Operators Manual PMPB-4546

204-254-304
PMOM-4022
S/N CL10043
Rev 10/08
Preface
This rough terrain forklift is manufactured by Pettibone/Traverse Lift, LLC, a subsidary of Pettibone, LLC.
The machine is designed to provide years of reliable operation with minimal maintenance.
This manual instructs the owner/operator in the correct operation of the Pettibone/Traverse Lift Rough
Terrain Forklifts. The location and operation of all controls are explained in this manual. It also contains
lubrication tables, which indicate the recommended servicing intervals for all fluids and greased
components.
This manual should be considered a permanent part of your vehicle. It should stay with the vehicle, if sold,
to provide the next owner with required operating instructions.
All instructions, illustrations and specifications contained herein are based upon the latest product
information available at the time of printing. Pettibone/Traverse Lift reserves the right to change
specifications without prior notice in order to follow its policy of constantly striving to manufacture a better
product without incurring any liability to provide these new features on any units previously manufactured.
Be sure your dealer has returned the Warranty Registration Form for your machine to Pettibone/Traverse
Lift, LLC. This form must be filled out properly in initiate warranty coverage on the machine. In addition, your
dealer will fill out a Machine Inspection Report, which the owner should sign. Also, a 30-day check up is
recommended as defined in this manual. If a problem occurs with your machine during the warranty period,
contact your dealer immediately. Do not continue to operate the machine until authorized.
 Contents

Preface.............................................................................................................................................................................2
Safety....................................................................................................................................................................................1
Safety Rules...................................................................................................................................................................1
Safety Statements.......................................................................................................................................................1
Safety Messages...........................................................................................................................................................2
Operator Qualifications.............................................................................................................................................7
Safe Operating Practices...........................................................................................................................................7
Transporting Safely.....................................................................................................................................................8
Parking the Machine..................................................................................................................................................8
Safety While Servicing the Machine.....................................................................................................................9
Maintenance Procedures..................................................................................................................................9
Decals........................................................................................................................................................................... 10
Safety.................................................................................................................................................................... 10
Decal Locations ................................................................................................................................................ 10
Identification............................................................................................................................................................... 11
Material Safety Data Sheets (MSDS).................................................................................................................. 11
Identification Numbers.......................................................................................................................................... 11
Machine Inspection and Delivery Report........................................................................................................ 12
Directional Reference.............................................................................................................................................. 12
Identification.............................................................................................................................................................. 13
Forklift Identification Plate............................................................................................................................ 13
Engine Identification Plate............................................................................................................................ 13
Transmission Identification Plate................................................................................................................ 13
Axle Identification Plate................................................................................................................................. 13
Equipment Description.......................................................................................................................................... 15

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Contents
Forklift Description.......................................................................................................................................... 15
Standard Engine Description....................................................................................................................... 15
Transmission Description.............................................................................................................................. 15
Axle Description................................................................................................................................................ 15
Options................................................................................................................................................................. 15
Ordering Parts.................................................................................................................................................... 15
Decals................................................................................................................................................................................ 17
LL-4774, LARGE PETTIBONE . ............................................................................................................... 17
LL-4775, SMALL PETTIBONE.................................................................................................................. 17
LL-4773, WATCH YOUR STEP.................................................................................................................. 17
LL-4628, GROUND WARNING................................................................................................................ 17
LL-4631, BATTERY WARNING................................................................................................................ 17
LL-4626, COOLANT PRESSURE CAUTION.......................................................................................... 17
LL-4633, POWER DANGER...................................................................................................................... 17
LL-4627, BRAKE CAUTION...................................................................................................................... 17
LL-4630, HAZARDS LABEL...................................................................................................................... 17
LL-4778, WORK HORSE............................................................................................................................ 17
LL-4813, NO RIDERS................................................................................................................................. 17
LL-4780, TRANSMISSION OIL FILL....................................................................................................... 17
LL-4781, HYDRAULIC OIL....................................................................................................................... 17
LL-4782, DIESEL FUEL.............................................................................................................................. 18
LL-6039, MADE IN THE USA................................................................................................................... 18
LL-6126, PINCH POINT............................................................................................................................ 18
LL-6453, WELDING AND MODIFICATION WARNING..................................................................... 18
LL-6163, MOTOR OIL................................................................................................................................ 18
LL-6456, COMBUSTIBLE FLUID WARNING........................................................................................ 18
LL-6461-1, CLOSING JAW DANGER..................................................................................................... 18
LL-6471, HOT EXHAUST.......................................................................................................................... 18
LL-6480, PINCH POINT............................................................................................................................ 18
LL-7136, HORN MUST SOUND.............................................................................................................. 18
L1-10297-1, SPINNING BLADES DANGER......................................................................................... 18
LL-7026, HYDRAULIC OIL DRAIN......................................................................................................... 18
L1-10298, BOTH HANDS......................................................................................................................... 18
L-9870, NO RIDERS WARNING............................................................................................................... 18
L-10297, MOVING BELTS WARNING.................................................................................................... 18
LL-1803-499, ACCUMULATOR WARNING.......................................................................................... 18
LL-5433, CARY-LIFT LOGO...................................................................................................................... 18
LL-5692, CLUTCH CUT-OFF.................................................................................................................... 18
LL-6462-6, EXCESS HYDRAULIC PRESSURE...................................................................................... 18
LL-6492, CARBON MONOXIDE WARNING......................................................................................... 18

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 Contents
LL-7304, PARK BRAKE SWITCH.............................................................................................................. 19
LL-7474, PROPOSITION 65 WARNING................................................................................................ 19
LL-7700, WELDING AND MODIFICATION HAZARD....................................................................... 19
LL-7731, DO NOT USE ETHER................................................................................................................ 19
FL-10561, PARK BRAKE APPLY.............................................................................................................. 19
LL-4624, SAFETY WARNING................................................................................................................... 19
LL-7405, FASTEN SEAT BELT................................................................................................................... 19
LL-7406, FORWARD AND REVERSE..................................................................................................... 19
LL-7617, IDENTIFICATION PLATE......................................................................................................... 19
LL-7157, CONTENTS UNDER PRESSURE............................................................................................ 19
LL-5948, NO STEP...................................................................................................................................... 19
LL-5972, SUPER 20 MODEL DECAL..................................................................................................... 19
LL-7838, TRANSMISSION OIL FILTER................................................................................................... 19
LL-7747, PRIMER DECAL......................................................................................................................... 19
LL-7185-5, HYDRAULIC PRESSURE...................................................................................................... 19
LL-6092, SUPER 25 MODEL DECAL..................................................................................................... 19
LL-7185-6, HYDRAULIC PRESSURE...................................................................................................... 19
LL-7232-1, HYDRAULIC PRESSURE...................................................................................................... 19
LL-7015, FUEL TANK DRAIN................................................................................................................... 19
LL-5973, SUPER 30 MODEL DECAL..................................................................................................... 19
LL-5940, STEERING SELECTOR.............................................................................................................. 19
Operation........................................................................................................................................................................ 21
General......................................................................................................................................................................... 21
Functional Description........................................................................................................................................... 21
Features........................................................................................................................................................................ 21
Fork Leveling...................................................................................................................................................... 21
Frame Tilt............................................................................................................................................................. 21
Steering................................................................................................................................................................ 21
Operation.................................................................................................................................................................... 22
Entering the Operator’s Compartment.................................................................................................... 22
Cab Doors............................................................................................................................................................ 22
Operator’s Seat.................................................................................................................................................. 22
Backrest Angle Adjustment.......................................................................................................................... 22
Fore/Aft Adjustment........................................................................................................................................ 22
Height Adjustment.......................................................................................................................................... 22
Seat Suspension Adjustment ...................................................................................................................... 22
Arm Rest............................................................................................................................................................... 22
Seat Belt............................................................................................................................................................... 23
Instrument, Indicator and Switch Panels................................................................................................. 29
Transmission Oil Temperature Gauge(Figure 9, (1))..................................................................... 29

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Contents
Torque Converter Oil Pressure Gauge(Figure 9, (2))..................................................................... 29
Hydraulic Power Switch (Figure 9, (3)).............................................................................................. 29
Boom Lights (Optional) (Figure 9, (4))............................................................................................... 29
Warning Beacon Switch (Optional)(Figure 9, (5)).......................................................................... 29
Rear Floodlight Switch (Optional)(Figure 9, (6))............................................................................ 29
Headlight/Taillight Switch (Figure 9, (7)).......................................................................................... 29
Wiper Switch (Figure 9, (8))................................................................................................................... 30
Blower Switch (Figure 9, (9))................................................................................................................. 30
Heater and A/C Selector Switch (Figure 9, (10))............................................................................. 30
Engine Ignition Switch (Figure 9, (11)).............................................................................................. 30
Engine Oil Pressure Gauge (Figure 9, (12))...................................................................................... 31
Voltmeter (Figure 9, (13))....................................................................................................................... 31
Engine Coolant Temperature Gauge(Figure 9, (14)).................................................................... 31
Engine Hour Meter (Figure 9, (15))..................................................................................................... 31
Fuel Gauge (Optional) (Figure 9, (16))............................................................................................... 31
Stop Engine Lamp (Figure 10, (17)).................................................................................................... 31
Air Intake Heater Lamp (Figure 10, (18))........................................................................................... 32
Clutch Cut Out Switch (Figure 10, (19))............................................................................................ 32
Park Brake Switch (Figure 10, (20))..................................................................................................... 32
Steering Selector (204 and 254 Only)(Figure 10, (21))................................................................ 33
Check Engine Lamp (Figure 10, (22))................................................................................................. 33
Steering Selector (304 Only)(Figure 11, (23)).................................................................................. 34
Engine Oil Pressure Warning Light..................................................................................................... 34
Low Voltage Warning Light................................................................................................................... 34
Parking Brake Warning Light................................................................................................................ 34
Transmission Filter Bypass Indicator Light...................................................................................... 34
Speedometer (Optional)........................................................................................................................ 34
Tachometer (Optional)............................................................................................................................ 34
Steering Column Controls............................................................................................................................. 35
Column Angle Adjustment................................................................................................................... 35
Horn Button................................................................................................................................................ 35
Turn Signal Lever (Optional)................................................................................................................. 36
Hazard Light Switch (Optional)........................................................................................................... 36
Defroster Switch (Optional).................................................................................................................. 36
Transmission Controls..................................................................................................................................... 36
Dual-Function Transmission Control Lever..................................................................................... 36
Twist Grip Gear Shifter............................................................................................................................ 37
Direction Selector..................................................................................................................................... 37
Throttle and Brake Controls.................................................................................................................................. 38
Display, Control or Indicator......................................................................................................................... 38
Function............................................................................................................................................................... 38
iv Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE
 Contents
Engine Diagnostic Plug-In..................................................................................................................... 39
Hydraulic Controls.................................................................................................................................................... 39
Left Hand Remote Control............................................................................................................................ 39
Right Hand Remote Control......................................................................................................................... 40
Fork Attachment Controls............................................................................................................................. 40
Left Hand Control..................................................................................................................................... 40
Right Hand Control ................................................................................................................................. 40
Pipe and Pole Baler Controls........................................................................................................................ 41
Left Hand Control..................................................................................................................................... 41
Right Hand Control.................................................................................................................................. 41
Tire Handler Controls...................................................................................................................................... 42
Left Hand Control..................................................................................................................................... 42
Right Hand Control.................................................................................................................................. 42
Swivel Clam Controls....................................................................................................................................... 43
Left Hand Control..................................................................................................................................... 43
Right Hand Control.................................................................................................................................. 43
Pre-Operational Checks and Services............................................................................................................... 44
Check Transmission Oil................................................................................................................................... 45
Radiator Coolant Level Check...................................................................................................................... 46
Check Hydraulic Fluid Level.......................................................................................................................... 47
To Fill Hydraulic Tank............................................................................................................................... 47
Tires and Rims.................................................................................................................................................... 47
Inspection for Leaks......................................................................................................................................... 47
General Inspection........................................................................................................................................... 47
Gauges and Indicators.................................................................................................................................... 48
Hydraulic Fluid Level....................................................................................................................................... 48
Changes in Performance................................................................................................................................ 48
Tire Pressure....................................................................................................................................................... 48
Operational Checks and Services....................................................................................................................... 48
Startup and Driving......................................................................................................................................... 48
Steering Modes......................................................................................................................................... 49
Raising the Load............................................................................................................................................... 52
Transporting the Load.................................................................................................................................... 52
Landing the Load............................................................................................................................................. 53
Shutdown............................................................................................................................................................ 53
Lubrication.................................................................................................................................................................... 55
204 Cary Lift w/ Cummins QSB6.7 190HP Tier III/Funk DF150 Transmission (S/N
CL10001+)................................................................................................................................................... 61
Engine Cummins QSB6.7-190 Tier III................................................................................................................. 62
Transmission Funk DF1544R Torque Converter DF3R2A............................................................................ 65
Axle Axletech PSC1764 (Front) / PSC826 (Rear) or PSC1764 (Front) / PSC1764 (Rear).................... 66
800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual v
Contents
General......................................................................................................................................................................... 67
254 Cary Lift w/ Cummins QSB6.7 220HP Tier III/Clark R32420 Transmission ................... 68
Engine Cummins QSB6.7-220 Tier III................................................................................................................. 69
Transmission Clark R32420 Torque Converter C323.1-19.......................................................................... 72
Axle Axletech PSC1485 (Front) / PSC1485 (Rear).......................................................................................... 73
General......................................................................................................................................................................... 74
304 Cary Lift w/ Cummins QSC 8.3 240HP Tier III/Clark 6000 Transmission........................ 75
Engine Cummins QSC8.3-240HP........................................................................................................................ 76
Torque Converter Clark C5000 Transmission Clark T6000......................................................................... 79
Axle Axletech PSC-5494......................................................................................................................................... 80
General......................................................................................................................................................................... 81
Thank you for choosing Pettibone/Traverse Lift, LLC.................................................................................. 82

