level Add oil to the proper level

Cooling fan shroud Replace shrouddamaged or missing

Loose fan drive belt Repair or replace tensioner

Faulty or incorrect Replace radiator cap withradiator cap correct cap

Faulty temperature gauge Replace gauge

Faulty or incorrect Replace thermostat with onethermostat of the proper temperature range


Faulty water pump Contact Cummins Dealer

Air in cooling system Check for and correct leaks onsuction side of the water pump

Check for compression leakthrough head gasket: ContactCummins Dealer if head gasketis leaking


Page 85



Coolant temp. above normal Plugged passages in Flush cooling system and refill(con’t) cooling system with clean coolant; if problem

persists, contact CumminsDealer

Coolant loss Leaking radiator Repair or replace radiator

Leaking hose, water pump, Locate and replace faultygasket or freeze pump component

Damage head gasket, Contact Cummins Dealercracked head or engineblock causing excessivepressure in cooling system,resulting in coolantoverflow from radiator

Coolant temperature below Faulty temperature gauge Replace faulty sender or gaugenormal or sender unit

Wrong thermostat or Replace thermostat with one ofthermostat stuck in the open the proper temperature rangeposition

Fuel or oil leaking from the Intake air restriction Replace air filter elementexhaust manifold

Faulty injector Contact Cummins Dealer

Obstructed turbocharger oil Clear obstruction fromdrain line drain line

Leaking turbocharger oil Contact Cummins Dealerseals

Excessive smoke when Air in the fuel system Bleed air from the fuel systemengine is under load and correct any leaks between

the fuel pump and the fuel tank

Plugged air cleaner Replace air cleaner element

Incorrect injector pump Contact Cummins Dealertiming


Page 86



Excessive smoke when Air leak between the Contact Cummins Dealerengine is under load (con’t) turbocharger and the

intake or exhaust manifold

Too many seals under an Contact Cummins Dealerinjector nozzle

Faulty injector nozzle Contact Cummins Dealer

Faulty turbocharger Contact Cummins Dealer

Engine running too cold Correct cooling system problem

Engine will not reach rated Engine overloaded Reduce loadspeed when loaded

Throttle linkage adjustment Adjust throttle linkageincorrect

Faulty tachometer Replace tachometer

Air fuel control tube Tighten fittings; replace tubeleaking and/or restricted if necessary

Fuel supply restriction Change fuel filter element. Ifproblem persists, locaterestriction and correct

High speed screw Contact Cummins Dealerincorrectly adjusted


Low power output Engine overloaded Reduce load

Engine oil level too high Drain oil to proper level

Throttle linkage adjustment Contact Cummins Dealerincorrect

Restriction in intake or Locate and clear restrictionexhaust system


Page 87



Low power output (con’t) Air fuel control tube Locate leak or restriction andleaking and/or restricted correct

Air leak between turbo- Tighten fittings; replace tubecharger and intake manifold if necessary

Exhaust leak between turbo- Locate and correct leakcharger and exhaust manifold

Air in the fuel system Bleed fuel system; correct anyleaks found between fuel pumpand tank

Improper grade or poor Fill with proper grade, goodquality fuel quality fuel

Restriction in fuel supply Locate restriction and correct

Faulty turbocharger Contact Cummins Dealer

Valves not properly adjusted Contact Cummins Dealer

Faulty injector pump, nozzle Contact Cummins Dealer

Engine misfires Contaminated fuel Drain fuel system, fill with cleanfuel and bleed fuel system

Poor quality fuel Drain fuel system, fill withgood quality fuel and bleed fuelsystem

Air in fuel system Bleed fuel system and correctany leaks found between thefuel pump and the fuel tank

Injection nozzles faulty Contact Cummins Dealer

Injector pump timing Contact Cummins Dealerimproperly adjusted

Excessive fuel consumption Fuel leak Locate leak and correct

Engine overloaded due to Locate faulty accessory andfaulty accessories repair or replace