vi Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE

 Safety
Safety Rules
Most accidents involving machine operation and
maintenance can be avoided by following basic
rules and precautions. Read and understand all
the safety messages in this manual, and the safety
signs on the machine before operating or servicing.
See the dealer for any questions. Failure to read
and follow these instructions could result in death,
serious injury or damage to the machine.
READ THIS MANUAL COMPLETELY and be sure
to understand the speed, stability and steering
characteristics of this machine. Do not remove this
manual from the machine. This manual must remain
with the machine at all times. The manual storage
box is located inside the operator’s compartment,
behind the operator’s seat. See your dealer or
contact Pettibone/Traverse Lift, LLC for additional
manuals.
The safety information given in this manual does
not replace safety codes, insurance regulations or
federal, state and local laws. Be sure the machine
has the correct equipment according to these rules
or laws. Safety messages in this section point
out situations that can be encountered during the
normal operation and maintenance of your machine.
These safety messages also give possible ways
of dealing with these conditions. Additional safety
messages are used in the text of the manual to
show specific safety hazards.
800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual
Safety Statements
This is the safety alert symbol. It is used
to alert you to potential personal injury
hazards. Obey all safety messages that
follow this symbol to avoid possible injury
or death.
AA DANGE
Indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
AA WARNIN
Indicates a hazardous situation which, if not
avoided, could result in death or serious
injury.
AA CAUTIO
Indicates a hazardous situation which, if not
avoided, could result in minor or moderate
injury.
NOTICE
Indicates a situation which, if not avoided,
can cause damage to the machine, personal
property and/or the environment or cause the
equipment to operate improperly.
Note: Provides additional information.
1
Safety
Safety Messages
AA DANGE
The safety messages that follow have
DANGER level hazards. These safety
messages describe a hazardous situation
which, if not avoided, will result in death or
serious injury.
Electrocution Hazard
• Avoid contact with high voltage power lines
and underground cables.
• Before driving or operating in an area with
high voltage lines or cables, disconnect the
power.
• Know the location of and keep a safe
working distance from any high voltage
power equipment.
• Observe federal, state/provincial and local
safety codes and regulations that apply to
the job site.
2 Cary-Lift 204, 254, 304 Operator’s Manual
AA WARNIN
The safety messages that follow have
WARNING level hazards. These safety
messages describe a hazardous situation
which, if not avoided, could result in death or
serious injury.
Tip Hazard
• Determine if weather, road or earth
conditions will permit safe operation on a
hill, ramp or rough ground.
• Stay away from hazardous areas such as
ditches and overhangs.
• Walk around the work area before starting
the forklift and look for hazards.
Crush Hazard
• No personnel should ever walk or
stand under a raised boom or walk
alongside a moving forklift.
• Be alert and always know the location of all
workers in the area.
• Keep all other persons completely away from
the machine.
• Do not attempt to remove a load from the
forks by stopping the forklift suddenly.
• Position loads squarely and evenly on both
forks before raising load.
800-GO-PETTIBONE

AA WARNIN
Fire and Explosion Hazard
Sparks or flame can cause the
hydrogen gas in a battery to
explode.
To prevent an explosion when disconnecting the
battery cables, disconnect the negative (-) cable
first. When connecting battery cables, connect
the negative (-) cable last. When connecting
jumper cables to start the engine, connect
the negative (-) cable last and disconnect the
negative (-) cable first after the engine starts.
• Do not short circuit the battery posts with
metal items.
• Do not weld, grind, or smoke near a battery.
• Sparks from the electrical system or engine
exhaust can cause an explosion and fire.
DO NOT operate this machine in an area
with flammable dust or vapors. Use proper
ventilation to remove the flammable dust or
vapors prior to starting the machine.
• Engine fuel can cause an explosion or fire.
Do not fill the fuel tank with the engine
running or near open flames or sparks.
• Use nonflammable cleaning solvent to clean
parts.
• Always have a fire extinguisher near or
on the machine. Make certain the fire
extinguisher is serviced according to
the manufacturer’s instructions. If a fire
extinguisher has been used, always recharge
or replace the fire extinguisher before
operating the machine.
• Check the electrical system for loose
connections or frayed insulation. Repair or
replace the loose or damaged parts.
• Clean the entire machine to reduce risk of
fire hazard before welding or using a torch
on the machine.
• If the battery electrolyte freezes, the battery
may explode if:
–– Attempting to charge the battery
–– Jump-starting the battery
800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual
Safety
• Learn the location of underground hazards
before operating the machine in a new area.
Alcohol and Drug Hazard
Do not operate this machine while
under the influence of alcohol, drugs
or if feeling ill.
Flying Debris Hazard
• Remove all trash or debris from the machine
each day. Double check the engine area and
exhaust system.
• Check that all guards and covers are
installed correctly.
Entanglement Hazard
Avoid loose fitting clothing, loose or
uncovered long hair, jewelry or loose
personal articles.
Fall Hazard
• Foreign material or grease on the step or
hand rail can cause an accident. Keep the
step and hand rail clean.
• If the machine has an oil, fuel or hydraulic
leak, always repair the leak and clean the
area before operating.
• Always face the machine and use the hand
rail and step when climbing aboard. Do not
rush and do not jump from the machine.
• Before starting the engine, always properly
fasten and securely tighten the seat belt,
and always keep the seat belt fastened while
operating the machine.
• Do not allow anyone to ride on the machine.
• Do not use the machine to lift personnel
or any type of personnel carrier, including
platforms. The machine operator may not
have control over such a carrier device.
3
Safety
AA WARNIN
Exhaust Hazard
• Engine exhaust fumes can
cause death. If you operate
this machine in an enclosed
area, use proper ventilation to
replace the exhaust fumes with
fresh air.
• Starting fluid (ether) can cause death or
serious injury.
• Do not inhale starting fluid vapors. Wear
face protection when removing or installing
a starting fluid container or when using
aerosol spray starting fluid.
• Use starting fluid according to the
instructions in this manual.
• Do not operate the forklift in a closed
building. Always operate in a well-ventilated
area.
Transport Hazard
• Attach a red flag attachment on furthest
projection of machine for safety.
• Know the dimensions of the machine when
mounted on truck.
• Be sure machine is within proper size and
weight limits for highway transporting.
• Check route to ensure sufficient clearances.
• Check bridges for adequate weight limits.
• Make sure the machine is securely tied down
whenever transporting.
Uncontrolled Movement Hazard
• Always wear the seat belt when operating the
forklift.
• Operate the machine controls from the
operator’s seat only.
• Avoid parking on an incline.
4 Cary-Lift 204, 254, 304 Operator’s Manual
Explosion Hazard
• Do not attempt to jump-start a frozen battery.
• Do not charge a frozen battery.
Chemical Burn Hazard
• 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 with milk of
magnesia, beaten egg or vegetable oil.
–– EYE: Flush with water for 15 minutes and
get prompt medical attention.
• Call a doctor immediately.
Burn Hazard
• Hot coolant can spray out when
the radiator cap is removed.
• Let the cooling system cool
down.
• Turn cap to the first notch.
• Wait until the pressure is released.
• Remove the radiator cap.
• Do not touch exhaust system components
when engine is running.
Structural Integrity Hazard
• Do not weld on any structural member
unless specifically authorized by Pettibone/
Traverse Lift, LLC. Before welding or using
a torch on the machine, disconnect the
ECM by removing plug from the face and
transmission TCM by unplugging connection
point (under the right side of cab).
• Any unauthorized welding may weaken the
structural temper and will void the warranty.
800-GO-PETTIBONE
 Safety

1  – Disconnect these plugs before welding.

Figure 1. Transmission TCM (204 Model)

1  – Disconnect these plugs before welding.

Figure 2. Engine ECM (204 and 254 Models)

800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual 5

Safety

1  – Disconnect these plugs before welding.

Figure 3. Engine ECM (304 Model)

6 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE

 Safety

AA WARNIN
Maintenance in Progress Hazard
Put a “Do Not Operate” lockout tag on the
ignition switch and steering wheel when people
are working on the machine.
AA CAUTIO
The safety messages that follow have
CAUTION level hazards. These safety
messages describe a hazardous situation
which, if not avoided, could result in minor or
moderate injury.
Exposure Hazard
• Different jobs will require
different protective equipment.
• Items such as hard hats,
protective shoes, heavy gloves,
reflector type vests, respirators
and ear protection may be
required.
• Know and use the equipment that is required
before starting the job.
• Be prepared for emergencies. Always have
a first aid kit and a properly working fire
extinguisher. Know how to use both.
Operator Qualifications
Only qualified personnel who have received Factory
Operator training should operate this forklift.
Safe Operating Practices
• Never allow anyone that is not trained or
qualified to operate this machine.
• Read and understand this operation manual
before you operate or service this machine to
ensure that you follow safe operating practices
and maintenance procedures.
• Machine safety signs, labels and decals are
additional reminders of safe operating and
maintenance techniques.
• Know the hand signals used on the job. Follow
the instructions of the flag man, signs, etc.
• Make sure all persons are away from the
machine and give a warning before starting the
engine.
• Remove all loose objects from the operator’s
compartment and from the machine. Loose
objects can jam controls and cause accidents.
• Before operating at night, check that all lamps
illuminate.
• Operate the machine controls from the
operator’s seat only.
• Check all controls while parked in a clear
area and make sure the machine is operating
correctly.
• Dust, fog, smoke, etc. can decrease your vision
and cause an accident. Stop the machine and
decrease the speed until visibility increases.
• Keep the forks low when moving around the
work area.
• Install markers to warn others of potential
dangers when operating in reduced visibility.
• Raise the boom only if there is sufficient
overhead clearance.
• Land loads on a level, solid surface.
• Avoid stacking loads.
• Avoid sudden stops and turns.

800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual 7

Safety
• Make certain that the load is secure and stable Parking the Machine
before raising.
1. Bring the forklift to a complete stop.
• Be sure the load and machine will fit in the
2. Engage the parking brake by flipping the switch
intended path before moving.
located on the left side of the dashboard.
• Move loads in reverse when forward visibility is
3. Lower the forks to the ground.
not complete.
4. Place the transmission in NEUTRAL.
• Do not make unauthorized modifications to this
machine. 5. Allow the engine to idle for 1-3 minutes.
See Pettibone/Traverse Lift, LLC for additional 6. Shut the engine off.
training.
7. Remove the ignition key from the switch.
Transporting Safely 8. Unfasten seat belt. WARNING! Fall Hazard.
When correctly loaded on the flatbed of a tractor- Use hand rail and step. Climb carefully from
trailer, this machine is designed to be safely cab.
transported between local work sites.
9. Block wheels of forklift if the machine is on an
• Know the rules, laws and safety equipment incline.
necessary for transporting this machine on
public roadways.
CALIFORNIA PROPOSITION 65
• Know which warnings must be placed on Diesel engine exhaust and some of its
machine for highway travel and whether an constituents are known to the State of
escort is needed. California to cause cancer, birth defects and
• Always shut down machine engine when other reproductive harm.
transporting.
• Do not put chains over or against hydraulic lines
or hoses. NOTICE: Always cap exhaust pipe
or cover the opening with tape to prevent
air from spinning the turbocharger while
vehicle is transported at highway speeds.
The turbochargers depend upon engine oil
pressure to lubricate shaft bearings and may
be damaged if spun dry.
• Be sure to remove tape after transporting
machine and before starting engine.