Page 88



Excessive fuel consumption Poor quality fuel Drain fuel system and fill with(con’t) good quality fuel. Bleed fuel

system afterward

Restriction in intake or Locate restriction and correctexhaust system

Incorrect fuel injector pump Contact Cummins Dealertiming

Faulty fuel injectors Contact Cummins Dealer

Improperly adjusted valves Contact Cummins Dealer

Excessive engine vibration Engine not running smoothly Refer to “Rough idle withengine at operating temperature”

Engine mount(s) loose or Tighten engine mount bolts orbroken replace broken mount

Damaged fan, faulty access. Replace faulty fan or accessory

Faulty vibration damper Replace vibration damper

Faulty alternator bearing Replace alternator

Excessive engine noise Faulty alternator, tensioner, Locate and replace defectivewater pump, fan hub or componentdrive belt

Internal damage to Contact Cummins Dealerturbocharger

Leak in intake or exhaust Locate leak and correct

Improper valve adjustment Contact Cummins Dealer

Gear train noise Replace vibration damper

Undercharged system Poor electrical connections Inspect and clean as necessaryon battery, group strap,starter or alternator

Defective battery Test battery; replace as needed


Page 89



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

No fuel Check fuel level

Air in fuel line Bleed fuel line

Cold weather Use cold weather starting aids

Slow starter speed See “Starter Cranks Slowly”

Crankcase oil too heavy Use proper viscosity oil

Improper type of fuel Consult fuel supplier; useproper type fuel for conditions

Water, dirt or air in fuel Drain, flush, fill and bleedsystem system

Clogged fuel filter Replace filter element

Dirty or faulty injection Have authorized dealer or enginenozzles distributor check injectors

Injection pump shut-off not Turn key switch to ‘OFF” thenreset to “ON”

TABLE VI. JOHN DEERE ENGINE TROUBLESHOOTING



Undercharged system (con’t) Defective alternator Test charging system

Excessive electrical load Remove accessories or installfrom added accessories higher output alternator

Excessive engine idling Increase engine rpm whenusing heavy electrical load

Battery uses too much water Cracked battery case Test battery, replace if needed

Battery charging rate Test charging system;too high replace faulty component

Page 90



Engine knocks Low engine oil level Add oil to engine crankcase

Injection pump out of time See authorized dealer orengine distributor

Low coolant temperature Check thermostat

Engine overheating See “Engine Overheats”

Engine runs irregularly or Low coolant temperature Check thermostatstalls frequently


Water, dirt or air in fuel Drain, flush, fill and bleedsystem system

Dirty or faulty injection Have authorized dealer ornozzles engine distributor check

injectors

Below normal engine Defective thermostat Check thermostattemperature

Defective temperature Check gauge, sender andgauge or sender connections

Lack of power Engine overloaded Reduce load

Air intake restriction Service air cleaner


Improper type of fuel Use proper fuel

Overheated engine See “Engine Overheats”

Low engine temperature Check thermostat

Improper valve clearance See authorized servicingdealer or engine distributor

TABLE VI. JOHN DEERE ENGINE TROUBLESHOOTING (Con’t)

Page 91



Lack of power (con’t) Dirty or faulty injection Have authorized servicingnozzles dealer or engine distributor

check injectors

Injection pump out of time See authorized servicingdealer or engine distributor

Leaking exhaust manifold See authorized servicinggasket dealer or engine distributor

Defective aneroid control See authorized servicingline dealer or engine distributor

Restricted fuel hose Clean or replace fuel hose

Low fast idle speed See authorized servicingdealer or engine distributor

Low engine oil pressure Low oil level Add oil

Improper type oil Drain, then fill crankcasewith oil of proper viscosityand quality

Clogged inlet screen on oil See authorized servicingpump pickup tube dealer or engine distributor

Faulty oil pump See authorized servicingdealer or engine distributor

High oil consumption Crankcase oil too light Use proper viscosity oil

Oil leaks Check for leaks in lines,gaskets, and oil drain plug

Restricted crankcase vent Clean vent tubetube

Engine emits white smoke Improper type of fuel Use proper fuel

Low engine temperature Warm up engine to normaloperating temperature


Page 92



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

Defective injection nozzles See authorized servicingdealer or engine distributor

Engine out of time See authorized servicingdealer or engine distributor

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

Clogged or dirty air cleaner Service air cleaner

Engine overloaded Reduce load

Injection nozzles dirty See authorized servicingdealer or engine distributor


Engine overheats Engine overloaded Reduce load

Low coolant level Fill radiator, check radiator andhoses for loose connections orleaks

Faulty radiator cap Have serviceman check

Loose or defective fan belt Adjust belt tension; replaceas required

Low engine oil level Check oil level; add oil asrequired

Cooling system needs Flush cooling systemflushing

Defective thermostat Remove and check thermostat

Defective temperature Check coolant temperature with agauge or sender thermometer and replace gauge

or sender as necessary


Page 93



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

Clogged or dirty air cleaner Service air cleaner

Engine overloaded Reduce load

Improper valve clearance See authorized servicingdealer or engine distributor

Injection nozzles dirty See authorized servicingdealer or distributor


Low engine temperature Check thermostat

TABLE VII. ENGINE ELECTRICAL TROUBLESHOOTING



Undercharged system Excessive electrical load Remove accessories or installfrom added accessories higher output alternator

Excessive engine idling Increase engine rpm when usingheavy electrical load

Poor electrical connections Inspect and clean ason battery, ground strap, necessarystarter or alternator

Defective battery Test battery and replace asrequired

Battery uses too much water Cracked battery case Test battery and replace ifnecessary

Battery charging rate too high Test charging system; replacefaulty component

Battery will not charge Loose or corroded connections Clean and tighten connections

Page 94



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

Loose or defective Adjust belt tension oralternator belt replace belts

Starter cranks slowly Low battery output See authorized servicingdealer or engine distributor

Crankcase oil too heavy Use proper viscosity oil

Loose or corroded Clean and tighten looseconnections connections

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

Entire electrical system Faulty battery connection Clean and tighten connectionsdoes not function

Sulfated or worn-out See authorized servicingbattery dealer or engine distributor

Blown fuse (MDL-25) Replace fuse

TABLE VIII. TRANSMISSION TROUBLESHOOTING


Transmission slips Low transmission oil level Fill transmission withproper oil to proper level

Worn clutches See authorized dealer

Contaminated transmission Drain transmission, replaceoil filter element, and refill with

clean oil. If problem persists,see authorized dealer

Transmission will not Linkage loose or out of Connect and/or adjustchange into selected gear adjustment linkage

TABLE VII. ENGINE ELECTRICAL TROUBLESHOOTING (Continued)

Page 95



Internal damage to See authorized dealer fortransmission valve service

Low transmission oil level Fill transmission withproper oil to proper level

TABLE VIII. TRANSMISSION TROUBLESHOOTING (Continued)

TABLE IX. HYDRAULIC SYSTEM TROUBLESHOOTINGSYMPTOM PROBLEM SOLUTION

Hydraulic system doesn’t function Plugged filter or strainer Clean and/or replace filter orstrainer element

Relief valve stuck open See authorized dealer

Defective pump See authorized dealer

Sluggish hydraulic action Partially plugged filter or Clean and/or replace filterin all functions strainer or strainer element

Defective pump See authorized dealer

Boom will not extend or retract Defective cylinder See authorized dealer

Defective hose or metallic Replace hose or lineline

Blown fuse Replace fuse

Defective valve See authorized dealer

Boom will not raise See “Boom will not extendor retract”

Cannot tilt or level frame See “Boom will not ...”

Cannot tilt or level forks See “Boom will not ...”

Hydraulic action erratic Air in hydraulic lines Bleed system by cyclingand jerky through each function several

times until action smoothsout

Page 96


REPLACE FUEL FIL TER ELEMENT (CUMMINS ENGINE)

1. Working through the right side engine compartment opening, clean the filter heads to prevent fuel contamina-tion during filter element replacement.