8 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE

 Safety

HYDRAULIC PRESSURE WARNING SHEET

AA WARNIN
OBSERVE ALL MAXIMUM HYDRAULIC SYSTEM PRESSURE WARNINGS AND DECALS FOR THIS
MACHINE.
SETTINGS HIGHER THAN POSTED PRESSURES MAY RESULT IN DEATH, SEVERE INJURY OR
PROPERTY DAMAGE.
In many instances, we have learned that the hydraulic relief valves of this equipment have been reset,
thereby increasing the maximum pressures and, with this, the load the unit will lift before the relief valve
opens. In some instances, the consequences of increasing this setting have been serious. The function of
the relief valve is to provide a fuse action to protect the machine and the operator from overloading. When
overloaded, different portions of the machine can become stressed to a level at which parts fracture,
possibly resulting in death, severe injury or property damage. Resetting hydraulic pressures above
factory settings is an extremely dangerous practice.
Accordingly, you are advised that the settings of these valves are limited to the maximum listed above.
Pressure settings in excess of this level render each and all Pettibone/Traverse Lift, LLC warranties null
and void, and constitute an obvious misuse and abuse of our product.
Pettibone/Traverse Lift, LLC

Safety While Servicing the Maintenance Procedures

Machine
The following section gives suggested
guidelines for operational maintenance on your
machine.
Check the Hour Meter regularly to determine when
the machine needs periodic maintenance. In severe
conditions (extreme dust, heat, cold, humidity,
etc.) you will need to service your machine more
often. Your experience may dictate a more severe
servicing program.
Safety while servicing machine is the owner’s
responsibility. Only qualified and authorized
personnel should be permitted to maintain,
repair, adjust and inspect the machine.
Read and understand warnings and safety
precautions in the “SAFETY” section and elsewhere
in this manual before doing any service on machine.
The following precautions should be used as
a reminder to safe servicing. NOTICE: Follow
the manufacturer’s recommendations when
servicing this machine. Unauthorized service
procedures can cause damage to the equipment.
• Before servicing the machine, put a “Do Not
Operate” tag on the instrument panel.
• Lower forks to ground, shut down machine to a
zero energy state, remove key from ignition and
allow machine to cool before beginning work.
• Relieve all hydraulic pressure in the hydraulic
reservoir before breaking any hydraulic
connection or before opening the reservoir
access cover.
• Disconnect battery.
WARNING! Uncontrolled Movement Hazard. Do
not leave the operator’s position unattended
while the machine is running.
• Do not support the machine, the boom, or any
attachments on cinder blocks, hollow tiles, or
props that may crumble under a load. Do not
work under a machine that is supported solely
by a jack.
• Remove, block or guard against body contact
with all other sources of hazardous pressure,
temperature, electricity or machine motion.

800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual 9

Safety
• Make sure that boom and attachments are
grounded to avoid electrical shock.
• Do not make any modifications to this machine
or weld on any structural member unless
specifically authorized by Pettibone/Traverse Lift.
Any unauthorized modifications made or welding
will void the warranty and may cause death,
serious injury or damage to the equipment.
NOTICE: Unauthorized modifications to this
machine may cause unexpected failures and
could void the machine warranty.
• Metal chips or debris can cause eye injury.
Always wear eye or face protection when using a
hammer on this machine. Use a hammer with a
soft face, such as brass, to drive hardened pins.
• Hydraulic fluid or grease injected into skin can
cause severe injury or death. Keep hands and
body away from any pressurized leak. If fluid is
injected into skin, see a doctor immediately.
• When servicing this machine, always wear
safety protection, including but not limited to
hard hat, workshoes and safety glasses.
• Don’t leave loose tools and rags on the machine.
Make sure that all walking and climbing surfaces
are clean.
• Handle fuel carefully. Do not smoke while filling
fuel tank or working near fuel. Refer to the
“Lubricants” table when replacing oils, fluids or
filling fuel tank.
10 Cary-Lift 204, 254, 304 Operator’s Manual
Decals
Safety
The decals pictured in Group 3 were accurate when
this publication was printed. Pettibone/Traverse
Lift, LLC reserves the right to add additional safety
decals to the machine as necessary to ensure
operator safety. It is the operator’s responsibility
to follow the instruction decals on the particular
machine being operated.
NOTICE: Safety decals contain important
information about hazardous situations and
procedures. Replace any decal that is worn
or illegible. Contact an authorized dealer or
Pettibone/Traverse Lift, LLC for new safety
decals.
• Be sure to read all safety decals and all
instruction decals. Check these decals daily.
Keep these decals clean.
• To clean the decals, use only a cloth, water and
soap. Do not use solvents, gasoline, etc.
• Replace decals if damaged, missing or
unreadable. If a decal is on a part that is
replaced, install a new decal on the replacement
part.
Decal Locations
Larger-size illustrations of these decals, along with
descriptions of each decal’s location, are shown in
the DECALS section of this manual.
800-GO-PETTIBONE
 Identification
Material Safety Data
Sheets (MSDS)
The Federal Occupational, Safety and Health
Administration (OSHA) Standard 29 CFR 1910.1200
and in some cases, state and local Right-To-Know
laws, may require that specific Material Safety Data
Sheets be available to employees prior to operating
this equipment. These sheets include information
on substances contained in the equipment such
as antifreeze, battery acid, diesel fuel, engine oil,
grease and hydraulic oil.
Upon written request, Pettibone/Traverse Lift,
LLC will provide the Material Safety Data Sheets
applicable to our product line, at no extra cost. Write
to:
Pettibone/Traverse Lift, LLC
P.O. Box 368
Baraga, MI 49908
Ph. 906-353-6611
Fax 906-353-6325
The customer’s return address, machine model and
serial number must be included to ensure a prompt
response.
800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual
Identification Numbers
Write the machine’s model number, Product
Identification Number and serial numbers on the
form provided. If necessary, give these numbers to
the dealer when parts or information are needed for
the machine.
Make a record of the numbers. Keep the record in
a safe place. If the machine is stolen, report the
numbers to the local law enforcement agency.
MACHINE MODEL NUMBER
_____________________________________________
PRODUCT IDENTIFICATION NUMBER
_____________________________________________
ENGINE SERIAL NUMBER
_____________________________________________
ROPS SERIAL NUMBER
_____________________________________________
11
Identification

Machine Inspection and Directional Reference

Delivery Report All directional references (right, left, front and rear
used in this manual are as seen from the operator’s
The Machine Inspection and Delivery report is
seat.
shipped loose with this manual. Make sure your
dealer performs a checkup within the first 150 hours
of operation or 30 days after delivery, whichever
comes first.
Note: The customer’s cost for this inspection will be
for filters, oil or other accessories. If the dealer
comes to the machine, there may also be a
cost for the time and travel.

Figure 4. Left Side of Machine Shown

12 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE

 Identification

Identification
Forklift Identification Plate
The forklift identification plate is located inside,
on the right side of the dashboard. It contains
the equipment model number, serial number and
vehicle weight (GVW).
Use numbers in correspondence. It is important that
the model designation, serial number, and assembly
part number be referred to when seeking service
information or ordering parts.

Engine Identification Plate Axle Identification Plate

The Cummins engine identification plate is located The axle identification plate is located on the drive
on the valve cover on top of the engine (204 and side of the axle, to the left of the driveshaft. The
254), or on the timing cover (304) on the front of the plate contains the axle part number, serial number
engine (right side of forklift). and build date. The front axle is mounted with its
backside toward the front of the forklift.
Transmission Identification Plate
The transmission identification plate is located on
the front right side of the transmission housing. It
contains the model, specification number and serial
number.

800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual 13

Identification

Figure 5. Transmission and Engine Identification Plate Locations

Figure 7. Axle Identification Plate Location

Figure 6. 204 Transmission Tag

1  – ID Plate
Figure 8. 254 and 304 Transmission ID Plates
14 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE
 Identification

Equipment Description Options

Forklift Description Your Pettibone/Traverse Lift dealer offers a wide
assortment of options for this forklift, including
This machine is a rough-terrain forklift with an a variety of forks, carriages, buckets and more.
approximate vehicle weight of 43,000 to 79,000 Contact your dealer for additional information and
pounds (depending on the model and options used) prices.
and has a lifting capacity up to 30,000 pounds.
This machine is equipped with four-wheel drive Ordering Parts
and a steering system that is capable of two-wheel
All replacement parts should be ordered from your
steering, four-wheel steering and oblique (crab)
dealer. The Parts Book lists replacement parts,
steering as selected by the operator.
service kits and subassemblies. Furnish complete
Standard Engine Description name plate information with each order.
The 204 machine is equipped with a Cummins
engine. This engine is a liquid-cooled, six cylinder,
four stroke, diesel engine with a displacement of
6.7 L. The engine is fuel injected and turbocharged
with a rated output of 190 horsepower at 2200 rpm.
The 254 machine is equipped with a Cummins
engine. This engine is a liquid-cooled, six cylinder,
four stroke, diesel engine with a displacement of
6.7 L. The engine is fuel injected and turbocharged
with a rated output of 220 horsepower at 2200 rpm.
The 304 machine is equipped with a Cummins
engine. This engine is a liquid-cooled, six cylinder,
four stroke, diesel engine with a displacement of
8.3 L. The engine is fuel injected and turbocharged
with a rated output of 240 horsepower at 2200 rpm.

Transmission Description
The transmission has four forward speeds and four
reverse speeds.

Axle Description
The forklift is equipped with two steerable drive
axles. Both axles are equipped with external disc
brakes.

800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual 15

Identification

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16 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE

 Decals

LL-4774, LARGE PETTIBONE LL-4627, BRAKE CAUTION

One located on baler on left side and lift arm on right Located on the dash
side.

LL-4630, HAZARDS LABEL

LL-4775, SMALL PETTIBONE Located on the dash
One located on the middle of the front of the fuel
tank and another located on the baler brace.
LL-4778, WORK HORSE
One located on each side of frame by the rear lights
LL-4773, WATCH YOUR STEP
Located on the battery cover
LL-4813, NO RIDERS
Located inside top of left side of the cab
LL-4628, GROUND WARNING
Located on the battery cover
LL-4780, TRANSMISSION OIL FILL
Located below the driver’s door
LL-4631, BATTERY WARNING
Located on the battery cover
LL-4781, HYDRAULIC OIL
Located on top of the hydraulic tank
LL-4626, COOLANT PRESSURE CAUTION
Located on top of the radiator near the rear of
machine

LL-4633, POWER DANGER

Located inside the cab in the top middle of the front
window

800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual 17

Decals

LL-4782, DIESEL FUEL L1-10297-1, SPINNING BLADES DANGER

Located on the fuel tank One located on each side of the back frame

LL-6039, MADE IN THE USA LL-7026, HYDRAULIC OIL DRAIN

Located on each side of the frame by the rear lights Located on bottom of left side of hydraulic tank

LL-6126, PINCH POINT L1-10298, BOTH HANDS

One located on each lift cylinder and each side of One located by the door handle and one on the
rear bracket back side of the cab, both on the left side

LL-6453, WELDING AND MODIFICATION L-9870, NO RIDERS WARNING

WARNING One located on the bottom of the door, one back by
Located above the battery cover on left side of the radiator, one of the front of the carriage position
frame and on the opposite side of the machine, below the
cab
LL-6163, MOTOR OIL
One located on dipstick, oil filler and on engine
enclosure L-10297, MOVING BELTS WARNING
One located on each side of the back frame

LL-6456, COMBUSTIBLE FLUID WARNING

Located on fuel tank LL-1803-499, ACCUMULATOR WARNING
Both located behind the battery box

LL-6461-1, CLOSING JAW DANGER

One located on top of baler and one located on LL-5433, CARY-LIFT LOGO
each side of baler
Located on both sides of lift arm

LL-6471, HOT EXHAUST LL-5692, CLUTCH CUT-OFF

Located on top left of radiator
Located on the dash, left side of steering column

LL-6480, PINCH POINT LL-6462-6, EXCESS HYDRAULIC PRESSURE

One located on each side of dog-bones
Located on the right side of reservoir

LL-7136, HORN MUST SOUND LL-6492, CARBON MONOXIDE WARNING

Located on dash
Located on cab, right side above window

18 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE

 Decals

LL-7304, PARK BRAKE SWITCH LL-5948, NO STEP

Located on dash, left side of steering column Located on thte right-hand battery box

LL-7474, PROPOSITION 65 WARNING LL-5972, SUPER 20 MODEL DECAL

Located on dash, left side of steering column Located on right and left side of fuel tank

LL-7700, WELDING AND MODIFICATION LL-7838, TRANSMISSION OIL FILTER

HAZARD Located on right side of frame in the middle
Located on the right side of machine (rear)

LL-7747, PRIMER DECAL

LL-7731, DO NOT USE ETHER Located on right rear of frame below pre-filter
Located on the right and left side of hood (by air
cleaner)
LL-7185-5, HYDRAULIC PRESSURE
Located on back right-hand middle of frame
FL-10561, PARK BRAKE APPLY
Located in cab on the left side
LL-6092, SUPER 25 MODEL DECAL
Located on the left and right side of fuel tank
LL-4624, SAFETY WARNING
Located in the cab
LL-7185-6, HYDRAULIC PRESSURE
Located on back right-hand middle of frame
LL-7405, FASTEN SEAT BELT
Located on the center of the dash
LL-7232-1, HYDRAULIC PRESSURE
Located on back right-hand middle of frame
LL-7406, FORWARD AND REVERSE
Located on shifter (steering column)
LL-7015, FUEL TANK DRAIN
Located on left side front
LL-7617, IDENTIFICATION PLATE
Located in cab on left side of dash
LL-5973, SUPER 30 MODEL DECAL
Located on left and right side of fuel reservoir
LL-7157, CONTENTS UNDER PRESSURE
Located on top of oil reservoir
LL-5940, STEERING SELECTOR
Located in cab on lower right corner

800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual 19

Decals

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20 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE