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

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

4. Fill the first element with fuel and install it on the filter head. Hand tighten the element only. DONOT OVER TIGHTEN.

5. Fill the second element with fuel and install it on the filter head. Hand tighten the element. DO NOTOVER TIGHTEN.

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

INNER SEAL

OUTER SEAL

FILTER ELEMENT

Figure 22. Fuel Filter Replacement (Cummins Engine)

REPLACE FUEL FIL TER ELEMENT (JOHN DEERE ENGINE)

1. Loosen the retaining ring (Figure 23) by turning it counterclockwise. Remove the filterelement.

2. Position the new element into the retaining ring and hand tighten the retaining ring ontothe filter base.

3. Bleed the fuel system [SEE “BLEEDING THE FUEL SYSTEM ( JOHN DEERE ENGINE )”]

MAINTENANCE PROCEDURES

Procedures included in the following paragraphs cover those that can normally be achieved by the owneror operator, using common hand tools. For more complex maintenance, contact an authorized dealer orservice representative.

Page 97


BLEEDING THE FUEL SYSTEM (CUMMINS ENGINE)

WARNINGNever attempt to bleed the fuel system of a hot engine. A fuel spill on a hotsurface could cause a fire, resulting in serious injury or death.

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

a. Open the vent screw, located on the side of the filter. (See Figure 24.)

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

c. Tighten the vent screw.

2. Bleed the injection pump as follows:

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

b. Energize the fuel solenoid.

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

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

3. Bleed the high pressure fuel lines as follows:

FILTER BASE

PACKING RING

RETAINING RING

Figure 23. Fuel Filter Replacement (John Deere Engine).

ELEMENT

Page 98


WARNINGThe pressure of the fuel in these lines is great enough that the fuel escaping can penetrate the skin, causingserious and possibly long-term injury.

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

b. Crank the engine while observing the fuel flow.

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

d. Start the engine and allow to idle.

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

Figure 24. Bleeding the Fuel System (Cummins Engine)

BLEEDING THE FUEL SYSTEM (JOHN DEERE ENGINE)

WARNINGEscaping fluid under pressure can penetrate the skin causing serious injury.Relieve the pressure before disconnecting fuel lines. Tighten allconnections before applying pressure. Keep hands and body away frompinholes and nozzles which eject fluids under high pressure. Use a piece ofcardboard or paper to search for leaks. Do not use hand to search for leaks.If any fluid is injected into the skin, IMMEDIATELY GO TO A DOCTORWITH EXPERIENCE IN THIS TYPE OF INJURY. Doctors unfamiliarwith this type of injury may call the Deere & Company MedicalDepartment in Moline, Illinois or other knowledgeable medical source.

1. Loosen the air bleed plug or air bleed screw on the fuel filter base.

2. Operate the supply pump primer lever.

VENTSCREW

PRIMINGLEVER

Page 99


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

5. Bleed the high pressure fuel lines as follows:

WARNINGThe pressure of the fuel in these lines is great enough that the fuel escaping canpenetrate the skin, causing serious and possibly long term injury.

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

b. Crank the engine while observing the fuel flow.

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

d. Start the engine and allow to idle.

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

3. Wait until the fuel flow is free of air bubbles. Tighten the bleed plug or screwsecurely, continue operating the hand primer until pumping action is not felt. Push thehand primer inward (toward the engine) as far as it will go.

AIRBLEEDSCREW

PRIMERLEVER

Figure 25. Bleeding the Fuel System (John Deere Engine)

Page 100

ARDCO/TRAVERSE LIFT L.L.C.ARDCO/Traverse Lift, L.L.C. OWNER/OPERATOR MANUAL Rev. 05/00-5 MODEL TL-6035SERVICE AIR CLEANER

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

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

CAUTIONRemove the safety element only if it is to be replaced. DO NOT attempt toclean the safety element. If the safety element is to be replaced, immediatelyinstall a new element in its place to prevent contaminants from entering theengine.

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

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

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

CAUTIONWhen using compressed air to clean the element, make certain the airpressure is less than 30 psi. Clear the area of bystanders, guard againstflying chips and wear proper protective safety equipment, includingeye protection.

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

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

a. If the element is coated with oil or soot, wash it in a solution of warm water and JohnDeere R36757 Filter Element Cleaner. Let the element soak at least 15 minutes, thenagitate gently to flush out dirt.

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

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

8. Inspect the primary element as follows:

a. Hold a bright light inside the filter element and check it for holes. Discard the filterelement if holes are found.

Page 101


b. Inspect the outer screen for dents. Discard the element if dented.

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

DRAIN AND REFILL COOLING SYSTEM (CUMMINS ENGINE)

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

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

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

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

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

9. Install the primary filter element as follows:

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

b. Install the wing nut to secure the element.

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

d. Install the cup assembly retaining clamp and tighten.

Figure 26. Air Cleaner Service.

WINGNUT

ELEMENT HOUSING

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6. Close the radiator drain valve.

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

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

Figure 27. Draining and Refill Cooling System (Cummins Engine)

DRAIN AND REFILL COOLING SYSTEM (JOHN DEERE ENGINE)

WARNINGNever attempt to remove the radiator cap from a hot engine. Escaping steamand hot coolant under pressure can cause serious burns.

1. Place a container beneath the radiator draincock.

2. After making sure the engine is cool, remove the radiator cap.

3. Open the radiator draincock by turning it counterclockwise. Allow the coolant to draininto the container.

4. Position a container beneath the engine block draincock, open the draincock and allowthe coolant to drain from the engine block into the container.

5. Discard the old coolant in a manner prescribed by the EPA or contact the local JohnDeere Distributor for disposal information.

6. Close the engine block draincock and the radiator draincock.

ENGINEWATERINLET

RADIATORHOSE

LOCATED INLEFT REAROF ENGINECOMPARTMENT

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THERMOSTAT REPLACEMENT (CUMMINS ENGINE)

1. Drain the cooling system.

2. Remove the lower radiator hose from the outlet connection.

3. Remove the alternator drive belt.

4. Disconnect the negative (-) battery cable.

5. Remove the alternator link bolt. (Item 3, Figure 29.)

6. Loosen the alternator mounting bolt. (Item 1, Figure 29.)

7. Swing the alternator upward, clear of the thermostat housing.

NOTEIn the following step, make a note of the order in which the parts areremoved. This will help in assembly.

8. Remove the three thermostat housing bolts (Item 4, Figure 29.) and separate the thermostathousing, lifting bracket, thermostat and thermostat seal from the engine.

7. Refill the radiator with the recommended coolant/water mixture, start the engine andidle until engine reaches operating temperature and the thermostat opens. At this point,the coolant level in the radiator will drop. Fill the radiator with coolant and install theradiator cap.

ENGINE DRAINCOCK(BEHIND TURBOCHARGER)

Figure 28. Draining and Refilling the Cooling System.

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9. Clean the gasket surface.

10. Test the thermostat, as outlined in “THERMOSTAT TEST.”

11. Install the thermostat by reversing the removal procedure. Tighten the thermostat housing mountingbolts (item 4, Figure 29) to 18 ft.-lb (24 Nm).

Figure 29. Thermostat Replacement (Cummins Engine)

THERMOSTAT REMOVAL (JOHN DEERE ENGINE)

WARNINGNever attempt the following procedure on a hot engine. Steam and hot coolantescaping under pressure from the cooling system can cause serious burns.

1. Drain the radiator.

2. Using a screwdriver, loosen the upper radiator hose clamp and pull the hose from thethermostat housing cover. (See Figure 30.)