 Operation
General
This chapter describes, locates, illustrates, and
furnishes the operator or driver sufficient information
about the various controls and instruments used
for the proper operation of the machine. Vehicle
operator’s controls are also illustrated in the
following pages.
Functional Description
This machine is a rough-terrain forklift designed
for material handling operations. The Cary-Lift is
built to customer specifications with an attachment
designed to handle a specific type of bulk material.
Attachments include balers for pipe, poles, logs,
lumber and baled paper waste.
Features
The Cary-Lift raises loads with an overhead lift
arm which is raised and lowered by two hydraulic
cylinders.
A unique Cary-Lift feature is the operator-controlled,
forward reach function. The overhead lift arm can
“reach” forward approximately four feet to provide
exact load placement in gondola cars or pulpwood
decks. Two hydraulic cylinders extend to push the lift
arm forward and retract to pull the arm back.
800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual
Fork Leveling
The forks on the Cary-Lift are leveled or tilted with
an operator-controlled, pilot-operated hydraulic
remote control. This remote controls two hydraulic
cylinders, which extend or retract to tilt the forks
forward or rearward.
Frame Tilt
The forklift maintains a level load with a manually
operated, optional frame tilt (sway) feature. This
function raises either side of the machine frame to
keep your load level when operating over uneven
terrain. Two frame tilt cylinders (one on each side
of the front cradle) control the tilting action. The
chassis tilts left or right when one cylinder extends
as the other cylinder retracts. Total degree of frame
tilt is 14° (7° left or right of center).
Steering
The Cary-Lift steering system features three
steering modes (two-wheel, four-wheel and oblique).
The two-wheel mode steers only the front wheels
and the four-wheel setting steers all four. The
oblique mode steers all four wheels at the same
angle to manuever the vehicle sideways, away from
obstacles.
21
Operation
Operation
This section describes the location and function
of each gauge and control in the operator’s
compartment. With the engine “off,” practice
reaching for these controls as you read about them.
This should help you become familiar with their
location.
Entering the Operator’s
Compartment
Proper care should be used whenever enter
ing or leaving the operator’s compartment. Use the
step and grab handle provided and always keep
them clear of debris. WARNING! Fall Hazard. Use
the steps and grab handles provided and keep
them clear of mud and debris. Never jump onto or
off of the machine.
Cab Doors
Open the cab door by sliding it toward the front of
the cab.
Operator’s Seat
The operator’s seat in this machine is equipped
with armrest consoles. To enter the seat, raise the
armrest console. When seated, push the console
back down to lock it in the normal working position.
The operator’s seat is equipped with the following
adjustment features:
1. Backrest angle adjustment.
2. Fore/aft adjustment.
3. Height adjustment.
4. Suspension adjustment.
5. Armrest height adjustment.
WARNING! Uncontrolled Movement Hazard. Do
not adjust the driver seat while the vehicle is
moving and keep both hands on the steering
wheel.
22 Cary-Lift 204, 254, 304 Operator’s Manual
Backrest Angle Adjustment
The backrest adjustment lever is located at the rear
of the seat, on the left side. Adjust the backrest as
follows:
1. Rotate and hold the adjustment lever to the right.
2. Tilt the backrest forward or back to your desired
position.
3. Release lever to lock.
Fore/Aft Adjustment
The fore/aft adjustment lever is located under
the front of the seat, on the left side. Adjust the
horizontal position of the seat as follows:
1. Move and hold the adjustment lever to the left.
2. Slide the seat forward or back to your
desired position.
3. Release lever to lock.
Height Adjustment
The height adjustment knob is located in front of the
seat (top knob). Rotate the knob counterclockwise
to raise the seat, clockwise to lower it.
Seat Suspension Adjustment
This adjustment allows you to select the correct
suspension setting for your body weight. The
suspension adjustment knob is located under the
front of the operator’s seat, near the floor (bottom
knob).
To adjust the suspension, rotate the knob until your
body weight is selected in the yellow
indicator. The suspension can be adjusted from
110-285 lbs. (50-130kg).
Arm Rest
The armrest height adjustment knobs are located
on the side of each armrest. Adjust the height as
follows:
1. Rotate the knob counterclockwise.
2. Raise or lower the armrest to your desired
position.
3. Rotate the knob clockwise to lock.
800-GO-PETTIBONE
 Operation

Seat Belt
Fasten the seat belt as follows:
1. Position both belts across your waist as low on
the hips as possible. This is necessary to spread
the force of the belt over the hipbone instead of
across the abdomen. If latch plate is too tight to
pull, slide the latch plate along the webbing. This
will provide more belt slack.
2. Insert latch plate into buckle until a “click” is
heard. To unlock the seat belt, press button on
buckle and pull latch plate from buckle.
WARNING! Uncontrolled Movement Hazard.
Always make sure the seat belt is not twisted
and fits snugly across your waist.
Pettibone/Traverse Lift, LLC recommends that
operators use the seat belt at all times when driving
this machine and will not be held responsible if the
operator does not use the safety restraints available.

800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual 23

Operation
11
19
1

10 3 18
12
9 4

13
17

5
14
8 16 15

20

7 6

24 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE

 Operation
1  – Cushion Assembly (LL-3625-69)
2  – Back Adjustment Knob w/Hardware (LL-3625-61)
3  – Arm Pad w/Cover (LL-3625-147)
4  – Vertical Adjustment Mounting Bracket w/Hardware (LL-3625-146)
5  – Edging Material, 5" Long, 2 Required (Front and Back)
6  – Height Adjustment Lever w/Hardware (LL-3625-139)
7  – Seat Track Control Handle Track Set (4 Tracks), 13" and 16.25" x 11" Mounting
(LL-3625-120)
8  – Tether Set w/Hardware (LL-3625-150)
9  – Vertical Adjustment Mounting Bracket w/Hardware (RH) (LL-3625-153)
10  – Arm Pad w/Cover (LL-3625-147)
11  – Manual Holder
12  – Vertical Adjustment Knob w/Hardware (LL-3625-133)
13  – 3" Retractable Belt w/Hardware (LL-3625-156)
14  – 2-Shock Absorbers (LL-3625-52)
15  – M200 Extreme Duty Chassis (LL-3625-149)
16  – Skirt w/Attaching Hardware (LL-3625-119)
17  – Ride Adjustment Knob (Grease) (LL-3625-53)
18  – Control Carrier Locking Knob w/Hardware (Grease) (LL-3625-62)
19  – Back Cover (LL-3625-144)
20  – Raise Lever for Height Adjustment

800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual 25

Operation
15 16

14
1

13

12 2

11 10 9 8 7 6 5 4

1  – Transmission Oil Temperature Gauge 9  – Blower Switch

2  – Torque Converter Oil Pressure 10  – Heater and A/C Selector Switch
Gauge 11  – Engine Ignition Switch
3  – Hydraulic Power Switch 12  – Engine Oil Pressure Gauge
4  – Boom Lights 13  – Voltmeter
5  – Warning Beacon Switch 14  – Engine Coolant Temperature Gauge
6  – Rear Floodlight Switch 15  – Engine Hour Meter
7  – Headlight / Taillight Switch 16  – Fuel Gauge
8  – Wiper Switch

Figure 9. 204, 254 and 304 Instrument Panel

26 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE

 Operation
17 18

22

19

20

21

17  – Stop Engine Lamp

18  – Air Intake Heater Lamp
19  – Clutch Cut-out Switch
20  – Park Brake Switch
21  – Steering Selector
22  – Check Engine Lamp
Figure 10. 204 and 254 Dash

800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual 27

Operation

23

23  – Steering Selector

Figure 11. 304 Steering Selector

28 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE


Instrument, Indicator and Switch
Panels
The instrument, indicator and switch panels are
shown in Figures 9, 10 and 11.
Transmission Oil Temperature Gauge
(Figure 9, (1))
Indicates transmission oil temperature. Normal
operating temperature is 180 - 200°F (82-93°C).
NOTICE: Do not operate transmission if oil
temperature is above 250°F (121°C).
Torque Converter Oil Pressure Gauge
(Figure 9, (2))
Indicates the oil pressure which actuates the
directions and speed range clutches in torque
converter. Normal oil pressure for the 204 (Funk)
is 240-280 psi. Normal oil pressure for the 254 &
304 (Clark) is 180-220 psi. NOTICE: Do not run
transmission if oil pressure is below normal
operating range.
Hydraulic Power Switch (Figure 9, (3))
This rocker switch controls hydraulic power to the
joystick valves on both sides of the operator’s seat.
When the switch is OFF, hydraulic pilot pressure is
cut off to the joystick valves. This feature prevents
accidental actuation of hydraulic functions when the
operator rises an armrest console to leave the cab.
The hydraulic power switch operates as follows:
1. To turn hydraulic power ON - Press top portion
of switch. A green indicator light in the switch
will come on.
2. To turn hydraulic power OFF - Press bottom
portion of switch. The indicator light will go off.
Note: The hydraulic power switch must be in the ON
position for the hydraulics to operate. Always
press the hydraulic power switch to OFF
before raising the armrest to leave the cab.
800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual
Operation
Boom Lights (Optional) (Figure 9, (4))
This rocker switch controls the boom mounted work
lights.
1. To turn the lights on, press top portion of switch.
A green indicator light in the switch will come on.
2. To turn the lights off, press the bottom portion of
the switch. The indicator light will go off.
Warning Beacon Switch (Optional)
(Figure 9, (5))
The rocker switch controls the flashing or rotating
beacon and operates as follows:
1. To turn beacon ON - Press top portion of switch.
A green indicator light in the switch will come on.
2. To turn beacon OFF - Press bottom portion of
switch. The indicator light will go off.
Rear Floodlight Switch (Optional)
(Figure 9, (6))
This rocker switch controls the rear floodlights and
operates as follows:
1. To turn lights ON - Press top portion of switch.
A green indicator light in the switch will come on.
2. To turn lights OFF - Press bottom portion of
switch. The indicator light will go off.
Headlight/Taillight Switch (Figure 9, (7))
This rocker switch controls the headlights and
taillights and operates as follows:
1. To turn lights ON - Press top portion of switch. A
green indicator light in the switch will come on.
2. To turn lights OFF - Press bottom portion of
switch. The indicator light will go off.
29
Operation

Wiper Switch (Figure 9, (8)) Heater and A/C Selector Switch

(Figure 9, (10))

This rocker switch controls the windshield wiper and

operates as follows:
1. For LOW wiper speed - Press top portion of
switch halfway. A green indicator light in the
switch will come on.
2. For HIGH speed - Press top portion of switch all
the way.
3. To turn wiper OFF - Press bottom portion of
switch all the way. The indicator light will go off.

Blower Switch (Figure 9, (9))

This toggle switch operates as follows:
1. To select HEATER - Move switch all the way
forward.
2. To select AIR CONDITIONING -
Move switch all the way back.
3. To switch heater and A/C unit OFF -
Move switch to center position.

Engine Ignition Switch (Figure 9, (11))

This rotary switch controls the blower speed and

operates as follows:
1. For LOW blower speed - Rotate switch clockwise
to LOW position.
2. For MEDIUM speed - Rotate switch clockwise to
MED position.
3. For HIGH speed - Rotate switch clockwise to The engine ignition switch has four positions:
HIGH position.
ACC: Provides power to operate auxiliary
4. To turn blower OFF - Rotate switch electrical equipment when the engine is not running.
counterclockwise, all the way.
OFF: Shuts off all electrical circuits.
RUN: Turns on all electrical circuits.
Start: Closes the circuit between the battery and
starter motor to crank the engine.

30 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE

 Operation

Engine Oil Pressure Gauge (Figure 9, (12)) Engine Coolant Temperature Gauge
(Figure 9, (14))

Indicates the oil pressure which lubricates the

engine bearings, piston and crankshaft.
Normal oil pressure for the Cummins engine should Indicates the engine coolant temperature of the
be at least 15 psi at idle or 45 psi at 2000 rpm. Oil engine cooling system. Normal coolant temperature
pressure at normal operating should be 20-40 psi. for the engine is 190-207°F (88-97°C). NOTICE:
Maximum oil pressure is 60 psi. NOTICE: Stop the Do not operate engine if coolant temperature is
engine immediately if the engine oil pressure above 225°F (107°C).
gauge does not register within 15 seconds after
start-up. Engine Hour Meter (Figure 9, (15))
• Check the engine oil level and inspect the
engine for oil leaks.
• Be sure the engine crankcase oil level is up Indicates hours of engine operation. It records up to
to the FULL mark on the dipstick. 9,999.9 hours then resets to zero.
• Restart engine. If gauge does not register,
consult engine manual. Fuel Gauge (Optional) (Figure 9, (16))
• Do not run engine if oil pressure is below the
normal operating range.
Do not run engine if oil pressure is below the normal
Indicates the level of diesel fuel in the fuel tank. The
operating range.
gauge is electrically operated and registers only
when ignition switch is in RUN position.
Voltmeter (Figure 9, (13))
Stop Engine Lamp (Figure 10, (17))

Indicates the charge state of the battery when the

ignition switch is in the ON position. The voltmeter
should indicate available battery voltage of 11 - 12
vdc before the engine is started.
The stop engine lamp is RED and indicates the
While the engine is running, the voltmeter indicates
need to shut the engine down as soon as it is safe
the condition of the charging system and should
to do so.
register 13 - 14 vdc.
The engine should remain shut down until the fault
is repaired.
Consult the Engine Operation & Maintenance
Manual for further information.

800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual 31

Operation

Air Intake Heater Lamp (Figure 10, (18))
WARNING! Uncontrolled Movement Hazard.
Fully release the throttle pedal before releasing
the brake pedal. If the brake pedal is released
before the throttle, the clutch will engage causing
the machine to surge forward or backward.