3. Using a 9/16" wrench, remove the two bolts from the thermostat housing and cover.

4. Separate the thermostat housing cover from the thermostat housing.

5. Remove the thermostat from the thermostat housing.

6. Discard the old thermostat gasket.

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THERMOSTAT TEST

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

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

3. The thermostat should open when the thermometer indicates a water temperature of180 degrees F. If not, replace the thermostat.

GASKET

Figure 30. Thermostat Removal (John Deere Engine)

UPPERRADIATORHOSE

HOSECLAMP

HOUSINGCOVER

THERMOSTAT

THERMOSTATHOUSING

Figure 31. Thermostat Test

THERMOMETERTHERMOSTAT

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THERMOSTAT INSTALLATION (JOHN DEERE ENGINE)

1. Position the thermostat into the thermostat housing, making sure that the thermostatseats fully into its recess.

2. Using gasket adhesive, position a new gasket on the thermostat housing cover.

3. Position the thermostat housing cover (with gasket) on the thermostat housing with the bolt holesaligned. Install the two bolts.

4. With the hose clamp positioned on the hose, slide the hose onto the thermostat housing cover.

5. Tighten the hose clamp.

6. Fill the radiator, start the engine and check for leaks.

DRIVE BELT TENSION ADJUSTMENT (CUMMINS ENGINE)

The Cummins engine is equipped with a spring-loaded tensioner and requires no drive belt adjustment.

DRIVE BELT TENSION ADJUSTMENT (JOHN DEERE ENGINE)

1. Hold a straightedge against the flat, outer side of the drive belt. Make sure the straightedge is longenough to reach from the crankshaft pulley to the alternator pulley.

2. Using a tension tester, apply 20 pounds of pressure to a point halfway between the crankshaft pulleyand the alternator pulley. If the belt deflects more the 3/4 inch away from the straightedge, the belt mustbe adjusted as described in steps 3 and 4.

3. Loosen the upper and lower alternator bolts and apply outward pressure on the alternator front frameto tighten the belt. Tighten the alternator bolts.

4. Recheck the belt tension and readjust if necessary, until proper tension is reached.

Figure 32. Drive Belt Tension Adjustment (John Deere Engine)

WATER PUMPPULLEY

CRANKSHAFTPULLEY

ALTERNATORPULLEY

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ALTERNATOR REPLACEMENT (CUMMINS ENGINE)

1. Remove drive belt as outlined in “DRIVE BELT REPLACEMENT.”

2. Disconnect the ground cable from the battery.

3. Tag each wire on the alternator for identification purposes and disconnect the wiring from thealternator.

4. Remove the lower bolt from the alternator and alternator link.

5. Remove the upper alternator mounting bolt.

6. Remove the alternator.

7. Position the replacement alternator in the upper mounting bracket and loosely install the uppermounting bolt. Do not over tighten.

8. Align the lower bolt holes and install and tighten the lower bolt.

9. Tighten the upper mounting bolt.

10. Connect the wiring harness to the alternator.

11. Install the drive belt as instructed in “DRIVE BELT REPLACEMENT.”

ALTERNATORMOUNTINGBRACKET

UPPERMOUNTINGBOLT

ALTERNATOR

WIRINGHARNESSCONNECTIONS

ALTERNATORLINK

LOWERMOUNTINGBOLT

Figure 33. Alternator Replacement (Cummins Engine)

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ALTERNATOR REPLACEMENT (JOHN DEERE ENGINE)

1. Disconnect the positive (+) battery cable from the battery.

2. Loosen the upper and lower alternator bolts and push the alternator toward the engine toloosen the drive belt.

3. Remove the drive belt.

4. Make a note of all wiring harness connectors and disconnect the wiring harness from thealternator.

5. Remove the nut and lockwasher from each of the two alternator mounting bolts.

6. Support the alternator and pull the two mounting bolts out of the alternator.

7. Lift the alternator from the mounting bracket.

8. Position the new alternator in the mounting bracket with the bolt holes aligned.

9. Insert the lower alternator mounting bolt through the aligned bolt holes of the mountingbracket and the alternator.

10. Using a new lockwasher, loosely install the lockwasher and nut on the lower alternatormounting bolt.

11. Insert the upper mounting bolt through the adjustment bracket and the upper bolt hole of thealternator and loosely install the nut with a new lockwasher.