This light indicates the air intake heater is ON. The Park Brake Switch (Figure 10, (20))
intake heater is a cold weather starting aid. When
starting the engine, turn the key switch to the RUN
position.
Depending on the ambient air temperature the
heater light will illuminate for a set period of time.
Once the light goes out the engine can now be
started. This light acts as the “What To Start” lamp in
the Engine Operation Manual.
The park brake switch is a two position
Refer to Engine Operation & Maintenance toggle switch.
Manual for further information.
1. To apply the park brake, move switch to the UP
Clutch Cut Out Switch (Figure 10, (19)) position.
2. To release the park brake, toggle the switch
DOWN.

This switch is a two position toggle switch. This

toggle switch disengages the transmission when
you apply the brake pedal. The declutch feature
shifts the transmission into neutral so you can
operate the hydraulic pumps at a faster speed.
Use the declutch feature to increase the speed of
hydraulic functions as follows:
1. Move declutch switch to ARM position.
2. Depress and hold the brake pedal to
disengage the transmission.
3. Depress the throttle pedal (to speed up the
hydraulic pumps) as you operate the desired
hydraulic control.

32 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE

 Operation

Steering Selector (204 and 254 Only) WARNING! Uncontrolled Movement Hazard.
(Figure 10, (21)) Never change the steering selector while the
vehicle is moving.
Steering Wheel Height Adjustment
This adjustment allows you to raise or lower the
wheel to your desired height.
The steering wheel can telescope up and down.
Adjust the height of the steering wheel as follows:
1. Push the lever down and hold.
2. Raise or lower wheel to desired position.
3. Release lever to lock.
The steering selector is located on the dash to the
left side of the seat. This switch controls the steering Check Engine Lamp (Figure 10, (22))
mode and operates as follows: The check engine lamp is YELLOW and
indicates the need to repair the fault at the
earliest oppotunity.
1. To select OBLIQUE steer - Move lever all the
way up. This mode allows you to steer all four Refer to the Engine Operation and Maintenance
wheels at the same angle. (Recommended for Manual for more information.
maneuvering sideways around obstacles in a
restricted area).
2. To select TWO-WHEEL (2W) steer - Move lever
to center position. This allows you to steer only
the front wheels. (Recommended for higher
speed travel).
3. To select FOUR-WHEEL (4W) steer - Move
lever all the way down. This mode allows you to
steer all four wheels. (Recommended for making
a shorter turning radius in restricted areas).
Note: Align the front and rear wheels before
changing from OBLIQUE to FOUR-WHEEL
steer.
Wheel Alignment
Align the front and rear wheels as follows:
1. Bring the machine to a complete stop.
2. Move steering selector to FOUR- WHEEL (4W)
steer position.
3. Turn steering wheel to align rear wheels parallel
to machine chassis.
4. Move steering selector to TWO-WHEEL (2W)
steer position.
5. Turn steering wheel to align front wheels parallel
to chassis.
800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual 33
Operation

Steering Selector (304 Only) Low Voltage Warning Light

(Figure 11, (23))

This light comes on if the alternator is not

charging the battery. It should also come on when
ignition switch is in RUN position and engine is off.
Light may stay on for a short time after start-up until
you have increased engine speed. If light stays on,
there may be a broken or loose alternator drive
belt. NOTICE: Driving this vehicle with the Low
Voltage light on will drain the battery. If the light
does not go out after a few minutes of running
time, shut the engine down and inspect the
charging system.

Parking Brake Warning Light

This light comes on when parking brake is applied
and goes off when brake is released. WARNING!
Fire Hazard. Do not drive the vehicle with the
parking brake applied.
NOTICE: Driving with the parking brake applied
will overheat the parking brake and cause
The steering selector is located on the floor to the excessive wear.
right side of the seat. This lever controls the steering
mode and operates as follows: Transmission Filter Bypass Indicator Light
1. To select OBLIQUE steer - Move lever all the
way to the left. This mode allows you to steer all
four wheels at the same angle. (Recommended
for maneuvering sideways around obstacles in a
restricted area).
2. To select TWO-WHEEL (2W) steer - Move lever
to center position. This mode allows you to steer
This light indicates that the transmission filter is
only the front wheels. (Recommended for higher
in bypass mode. The filter needs to be serviced
speed travel.)
to prevent damage to the torque convertor and/or
3. To select FOUR-WHEEL (4W) steer - Move lever transmission.
all the way to the right. This mode allows you to
steer all four wheels. (Recommended for making Speedometer (Optional)
a shorter turning radius in restricted areas.) Indicates machine travel speed.

Engine Oil Pressure Warning Light Tachometer (Optional)

This light comes on if engine oil pressure drops Indicates engine speed in revolutions per minute
below the normal operating range, 10 psi. It should (rpm).
also come on when ignition switch is in RUN
position and engine is not running.

34 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE

 Operation

Steering Column Controls

The steering column is equipped with the
following adjustment features:
1. Steering column angle adjustment.
2. Steering wheel height adjustment.

Column Angle Adjustment

This adjustment allows you to:
1. Move the steering wheel out of the way when
entering or leaving the cab.
2. Position the steering wheel at a comfortable
working angle to reduce arm fatigue.
The tilt and telescope adjustment lever is Figure 13. Steering Wheel
located on the left side of the steering column. Tilt
the steering column as follows: The steering wheel and gear are of the conventional
type. Turning the wheel clockwise turns the vehicle
1. Lift and hold the tilt lever UP. to the right; turning the wheel counterclockwise
turns the vehicle to the left. WARNING!
2. Tilt the steering column up or down to your
Uncontrolled Movement Hazard. Do not adjust
desired position.
the steering column while the vehicle is in
3. Release lever to lock. motion.

Horn Button
Depress button in middle of steering wheel to sound
horn.

1  – Tilt and Telescope Lever

Figure 12. Tilting the Steering Column

800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual 35

Operation

Turn Signal Lever (Optional) Defroster Switch (Optional)

This lever is located on the left side of the steering The defroster switch is located on the defroster
column. It activates the front and rear turn signals fan in the upper right corner of the windshield. The
and operates as follows: defroster switch controls the fan speed and operates
as follows:
1. To signal a LEFT turn - Move lever toward you.
The lower green indicator light on the switch 1. For HIGH fan speed - Move the switch to the left
assembly will flash indicating that left turn of center.
signals are working.
2. For LOW fan speed - Move switch to right of
2. To signal a RIGHT turn - Move lever away from center position.
you. The upper green indicator light on the
3. To turn defroster OFF - Move switch to center
switch assembly will flash indicating that right
position.
turn signals are working.
3. To CANCEL signal - Move lever to center
position.

Transmission Controls
The Model Cary-Lift is equipped with a 4-speed
forward, 4-speed reverse powershift transmission.
Hazard Light Switch (Optional)
The hazard light switch is located on the turn signal Dual-Function Transmission Control
switch assembly. Lever
It activates the vehicle 4-way hazard light and The transmission control lever is located on the
operates as follows: left side of the steering column. The control handle
funcitons as both a gear shifter and direction
1. To turn hazard light ON - Pull switch out until it
selector.
locks into place. The red indicator light on the
switch assembly will flash indicating that hazards
are working.
2. To turn hazard lights OFF - Signal a left or right
turn with the turn signal lever. Hazard switch will
“click” as it releases.

36 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE


Twist Grip Gear Shifter
The twist grip on the control handle shifts the
transmission gears and operates as follows:
1. To shift into FIRST gear - Rotate grip all the way
back so the number 1 is lined up with the white
mark.
2. To shift into SECOND gear - Rotate grip forward
so the number 2 lines up with the white mark.
3. To shift into THIRD gear - Rotate grip forward so
the number 3 lines up with the white mark.
4. To shift into FOURTH gear - Rotate grip all the
way forward so the number 4 lines up with the
white mark.
NOTICE: Downshifting to slow the vehicle will
cause severe damage to the transmission.
800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual
Operation
Direction Selector
The transmission control handle also functions as a
direction selector and operates as follows:
1. To shift into FORWARD - Move lever all the way
forward.
2. To shift into NEUTRAL - Move lever to center
position.
3. To shift into REVERSE - Move lever all the way
back.
NOTICE: Severe damage to the transmission will
occur if the direction selector is changed while
the vehicle is in motion.
37
Operation
WARNING! Uncontrolled Movement Hazard. Test
the brake pedal before moving the machine.

Throttle and Brake Controls

Display, Control or Indicator Function

Throttle and Brake Controls The throttle and brake controls are shown
below.

Brake Pedal Depress this pedal to apply brakes to all four

wheels.

Throttle Pedal Depress this pedal to increase engine speed.

1 2

1  – Brake
2  – Throttle
Figure 14. Throttle and Brake Controls
38 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE
 Operation

Engine Diagnostic Plug-In Hydraulic Controls

There are two hydraulic remote control levers
mounted on the seat, one on either side.

This Plug-In connection is used to connect the

diagnostic computer to the Engine ECM to monitor
engine parameters and fault codes.
Refer to Engine Operation and Maintenance
Manual for more information.
Left Hand Remote Control
The left hand arm rest and control carrier pivot
upward to allow access to and from the operator
seat.
In addition to the remote control power switch on the
switch panel, there is a switch mounted to the seat.
If the left hand control carrier is in the up position,
the switch will disable power to a solenoid valve,
disabling the hydraulic functions. The left hand
control carrier must be in the down position and
the power switch in the on position for the hydraulic
remote controls to function.
The left hand remote control lever is a dual axis
lever with an electric rocker type switch located
on the top of the handle. This lever will control
three hydraulic functions dependent on the type of
attachment installed on the machine.

Figure 15. Left Hand Joystick

800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual 39

Operation
Right Hand Remote Control
The right hand remote control lever is mounted in a
stationary control carrier. It is also a dual axis lever
with an electric rocker type switch on the top of the
handle. This lever will also control three hydraulic
functions dependent on the type of attachment Right Hand Control
installed on the machine.
Figure 16. Right Hand Joystick
WARNING! Uncontrolled Movement Hazard. Turn
the hydraulic remote control power switch off
before leaving the operator’s cab.
Fork Attachment Controls
Left Hand Control
The longitudinal axis (front to back) controls the
reach function.
1. To move the fork attachment forward, push the
control lever straight forward.
2. To move the fork attachment back towards the
machine, pull the control lever straight back.
The lateral axis (left to right) is not used for a
stationary fork attachment.
The electric rocker switch controls the side shift
function if so equipped. This will move the fork frame
assembly 6 inches to left or right of center.
40 Cary-Lift 204, 254, 304 Operator’s Manual
1. To shift the fork frame assembly to the left, press
and hold the left side of the switch.
2. To shift the fork frame assembly to the right,
press and hold the right side of the switch.
The longitudinal axis (front to back) raises
and lowers the attachment.
1. To raise the attachment, pull the right hand
control straight backward.
2. To lower the attachment, push the right hand
control straight forward.
DANGER! Electrocution Hazard. Avoid contact
with overhead power lines.
The lateral axis (left to right) controlls tilting the forks
up or down.
1. To tilt the forks forward (down), push the control
lever directly to the right.
2. To tilt the forks backward (up), pull the control
lever directly to the left.
The electric rocker switch controls the machine
frame tilt (sway).
1. To sway the machine to the left, press and hold
the left portion of the switch.
2. To sway the machine to the right, press and hold
the right portion of the switch.
WARNING! Tip Hazard. Do not use the frame
sway function when forks are raised above 12 ft
(3.6 m).
800-GO-PETTIBONE
 Operation

Pipe and Pole Baler Controls Right Hand Control

Left Hand Control

The longitudinal axis (front to back) raises and

The longitudinal axis (front to back) controls the
reach function.
1. To reach the forks forward, push the control lever
straight forward.
2. To move the forks back towards the machine,
pull the control lever straight back.
The lateral axis (left to right) controls the baler open
and close functions.
1. To open the baler arms, push the control lever
straight to the left.
2. To close the baler arms, pull the control lever
straight to the right.
The electric rocker switch controls the side shift
function if so equipped. This will move the baler
assembly 6 inches to left or right of center.
1. To shift the baler assembly to the left, press and
hold the left side of the switch.
2. To shift the baler assembly to the right, press
and hold the right side of the switch.
lowers the attachment.
1. To raise the attachment, pull the control lever
straight backward.
2. To lower the attachment, push the control lever
straight forward.
DANGER! Electrocution Hazard. Avoid contact
with overhead power lines.
The lateral axis (left to right) controls tilting of
the forks up or down.
1. To tilt the forks forward (down), push the control
lever directly to the right.
2. To tilt the forks backward (up), pull the control
lever directly to the left.
The electric rocker switch controls the machine
frame tilt (sway).
1. To sway the machine to the left, press and hold
the left portion of the switch.
2. To sway the machine to the right, press and hold
the right portion of the switch.
WARNING! Tip Hazard. Do not use the frame
sway function when forks are raised above 12 ft
(3.6 m).

800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual 41

Operation

Tire Handler Controls Right Hand Control

Left Hand Control

The longitudinal axis (front to back) raises and

lowers the attachment.
The longitudinal axis (front to back) controls the
1. To raise the attachment, pull the control lever
reach function.
straight backward.
1. To move the attachment forward, push the
2. To lower the attachment, push the control lever
control lever straight forward.
straight forward.
2. To move the attachment back toward the
DANGER! Electrocution Hazard. Avoid contact
machine, pull the control lever straight back.
with overhead power lines.
The lateral axis (left to right) controls the clamp
The lateral axis (side to side) controls tilting of the
open and close functions.
forks up or down.
1. To open the clamp, push the control lever
1. To tilt the forks forward (down), push the control
straight to the left.
lever directly to the right.
2. To close the clamp, pull the control lever straight
2. To tilt the forks backward (up), pull the control
to the right.
lever directly to the left.
The electric rocker switch controls the side shift
The electric rocker switch controls the machine
function if so equipped. This will move the baler
frame tilt (sway).
assembly 6 inches to left or right of center.
1. To sway the machine to the left, press and hold
1. To shift the fork frame assembly to the left, press
the left portion of the switch.
and hold the left portion of the switch.
2. To sway the machine to the right, press and hold
2. To shift the fork frame assembly to the right,
the right portion of the switch.
press and hold the right portion of the switch.
WARNING! Tip Hazard. Do not use the frame
sway function when forks are raised above 12 ft
(3.6 m).

42 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE

 Operation

Swivel Clam Controls Right Hand Control

Left Hand Control

The longitudinal axis (front to back) raises and

The longitudinal axis (front to back) controls the lowers the attachment.
reach function.
1. To raise the clam bucket, pull the right hand
1. To move the clam bucket forward, push the control straight backward.
control lever straight forward.
2. To lower the clam bucket, push the right hand
2. To move the clam bucket back toward the control straight forward.
machine, pull the control lever straight back.
DANGER! Electrocution Hazard. Avoid contact
The lateral axis (left to right) controls the clam with overhead power lines.
bucket tilt functions.
The lateral axis (left to right) controls opening and
1. To move the bottom of the clam bucket away closing of the clam bucket.
from the machine, push the control lever straight
to the left. 1. To close the clam bucket, pull the control lever
directly to the left.
2. To move the bottom of the clam bucket toward
the machine, pull the control lever straight to the 2. To open the clam bucket, push the control lever
right. directly to the right.
Note: The tilt function of the clam bucket is The electric rocker switch controls the bucket
controlled by a floating spool. Upon release rotation.
of the handle, the bucket returns to a vertical
1. To rotate the bucket clockwise, push and hold
hanging position. There is no load-holding
the left portion of the switch.
feature in this circuit.
2. To rotate the bucket counter-clockwise, push
The rocker switch on top of the handle controls the
and hold the right portion of the switch.
frame tilt (sway) function.
1. To sway the machine frame to the left, press and
hold the left side of the switch.
2. To sway the machine frame to the right, press
and hold the right side of the switch.
WARNING! Tip Hazard. Do not use the frame
sway function when forks are raised.

800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual 43

Operation

Pre-Operational Checks
and Services
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. Ensure that oil is between FULL and ADD
marks, preferably FULL.

44 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE

 Operation

Check Transmission Oil

1. Start the engine and allow it to idle with the
transmission in neutral until the transmission
reaches operating temperature.
2. Remove the transmission dipstick (under cab)
and check the oil level on the dipstick.
3. Add oil through dipstick tube to desired level.

Figure 17. Transmission Service Points

800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual 45

Operation

Radiator Coolant Level Check

1. WARNING! Burn Hazard. Allow radiator to
cool before opening cap. With the engine
off and cold, look into the radiator filler neck
to check the coolant level. The proper level is
approximately 3/4 inch below the bottom of the
radiator filler neck. Add coolant as needed.
2. Replace the radiator cap by pressing down while
turning it clockwise.

1  – 3/4"

46 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE

 Operation

Check Hydraulic Fluid Level

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

To Fill Hydraulic Tank

1. Turn machine off with boom forward and resting
on the ground.
2. Remove breather.
3. Pour oil into fill plug hole.
Note: This oil must pass through return filters to get
to the suction area of tank, sight glass level
will “lag” behind oil level in filter housing.
4. Allow level to equalize between filter housing
and sight glass, oil should be added until a “full” 1
level on the sight glass is attained.
5. Reinstall breather and fill cylinders by exercising
each cylinder to its full stroke. 1  – Breather
6. Repeat steps 1-4 as needed.
NOTICE: With cylinders retracted, oil should Tires and Rims
always be between HI and LOW levels as Inspect the tires for punctures, wear and if
indicated on the sight glass. applicable, proper tire pressure. Check the rims for
missing lug nuts and wheel studs.
NOTICE: The tire specifications of this forklift
apply to the machine as it was tested in
accordance with ASME B56.6A-1994. Any
replacement of tires must meet or exceed these
specifications for sidewall stiffness.

Inspection for Leaks

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

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

800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual 47

Operation
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
indication. Be constantly aware of the fuel level,
engine coolant temperature, transmission oil
temperature and electrical system voltage.
Hydraulic Fluid Level
Perform a daily check of the hydraulic oil level and
temperature as indicated on the sightglass, located
on the side of the hydraulic tank. Add hydraulic oil if
necessary.
Changes in Performance
Be constantly alert to changes in the equipment’s
operating characteristics. Such changes in
performance are sometimes an indication of a
malfunction.
Tire Pressure
Proper tire cold inflation pressure is dependent
on tire size and tire load. Due to the numerous
attachments and tire sizes available, please consult
factory for proper tire pressure for your Cary-Lift.
48 Cary-Lift 204, 254, 304 Operator’s Manual
Operational Checks and
Services
Startup and Driving
NOTICE: Never operate the starter for more
than 20 seconds continuously. Allow 2 minutes
between starting efforts.
NOTICE: Do not use starting fluids with this
engine.
1. Start the engine by applying the parking brake,
placing the transmission in neutral, inserting the
ignition key into the switch and turning the key
clockwise. Release the key when the engine
starts.
NOTICE: Select the steering mode while the
machine is standing still or severe damage to
the transmission may result.
Depending on model, steering selector will be either
a valve with a lever, or a 3 position toggle switch.
2. Determine which of the following steering modes
is to be selected:
a. OBLIQUE (CRAB). In this position all four
wheels will turn in the same direction. This
steering mode should not be used at speeds
exceeding 2 MPH.
b. TWO-WHEEL STEER. In this position only
the front wheels will steer. Before selecting
this mode, the rear wheels must be turned
straight using the 4 WHEEL STEER mode.
Use ONLY 2 WHEEL STEER mode when
travel speeds exceed 10 MPH.
c. FOUR-WHEEL STEER. In this mode the
rear wheels will turn in the opposite direction
from the front wheels, providing the shortest
turn radius. Do not use 4-wheel steer at
speeds over 10 mph.
3. Position the steering selector switch in the
desired mode of steer, either TWO-WHEEL
STEER, FOUR-WHEEL STEER, or OBLIQUE
(CRAB).
800-GO-PETTIBONE

Steering Modes
Figure 18. 204 and 254 Models
4. Raise the forks to a safe travel height by pulling
the right control joystick to the rear until a safe
height is reached.
5. Hold the brake pedal down and select either
forward (F) or reverse (R) travel, using the
forward and reverse gear shift lever. While
continuing to hold the brake pedal down, select
either 1 for first gear, 2 for second gear, 3 for
third gear or 4 for fourth, using the gear shift
lever.
800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual
Operation
Figure 19. 304 Models
6. Make certain that the area around the forklift is
clear. Continue to hold the brake pedal down
and release the parking brake.
7. WARNING! Crush Hazard. Clear the area
before moving the machine. The forklift is now
ready to drive by carefully releasing the brake
pedal.
WARNING! Uncontrolled Movement Hazard. Be
certain the proper direction has been selected.
This forklift is capable of 20 mph regardless of the
selected direction.
49
Operation

1  – Joysticks
2  – Steering Selector
3  – Directional Lever
Figure 20. 204 and 254 Models

50 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE

 Operation

1  – Steering Selector
2  – Joysticks
3  – Directional Lever
Figure 21. 304 Model

800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual 51

Operation
Raising the Load
Refer to “Hydraulic Controls” for identification of
components mentioned in this procedure.
WARNING! Tip Hazard. Refer to the Load
Range and Lift Capacity charts located on the
operator’s information data plates.
1. Inspect every load before attempting to lift. Make
certain the loads are properly bound and will
not fall apart while lifting and transporting. Also,
make sure the weight of the loads are within the
safe lifting range of the forklift.
2. Position the forklift directly and squarely in front
of the load.
3. Lower the boom by pushing the right joystick
forward until the forks are at the necessary level
to engage the load.
4. Level forks to load by moving right joystick either
right or left.
5. If necessary, adjust the width of the forks to
accommodate the load.
6. To position the load for transport:
a. Tilt the forks back by moving right joystick to
the left.
b. Retract the boom by moving the left joystick
back.
c. Travel with load resting on carry pad in front
of fuel tank.
WARNING! Crush Hazard. Do not transport
stacked loads. The top of a stacked load may not
be visible to an operator. If the load is too tall, it
should be transported in two or more moves.
52 Cary-Lift 204, 254, 304 Operator’s Manual
Transporting the Load
Refer to “Hydraulic Controls” for identification of
components mentioned in this procedure.
1. Make certain that all the steps outlined
in “STARTUP AND DRIVING” have been
performed.
2. Always observe the path ahead and be aware
of anything to the sides of the path that may
pose a problem and act accordingly. DO NOT
OVERDRIVE THE CONDITIONS.
3. Be constantly aware of the area overhead and
make sure, before entering an area with limited
overhead, that the forklift will fit. DANGER!
Electrocution Hazard. Stay clear of power
lines.
4. Keep the load as close to the ground as possible
when moving and avoid sudden stops. Approach
a turn or uneven and/or slippery surface very
slowly. Use a flagman and sound horn, and
drive slowly in congested areas. WARNING!
Crush Hazard. Never attempt to drive across
(parallel to) an excessively steep incline,
regardless of circumstances.
5. Driving on inclines or unstable surfaces is
unsafe but sometimes unavoidable. If driving on
an incline cannot be avoided, level the forklift by
using the Frame Tilt (sway) switch as follows:
a. Push left side of switch to tilt the forklift
frame to the left.
b. Push right side of 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. (Forks should
also be pointed uphill when backing down an
incline with a load.)
b. If empty, approach the incline with the forks
pointed downhill. WARNING! Tip Hazard.
Do not approach an incline at an angle.
Drive straight up or straight down an incline.
Drive forward to go down an incline and use
reverse to go up an incline.
800-GO-PETTIBONE

Landing the Load
Refer to “Hydraulic Controls” for identification of
components mentioned in this procedure.
1. Keep the load low and position the forklift
as close to the landing point as possible.
WARNING! Crush Hazard. Do not raise
the load if the machine is tilted in either
direction. Level the machine by using the
Frame Tilt switch before raising the load.
2. Raise the load to the proper height by pulling
back on the Right Control joystick.
3. WARNING! Crush Hazard. Clear the area.
Carefully lower the load by slowly pushing the
Right Control joystick forward until the load tests
solidly on the landing location. Continue to lower
until the forks have no weight on them.
4. By moving the Right Control joystick left or right
as necessary, tilt the forks so that they are not
contacting the load or the landing area beneath
them.
5. Move the Left Control joystick back to retract the
boom and move the forks away from load.
800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual
Operation
Shutdown
1. Bring the forklift to a complete stop.
2. Apply the parking brake by flipping the switch
located on the left side of the dashboard.
3. Lower the forks to the ground by moving the
Right 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. Unfasten seat belt. WARNING! Fall Hazard.
Face the machine and use hand rail and step
when getting off the machine. Climb carefully
from cab. Do not rush and do not jump from the
machine.
10. Block wheels of forklift if the machine is on an
incline.
53
Operation

This Page Intentionally Left Blank

54 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE

 Lubrication

This section describes lubrication and filter

information. The suggestions and recommendations
presented should be followed as closely as possible
to extend the life of this machine. This section
consists of:
• illustrations (which identify service points).
• filter listings.

1
1

1  – Pipe and Pole Baler Lubrication Points

800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual 55

Lubrication
1

1
1

1  – Clam Lubrication Points

1  – Axle Lubrication Point

56 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE

 Lubrication
1
1

1  – Planetary Wheel End Lubrication Point

To check gear oil level, rotate hole “A” to horizontal

level. Oil should be flush with bottom of hole.
To drain oil, rotate hole “A” to bottom.

1  – Differential Attachment Lubrication Points

Gear oil level should be flush with bottom of hole “B.”

800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual 57

Lubrication
1

1 1

1 1 1 1

1  – Axle, Cradle and Driveshaft Lubrication Points

58 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE

 Lubrication
1 1

1 1

1  – Frame Tilt Cylinder Lubrication Points

800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual 59

Lubrication

Joystick HYDRAULIC PRESSURE SETTINGS Joystick

450 450
204 = LL-7185-5
254 = LL-7185-6
304 = LL-7232-1
Steering Steering

2100 2200

Main Main

2100 2200

LL-7185-5 LL-7185-6

Joystick Steering Main Lift

400 2750 1750 1750
304 Cary-Lift LL-7232-1

Figure 22. Hydraulic Pressure Decals

The following pages are for the 204 Tier III Cary-Lift.