12. Position the drive belt around the pulleys of the crankshaft, water pump and alternator.

13. Adjust the tension of the drive belt. See “ADJUST DRIVE BELT TENSION “.

ADJUSTMENTBRACKET

FRONT MOUNTINGBRACKET

WIRINGHARNESS

REAR MOUNTINGBRACKET

SHIELD

ALTERNATOR

Page 109


BATTERY REPLACEMENT

WARNINGThe Environmental Protection Agency (EPA) has established guidelines for thedisposal of batteries. Make certain that EPA requirements are met whendisposing of batteries.

1. Remove the nut from each battery post.

2. Remove the battery ground cable from the negative (-) battery post, then remove the positive cablefrom the positive (+) battery post.

3. Loosen the two battery clamp nuts and lift the hold-down clamp from the battery.

4. Lift the battery from the forklift.

5. Position the new battery in the forklift.

6. Place the battery hold-down clamp on the battery with the threaded rods of the clamp hooked into theslots provided.

7. Tighten the hold-down clamp nuts.

8. Position the battery cables on the posts in the following order, first the red cable to the positive (+) post and then the black cable to the negative (-) post.

9. Install a nut on each battery post.

10. Dispose of the old battery in a manner approved by the EPA.

HOLD DOWNCLAMP

BATTERY

THREADEDROD

BATTERYCABLE

Figure 31. Battery Replacement.

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FUSE REPLACEMENT

1. Using a 1/2 inch flat tip screwdriver or a 1/4 inch rachet, loosen the two latches located belowthe operator’s panel.

2. Open the lower panel by swinging it downward. The fuse panel is located on the inner side ofthe lower panel

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

4. Close and latch the lower panel.

Figure 32. Fuse Replacement

ENGINE OIL CHANGE (CUMMINS ENGINE)

WARNINGNever dispose of engine oil by pouring it on the ground or down a drain.Contact the local EPA or Cummins distributor for information.

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

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

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

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

LOW BRAKEPRESSURE BUZZER/

EMERGENCY BRAKEBUZZER BLANK (NO FUSE)

JOYSTICKS

TRANSMISSIONSHIFTER

INJECTION PUMP

HORN &GAUGES

15A 15A 10A 10A 6A

NOTE: INLINE FUSE (5 AMP) LOCATED IN THE STARTER WIREFOR NEUTRAL SAFETY SWITCH.

Page 111


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

6. Install and tighten the engine oil drain plug.

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

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

Figure 33. Cummins Engine Oil Filter

ENGINE OIL CHANGE (JOHN DEERE ENGINE)

WARNINGNever dispose of engine oil by pouring it on the ground or down a drain.Contact the local EPA or John Deere engine distributor for information.

1. Position a container beneath the engine oil drain plug.

2. Remove the engine drain plug and allow the oil to drain into the container.

3. Position a container beneath the oil filter and, using a filter wrench, remove the oil filter.

4. Apply a light coat of engine oil to the gasket of the new oil filter and install the filter on the engine.Hand tighten only.

5. Install the engine oil drain plug.

6. Remove the oil filter cap from the engine and add oil to the full make on the oil dipstick. Replace thefiller cap on the engine.

7. Start the engine and allow it to idle while checking for leaks, especially at the oil drain plug and the oil filter.

FILTERWRENCH

FILTERELEMENT

Page 112


CLEAN CRANKCASE VENT TUBE

1. Using a screwdriver, loosen the hose clamp and remove the crankcase vent hose from the elbow,located in the engine rocker cover.

2. Pull the elbow from the engine rocker cover and clean the elbow and hose.

3. If the hose is to be replaced, use a 9/16 inch wrench and remove the bolt from the retainer clamp,located on the front of the flywheel cover. Remove the clamps from the old hose and position themon the new hose. Install the retainer clamp and bolt on the front of the flywheel cover.