60 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE

 Lubrication

204 Cary Lift w/ Cummins QSB6.7 190HP

Tier III/Funk DF150 Transmission
(S/N CL10001+)
HYDRAULIC (AL-12096 Hydraulic Tank)
(2) LL-6330-76 Main and Auxiliary Strainer
(1) LL-423-38 Return Filter Element
TRANSMISSION (LL-3154-738 Filter Assembly)
(1) LL-3154-740 Filter Element
AIR (LL-847-435 Air Cleaner Assembly)
(1) LL-847-440 Primary Element
(1) LL-847-441 Safety Element
FUEL/WATER SEPARATOR (On LL-1189-355
Cummins QSB6.7 Engine)
(1) LL-1189-375 Filter Element
(1) LL-1189-373 Fuel Pre-Filter
OIL (On LL-1189-355 Cummins QSB6.7
Engine)
(1) LL-1189-374 Filter Element

800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual 61

Lubrication

Engine Cummins QSB6.7-190 Tier III

Machine Model/Serial No.:_________________________________________________________________________

Service Technician:_______________________________________________________________________________

Date:_ ___________________________________ Hour Meter:_______________________________________

Work Order:_____________________________________________________________________________________

Completed
Daily or Refueling Checks Operation Part No. / Specification
Yes No
Engine oil or coolant leaks on block Inspect
Belt tension and appearance Check/correct 3289941 plus LL-229-337 with A/C
Air intake piping Inspect
Drain air tanks and reservoirs Drain
Exhaust piping Inspect
Engine coolant level Check/correct 50/50
Engine oil level Check/correct 15W-40
Fan blades Inspect
Crankcase breather tube Inspect
Drain water separator Drain
LL-847-440 Primary Element
Air cleaner restriction Check/correct
LL-847-441 Safety Element
Fuel level Check/correct #1 Off-road
250 hours or 3 months
Charge - Air piping/cooler Inspect/clean
Fuel injection pump, mounting,
Inspect
plumbing
Upper hose LL-229-155-30
Radiator hoses and connections Inspect
Lower hose LL-229-221
500 hours or 6 months
Check antifreeze Check -32°F (-35°C)
Replace fuel filter element Change LL-1189-375
Replace fuel pre-filter Change LL-1189-373
Change oil and oil filter Change LL-1189-374/15W-40 14 qt (13.2 L)
Fuel injection pump, mounting,
Inspect
plumbing
Upper hose LL-229-155-30
Radiator hoses and connections Inspect
Lower hose LL-229-221
Charge - Air piping/cooler Inspect/clean

62 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE

 Lubrication

Completed
Daily or Refueling Checks Operation Part No. / Specification
Yes No
750 hours or 9 months
Charge - Air piping/cooler Inspect/clean
Fuel injection pump, mounting,
Inspect
plumbing
Upper hose LL-229-155-30
Radiator hoses and connections Inspect
Lower hose LL-229-221
1000 hours or 12 months
Fan belt tensioner Check/correct 3976831
Belt-driven fan hub Check/correct
Overhead set Adjust
Check antifreeze Check -32°F (-35°C)
Replace fuel filter element Change LL-1189-375
Replace fuel pre-filter Change LL-1189-373
Change oil and oil filter Change LL-1189-374/15W-40 14 qt (13.2L)
Fuel injection pump, mounting,
Inspect
plumbing
Upper hose LL-229-155-30
Radiator hoses and connections Inspect
Lower hose LL-229-221
Charge - Air piping/cooler Inspect/clean
1250 hours or 15 months
Charge - Air piping/cooler Inspect/clean
Fuel injection pump, mounting,
Inspect
plumbing
Upper hose LL-229-155-30
Radiator hoses and connections Inspect
Lower hose LL-229-221
1500 hours or 18 months
Check antifreeze Check -32°F (-35°C)
Replace fuel filter element Change LL-1189-375
Replace fuel pre-filter Change LL-1189-373
Change oil and oil filter Change LL-1189-374/15W-40 14 qt (13.2L)
Fuel injection pump, mounting,
Inspect
plumbing
Upper hose LL-229-155-30
Radiator hoses and connections Inspect
Lower hose LL-229-221
Charge - Air piping/cooler Inspect/clean

800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual 63

Lubrication

Completed
Daily or Refueling Checks Operation Part No. / Specification
Yes No
1750 hours or 21 months
Fuel injection pump, mounting,
Inspect
plumbing
Upper hose LL-229-155-30
Radiator hoses and connections Inspect
Lower hose LL-229-221
Charge - Air piping/cooler Inspect/clean
2000 hours or 24 months
Fan belt tensioner Check/correct
Belt-driven fan hub Check/correct
Overhead set Adjust
Flush and change antifreeze Change -32°F (-35°C)/9 gal (34 L)
Replace fuel filter element Change LL-1189-375
Replace fuel pre-filter Change LL-1189-373
Change oil and oil filter Change LL-1189-374/15W-40 14 qt (13.2L)
Fuel injection pump, mounting,
Inspect
plumbing
Upper hose LL-229-155-30
Radiator hoses and connections Inspect
Lower hose LL-229-221
Charge - Air piping/cooler Inspect/clean

Refer to Cummins Operation and Maintenance Manual 4021531 for complete maintenance procedures at
the designated intervals.

64 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE

 Lubrication

Transmission Funk DF1544R

Torque Converter DF3R2A
Daily or Refueling Checks Operation Part No. / Specification
Transmission oil level Check/correct Mobil 424 or DEXRON II-D
50 hours or 2 weeks (first time only)
Mobil 424 or DEXRON II-D 44 qt (42 L)
Change oil and oil filter Change
LL-3154-740 filter
500 hours or 3 months
Change filter Change LL-3154-740 filter
1000 hours or 12 months
Mobil 424 or DEXRON II-D 44 qt (42 L)
Change oil and oil filter Change
LL-3154-740 filter
Check for loose mechanical parts
(flanges, threaded conenctions, Inspect
manifold, pipe connections)
Check electrical connections and
components (wire harness, shift Inspect
solenoids, ECM)
1500 hours or 18 months
Change filter Change LL-3154-740 filter
2000 hours or 24 months
Mobil 424 or DEXRON II-D 44 qt (42 L)
Change oil and oil filter Change
LL-3154-740 filter
Check for loose mechanical parts
(flanges, threaded conenctions, Inspect
manifold, pipe connections)
Check electrical connections and
components (wire harness, shift Inspect
solenoids, ECM)

800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual 65

Lubrication

Axle Axletech PSC1764 (Front) / PSC826 (Rear) or PSC1764

(Front) / PSC1764 (Rear)
Daily or Refueling Checks Operation Part No. / Specification
Check for any worn or loose parts Inspect
Weekly
Grease kingpins top and bottom Check/correct NLGI-1, -2 with lithium base
100 hours or 1 month initially, then every 250 hours or bi-monthly
Check differential oil level and top off Check/correct GL-5, SAE 80W-90
Check planetary oil level and top off Check/correct GL-5, SAE 80W-90
Clean axle breathers Check/correct LL-2682-2397 for front and rear axle
Check wheel lug nut torque Check/correct 405 ft-lb (550 N•m)
Clean magnetic drain plugs Check/correct
250 hours or 2 months initially, then every 15000 hours or twice seasonally *
Change oil in differential Change GL-5, SAE 80W-90
Change oil in planetary wheel end Change GL-5, SAE 80W-90
Clean magnetic drain plugs Check/correct

* This service interval is 3000 hours or once yearly if synthetic or semi-synthetic fluids are used.

66 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE

 Lubrication

General
Daily or Refueling Checks Operation Part No. / Specification
Check hydraulic fluid level Check/correct ISO 32
Check function of backup alarm Inspect
Check horn function Inspect
Check service brake function Inspect
Check parking brake function Inspect
Check tire pressure and observe tire
Check/correct 70 psi (4.8 bar)
condition
Check the fork tines and attachment for
Inspect
damage or wear
Check seat belt function Inspect
Check all steering modes Inspect
Check instrument cluster is active Inspect
Weekly
Grease all fittings Check/correct NLGI-1, -2 with lithium base
Check pin retaining fasteners Inspect
Clean radiator core Clean
Inspect hydraulic components for leaks Check/correct
Monthly
Inspect fuel lines Inspect
Check battery for charge and fluid level Check/correct
Check lug nut torque Check/correct 405 ft-lb (550 N•m)
1000 hours or 12 months
(2) LL-6330-76 and (1) LL-423-38
Change hydraulic fluid and filters Change
ISO 32/50 gal (190 L)

The following pages are for the 254 Tier III Cary-Lift.

800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual 67

Lubrication

254 Cary Lift w/ Cummins QSB6.7 220HP

Tier III/Clark R32420 Transmission
HYDRAULIC (AL-12096 Hydraulic Tank)
(2) LL-6330-76 Main and Auxiliary Strainer
(1) LL-423-38 Return Filter Element
TRANSMISSION (LL-1670-3176 Filter Assembly)
(1) LL-1670-3175 Filter Element
AIR (LL-847-435 Air Cleaner Assembly)
(1) LL-847-440 Primary Element
(1) LL-847-441 Safety Element
FUEL/WATER SEPARATOR (On LL-1189-385
Cummins QSB6.7 Engine)
(1) LL-1189-375 Filter Element
(1) LL-1189-373 Fuel Pre-Filter
OIL (On LL-1189-385 Cummins QSB6.7 Engine)
(1) LL-1189-374 Filter Element

68 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE

 Lubrication

Engine Cummins QSB6.7-220 Tier III

Machine Model/Serial No.:_________________________________________________________________________

Service Technician:_______________________________________________________________________________

Date:_ ___________________________________ Hour Meter:_______________________________________

Work Order:_____________________________________________________________________________________

Completed
Daily or Refueling Checks Operation Part No. / Specification
Yes No
Engine oil or coolant leaks on block Inspect
Belt tension and appearance Check/correct 3289941 plus LL-229-337 with A/C
Air intake piping Inspect
Drain air tanks and reservoirs Drain
Exhaust piping Inspect
Engine coolant level Check/correct 50/50
Engine oil level Check/correct 15W-40
Fan blades Inspect
Crankcase breather tube Inspect
Drain water separator Drain
LL-847-440 Primary Element
Air cleaner restriction Check/correct
LL-847-441 Safety Element
Fuel level Check/correct #1 Off-road
250 hours or 3 months
Charge - Air piping/cooler Inspect/clean
Fuel injection pump, mounting,
Inspect
plumbing
Upper hose LL-229-155-30
Radiator hoses and connections Inspect
Lower hose LL-229-221
500 hours or 6 months
Check antifreeze Check -32°F (-35°C)
Replace fuel filter element Change LL-1189-375
Replace fuel pre-filter Change LL-1189-373
Change oil and oil filter Change LL-1189-374/15W-40 14 qt (13.2 L)
Fuel injection pump, mounting,
Inspect
plumbing
Upper hose LL-229-155-30
Radiator hoses and connections Inspect
Lower hose LL-229-221
Charge - Air piping/cooler Inspect/clean

800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual 69

Lubrication

Completed
Daily or Refueling Checks Operation Part No. / Specification
Yes No
750 hours or 9 months
Charge - Air piping/cooler Inspect/clean
Fuel injection pump, mounting,
Inspect
plumbing
Upper hose LL-229-155-30
Radiator hoses and connections Inspect
Lower hose LL-229-221
1000 hours or 12 months
Fan belt tensioner Check/correct 3976831
Belt-driven fan hub Check/correct
Overhead set Adjust
Check antifreeze Check -32°F (-35°C)
Replace fuel filter element Change LL-1189-375
Replace fuel pre-filter Change LL-1189-373
Change oil and oil filter Change LL-1189-374/15W-40 14 qt (13.2L)
Fuel injection pump, mounting,
Inspect
plumbing
Upper hose LL-229-155-30
Radiator hoses and connections Inspect
Lower hose LL-229-221
Charge - Air piping/cooler Inspect/clean
1250 hours or 15 months
Charge - Air piping/cooler Inspect/clean
Fuel injection pump, mounting,
Inspect
plumbing
Upper hose LL-229-155-30
Radiator hoses and connections Inspect
Lower hose LL-229-221
1500 hours or 18 months
Check antifreeze Check -32°F (-35°C)
Replace fuel filter element Change LL-1189-375
Replace fuel pre-filter Change LL-1189-373
Change oil and oil filter Change LL-1189-374/15W-40 14 qt (13.2L)
Fuel injection pump, mounting,
Inspect
plumbing
Upper hose LL-229-155-30
Radiator hoses and connections Inspect
Lower hose LL-229-221
Charge - Air piping/cooler Inspect/clean

70 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE

 Lubrication

Completed
Daily or Refueling Checks Operation Part No. / Specification
Yes No
1750 hours or 21 months
Fuel injection pump, mounting,
Inspect
plumbing
Upper hose LL-229-155-30
Radiator hoses and connections Inspect
Lower hose LL-229-221
Charge - Air piping/cooler Inspect/clean
2000 hours or 24 months
Fan belt tensioner Check/correct
Belt-driven fan hub Check/correct
Overhead set Adjust
Flush and change antifreeze Change -32°F (-35°C)/9 gal (34 L)
Replace fuel filter element Change LL-1189-375
Replace fuel pre-filter Change LL-1189-373
Change oil and oil filter Change LL-1189-374/15W-40 14 qt (13.2L)
Fuel injection pump, mounting,
Inspect
plumbing
Upper hose LL-229-155-30
Radiator hoses and connections Inspect
Lower hose LL-229-221
Charge - Air piping/cooler Inspect/clean

Refer to Cummins Operation and Maintenance Manual 4021531 for complete maintenance procedures at
the designated intervals.