4. Install the elbow into the engine rocker cover, making certain that the O-ring is properly positioned inthe rocker cover.

5. Install the hose on the elbow and tighten the hose clamp.

Correct any leaks found.

8. Shut the engine down and recheck the engine oil level. Add oil as required.

9. Dispose of the old engine oil and filter in a manner consistent with EPA regulations.

OIL FILTER

OIL DRAIN

Figure 34. Engine Oil Change (John Deere Engine)

HOSE CLAMP ELBOW

O-RING ROCKER COVER

CLAMP

HOSE

Figure 35. Crankcase Vent Tube

Page 113


TRANSMISSION OIL CHANGE

NOTETransmission oil should be changed with the transmission warm.

WARNINGNever dispose of transmission oil by pouring it out on the ground or pouring itdown a drain. Contact the local Environmental Protection Agency (EPA) officeor the nearest Clark Distributor for proper disposal information.

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

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

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

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

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

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

DRAINPLUG

IDENTIFICATIONPLATE

DIPSTICK ANDFILL TUBE

FILTERELEMENT

Figure 36. Transmission Drain Plug Location.

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TRANSMISSION FIL TER ELEMENT REPLACEMENT

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

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

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

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

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

AXLE LUBRICANT CHANGE

WARNINGThe Environmental Protection Agency has established guidelines for lubricantdisposal. Contact the local office of the EPA or the nearest axle manufacturerfor the proper disposal procedure.

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

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

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

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

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

HIGH LUBRICANT LEVELINSPECTION PLUG

DRAIN PLUG

Figure 37. Axle Drain and Fill Plug Location.

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HYDRAULIC STRAINER ELEMENT REPLACEMENT

1. Separate the piping from the top of the strainer.

2. Remove the four bolts from the base of the strainer.

3. Lift the strainer assembly from the hydraulic reservoir.

4. Remove the cover to expose the element.

5. Using a 17 mm wrench, remove the element restraining bolt, plate and spring.

6. Remove the element.

7. Position the new element on the center post of the strainer assembly.

8. Install the spring, plate and nut.

9. Check the condition of the rubber seal and replace it if damaged.

10. Position the rubber seal back into the groove of the strainer base.

11. Place the element cover back on the strainer base with the rubber seal properly positioned.

Figure 38. Planetary Check and Fill Plug

INSPECTION ANDDRAIN PLUG

ARROW

LUBRICANTLEVEL LINE

12. Clean all remnants of the old base gasket from the base of the strainer and the reservoir.

13. Install a new gasket, using gasket sealer.

14. Position the strainer assembly on the reservoir with the four bolt holes aligned.

15. Install the four bolts and reconnect the piping.

Page 116


Figure 39. Hydraulic Strainer Element Replacement.

NUT

PLATE

SPRING

ELEMENT

SEAL

BASE

COVER

SUMMARY

This manual has been furnished by ARDCO/Traverse Lift L.L.C. to be used as a guide for equipment operationand routine maintenance. Remember, this machine can be extremely dangerous when operated recklessly. Themost important safety feature of a Pettibone Extendo. is the operator himself.

The TL 6035 is designed to encourage daily, routine maintenance by locating maintenance points ineasily accessible locations. Constant adherence to the maintenance schedules listed herein will serve tolengthen the usable life of this machine. Should a problem arise which you cannot resolve, contact yourservicing dealer immediately, or call us at (800) 909-0919; we’re here to ensure your satisfaction withARDCO/Traverse Lift L.L.C. products.

THANK YOU FOR CHOOSING ARDCO/TRAVERSE LIFT L.L.C.

Documents

ARDCO/Traverse Lift, L.L.C. OWNER/OPERATOR MANUAL Rev. 05 ... · page 1 ardco/traverse lift, l.l.c. owner/operator manual rev. 05/00-5 model tl-6035 rough terrain variable reach forklift