800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual 71

Lubrication

Transmission Clark R32420

Torque Converter C323.1-19
Daily or Refueling Checks Operation Part No. / Specification
Transmission oil level Check/correct Mobil 424
50 hours or 2 weeks (first time only)
Mobil 424
Change oil and oil filter Change
LL-1670-3175 filter
500 hours or 3 months
Change filter Change LL-1670-3175 filter
1000 hours or 12 months
Mobil 424
Change oil and oil filter Change
LL-1670-3175 filter
Check for loose mechanical parts
(flanges, threaded conenctions, Inspect
manifold, pipe connections)
Check electrical connections and
components (wire harness, shift Inspect
solenoids, ECM)
1500 hours or 18 months
Change filter Change LL-1670-3175 filter
2000 hours or 24 months
Mobil 424
Change oil and oil filter Change
LL-1670-3175 filter
Check for loose mechanical parts
(flanges, threaded conenctions, Inspect
manifold, pipe connections)
Check electrical connections and
components (wire harness, shift Inspect
solenoids, ECM)

72 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE

 Lubrication

Axle Axletech PSC1485 (Front) / PSC1485 (Rear)

Daily or Refueling Checks Operation Part No. / Specification
Check for any worn or loose parts Inspect
Weekly
Grease kingpins top and bottom Check/correct NLGI-1, -2 with lithium base
100 hours or 1 month initially, then every 250 hours or bi-monthly
Check differential oil level and top off Check/correct GL-5, SAE 80W-90
Check planetary oil level and top off Check/correct GL-5, SAE 80W-90
Clean axle breathers Check/correct LL-2682-2397 for front and rear axle
Check wheel lug nut torque Check/correct 405 ft-lb (550 N•m)
Clean magnetic drain plugs Check/correct
250 hours or 2 months initially, then every 15000 hours or twice seasonally *
Change oil in differential Change GL-5, SAE 80W-90
Change oil in planetary wheel end Change GL-5, SAE 80W-90
Clean magnetic drain plugs Check/correct

* This service interval is 3000 hours or once yearly if synthetic or semi-synthetic fluids are used.

800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual 73

Lubrication

General
Daily or Refueling Checks Operation Part No. / Specification
Check hydraulic fluid level Check/correct ISO 32
Check function of backup alarm Inspect
Check horn function Inspect
Check service brake function Inspect
Check parking brake function and pads Inspect
Check tire pressure and observe tire
Check/correct 83 psi (5.7 bar)
condition
Check the fork tines and attachment for
Inspect
damage or wear
Check seat belt function Inspect
Check all steering modes Inspect
Check instrument cluster is active Inspect
Weekly
Grease all fittings Check/correct NLGI-1, -2 with lithium base
Check pin retaining fasteners Inspect
Clean radiator core Clean
Inspect hydraulic components for leaks Check/correct
Monthly
Inspect fuel lines Inspect
Check battery for charge and fluid level Check/correct
Check lug nut torque Check/correct 405 ft-lb (550 N•m)
1000 hours or 12 months
(2) LL-6330-76 and (1) LL-423-38
Change hydraulic fluid and filters Change
ISO 32/50 gal (190 L)

The following pages are for the 304 Tier III Cary-Lift.

74 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE

 Lubrication

304 Cary Lift w/ Cummins QSC 8.3 240HP

Tier III/Clark 6000 Transmission
HYDRAULIC (AL-10957 Hydraulic Tank)
(2) LL-6330-76 Main and Auxiliary Strainer
(1) LL-6330-77 Steering Strainer
(1) LL-423-38 Return Filter Element
(1) LA-1776-20 Filter Element
(1) LL-3623-6 Filter
(1) LL-3146-13 Tank Breather
TRANSMISSION (LL-1670-2184 Filter Assembly)
(2) LL-1670-1979 Filter Element
AIR (LL-847-459 Air Cleaner Assembly)
(1) LL-847-466 Primary Element
(1) LL-847-467 Safety Element
FUEL/WATER SEPARATOR (On LL-1189-380
Cummins QSC8.3 Engine)
(1) LL-1189-383 Main Filter
(1) LL-1189-373 Water Separator
OIL (On LL-1189-380 Cummins QSC8.3
Engine)
(1) LL-1189-321 Filter Element
CORROSION RESISTOR (On LL-1189-380
Cummins QSC8.3 Engine)
(1) LL-1189-358 Filter
STRAINER (On LL-1189-380 Cummins QSC8.3
Engine)
(1) LL-1189-357 In-Line Strainer

800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual 75

Lubrication

Engine Cummins QSC8.3-240HP

Machine Model/Serial No.:_________________________________________________________________________

Service Technician:_______________________________________________________________________________

Date:_ ___________________________________ Hour Meter:_______________________________________

Work Order:_____________________________________________________________________________________

Completed
Daily or Refueling Checks Operation Part No. / Specification
Yes No
Engine oil or coolant leaks on block Inspect
Fan belt tension and appearance Check/correct 3289179
A/C belt tension and appearance Check/correct LL-229-266
Air intake piping Inspect
Exhaust piping Inspect
Engine coolant level Check/correct 50/50
Engine oil level Check/correct 15W-40
Fan blades Inspect
Crankcase breather tube Inspect
Drain water separator Drain
LL-847-440 Primary Element
Air cleaner restriction Check/correct
LL-847-441 Safety Element
Fuel level Check/correct #2 Off-road diesel fuel
250 hours or 3 months
Clean charge air cooler Clean
Charge air piping Inspect
Fuel injection pump, mounting,
Inspect
plumbing
Radiator hoses and connections Inspect
500 hours or 6 months
Replace fuel filter (engine) Change LL-1189-383
Replace water separator Change LL-1189-373
Replace fuel strainer (in-line) Change LL-1189-357
Change oil and oil filter Change LL-1189-321/15W-40
Check antifreeze and supplemental
Check -32°F (-35°C)
coolant additive
Coolant filter Replace LL-1189-358
Batteries Inspect
Battery cables and connections Inspect
Clean charge air cooler Clean

76 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE

 Lubrication

Completed
Daily or Refueling Checks Operation Part No. / Specification
Yes No
500 hours or 6 months (continued)
Charge air piping Inspect
Fuel injection pump, mounting,
Inspect
plumbing
Radiator hoses and connections Inspect
750 hours or 3 months
Clean charge air cooler Clean
Charge air piping Inspect
Fuel injection pump, mounting,
Inspect
plumbing
Radiator hoses and connections Inspect
1000 hours or 12 months
Belt tension and appearance Check/correct 3289179
Belt-driven fan hub Check/correct
Turbocharger Inspect
Replace fuel filter (engine) Change LL-1189-383
Replace water separator Change LL-1189-373
Replace fuel strainer (in-line) Change LL-1189-357
Change oil and oil filter Change LL-1189-321/15W-40
Check antifreeze and supplemental
Check -32°F (-35°C)
coolant additive
Coolant filter Replace LL-1189-358
Batteries Inspect
Battery cables and connections Inspect
Clean charge air cooler Clean
Charge air piping Inspect
Fuel injection pump, mounting,
Inspect
plumbing
Radiator hoses and connections Inspect
1250 hours or 15 months
Clean charge air cooler Clean
Charge air piping Inspect
Fuel injection pump, mounting,
Inspect
plumbing
Radiator hoses and connections Inspect
1500 hours or 18 months
Replace fuel filter (engine) Change LL-1189-383
Replace water separator Change LL-1189-373
Replace fuel strainer (in-line) Change LL-1189-357
Change oil and oil filter Change LL-1189-321/15W-40

800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual 77

Lubrication

Completed
Daily or Refueling Checks Operation Part No. / Specification
Yes No
1500 hours or 18 months (continued)
Check antifreeze and supplemental
Check -32°F (-35°C)
coolant additive
Coolant filter Replace LL-1189-358
Batteries Inspect
Battery cables and connections Inspect
Clean charge air cooler Clean
Charge air piping Inspect
Fuel injection pump, mounting,
Inspect
plumbing
Radiator hoses and connections Inspect
1750 hours or 21 months
Clean charge air cooler Clean
Charge air piping Inspect
Fuel injection pump, mounting,
Inspect
plumbing
Radiator hoses and connections Inspect
2000 hours or 24 months
Vibration damper Inspect
Engine mounting hardware Inspect
Belt tension and appearance Check/correct 3289179
Belt-driven fan hub Check/correct
Turbocharger Inspect
Replace fuel filter (engine) Change LL-1189-383
Replace water separator Change LL-1189-373
Replace fuel strainer (in-line) Change LL-1189-357
Change oil and oil filter Change LL-1189-321/15W-40
Check antifreeze and supplemental
Check -32°F (-35°C)
coolant additive
Coolant filter Replace LL-1189-358
Batteries Inspect
Battery cables and connections Inspect
Clean charge air cooler Clean
Charge air piping Inspect
Fuel injection pump, mounting,
Inspect
plumbing
Radiator hoses and connections Inspect

Refer to Engine Operation and Service Manual 4021518 for further information.

78 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE

 Lubrication

Torque Converter Clark C5000

Transmission Clark T6000
Daily Operation Part No. / Specification
Mobil 424/refer to transmission service
Check transmission oil level Check
manual
50 hours
Transmission oil filter elements Replace LL-1670-1979, qty (2)
100 hours
Transmission oil filter elements Replace LL-1670-1979, qty (2)
Clean filter Clean
Check breather/replace Clean/replace LL-3146-13, qty (2)
1000 hours or 12 months, then every 1000 hours or 12 months
Mobil 424/refer to transmission service
Change oil Change
manual
Transmission oil filter elements Replace LL-1670-1979, qty (2)
Check for loose mechanical parts
(flanges, threaded connections, Inspect
manifold, pipe connections)
Check electrical connections and
components (wire harness, shift Inspect
solenoids)
1500 hours or 18 months
Mobil 424/refer to transmission service
Transmission oil level and top off Check/correct
manual
Check gaskets and seals Check/correct

800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual 79

Lubrication

Axle Axletech PSC-5494

Daily or Refueling Checks Operation Part No. / Specification
Check for any worn or loose parts Inspect
Weekly
Grease kingpins top and bottom Check/correct NLGI-1, -2 with lithium base
50 hours or 3 weeks initially, then every 250 hours or monthly
Check differential oil level and top off Check/correct GL-5, SAE 80W-90
Check planetary oil level and top off Check/correct GL-5, SAE 80W-90
Clean axle breathers Check/correct LL-2682-2397
Check wheel lug nut torque Check/correct 405 ft-lb (550 N•m)
250 hours or 2 months initially, then every 1500 hours or seasonally
Change oil in differential Change GL-5, SAE 80W-90
Change oil in planetary wheel end Change GL-5, SAE 80W-90
Clean magnetic drain plugs Check/correct

80 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE

 Lubrication

General
Daily or Refueling Checks Operation Part No. / Specification
Check hydraulic fluid level Check/correct ISO 32
Check function of backup alarm Inspect LL-4531-4
Check horn function Inspect
Check service brake function Inspect
Check parking brake function and adjust Inspect/adjust
Check tire pressure and observe tire
Check/correct 65 psi (4.8 bar)
condition
Check the fork tines and attachment for
Inspect
damage or wear
Check seat belt function Inspect
Check all steering modes Inspect
Check instrument cluster is active Inspect
Weekly
Grease all fittings per grease fitting chart Check/correct NLGI-1, -2
Check pin retaining fasteners Inspect
Clean radiator core Clean
Clean air conditioning condenser core (if
Clean
equipped)
Inspect hydraulic components for leaks Check/correct
Monthly
Inspect fuel lines Inspect
Check battery for charge Check/correct
Check lug nut torque Check/correct 405 ft-lb (550 N•m)
Check hydraulic filter restriction; change In tank: LL-3748-46
Check/replace
filters if above 20 psi In line: OLA-01766-020
250 hours or 3 months
Change hydraulic tank breather * Change LL-3146-13 qty (2)
1000 hours or 12 months
ISO 32
Change hydraulic fluid Change Main LL-6330-76
Lift LL-6330-76
Steering LL-6330-77
Change hydraulic suction strainers Change
Brakes LL-3623-11
In tank: LL-3748-46
Change hydraulic return filters Change
In line: OLA-01766-020

* Beginning with machine serial number 103, remove spring from check valve.

800-GO-PETTIBONE Cary-Lift 204, 254, 304 Operator’s Manual 81

Lubrication

This manual has been furnished by Pettibone/Traverse Lift, LLC to be used as a guide for equipment
operation and maintenance. Remember, this machine can be extremely dangerous when operated
recklessly. The most important safety feature of the machine is the operator.
This forklift is designed to encourage daily, routine maintenance by locating maintenance points in easily
accessible locations. Constant adherence to the maintenance schedules listed herein will serve to lengthen
the usable life of this machine. Should a problem arise which you cannot resolve, contact your servicing
dealer immediately, or call us at (906) 353-6611.
We’re here to ensure your satisfaction with Pettibone/Traverse Lift, LLC products.

Thank you for choosing Pettibone/Traverse Lift, LLC

82 Cary-Lift 204, 254, 304 Operator’s Manual 800-GO-PETTIBONE