JLG SKYTRAK 5522 Instruction Manual

Operators and Safety Manual
Model
5522
S/N 7D5269 & After
8990118
FEBRUARY 1988
ANSI
Operators and Safety Manual
Model
5522
S/N 7D5269 & After
8990118
FEBRUARY 1988
ANSI
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IMPROPER OPERATION OF THIS FORKLIFT CAN CAUSE INJURY OR DEATH.
BEFORE STARTING THE ENGINE,
DO THE FOLLOWING:
1. READ THIS OPERATOR'S MANUAL.
2. READ ALL THE SAFETY DECALS ON THE FORKLIFT.
3. CLEAR THE AREA OF OTHER PERSONS.
LEARN AND PRACTICE SAFE USE OF THE FORKLIFT CONTROLS IN A SAFE,
CLEAR AREA BEFORE YOU OPERATE THE FORKLIFT ON A JOB SITE.
It is your responsibility to observe pertinent laws and regulations and to follow
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Table Of Contents
Introduction ..............................................2 General Maintenance .............................32
The Manual ................................................................2 Safety Check-list ......................................................32
Replacement Parts ....................................................2 Decals ......................................................................33
Reports ......................................................................2 Maintenance Schedule and Check List....................35
Disclaimer ..................................................................2
1. Lubrication Points .............................................38
Safety Practices .......................................3
Signal Words ..............................................................3
New or Additional Operator's ....................................
.4
Personal Considerations ............................................4
Operational Considerations .......................................6
Equipment Considerations ..............;..........................8
2. Air Cleaner and Precleaner ..............................39
3. Engine Cooling System ....................................40
4. Engine Oil and Filter ........................;................42
5. Engine Fuel System ..........................................44
6. Engine Fan Belt Check .....................................48
7. Hydraulic Oil and Filters .................................... 49
8. Transfer Case Oil ..............................................52
Operation ..................................................8
General ......................................................................8
9. Axle Oil .............................................................53
1
0. Wheel End Oil ...................................................54
Controls ......................................................................9 11. Wheels and Tires ..............................................56
Instruments .............................................................. 18
12. Battery ..............................................................56
Warning Lights .........................................................20
Condition Indicators ..................................................20 13. Fuse Replacement .................;..........................60
14. Brakes ............................................................... 61
Walk- Around Inspection ......................................... 21
Normal Starting ..................................;..................... 21
15. Boom Wear Pads ..............................................64
Specifications.........................................66
Cold Starting ............................................................22 Fluid and Lubricant Capacities .................................66
Jump Starting ...........................................................23 Tires ......................................................................... 66
Operating .................................................................24 Electrical System ..............................................
·-'···. 67
Using The Capacity Chart ........................................29 Engine ..................................................................... 67
Shut- Off .................................................................. 31
Weights ................................................................... 67
Towing .....................................................................
31 Machine Dimensions ............................................... 67
Machine Operating Limits .......................................
68
5522
Origin 2/88 Page 1
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Introduction
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This Owners/Operator's manual has been prepared to pro-
vide the information you need to correctly operate and
maintain this forklift.
Read this manual completely and carefully to familiarize
yourself with the operation of all controls, safety equipment,
and safety
precautions~ operatingthis forklift. Compli-
ance with all CAUTION and WARNING notes used through-
out this manual are mandatory !They are for your benefit.
All reference made in the manual to the right side, left side,
front, or rear are given relative to the operator when
he is
seated.
For reference when ordering replacement parts or making
service inquiries, record the modeland serial numbersonthe
back cover of this manual.
Page 2
IMPORTANT!
The replacementof any part on this product byotherthan the
manufacturer's authorized replacement part may adversely
affect the performance, durability, or safety of this product.
IMPORTANT!
As with any TRAK International product, a Delivery Report
must be filled out by the TRAK International distributor and
returned to us oncethe product
is sold and/orput into service
(rental). This report activates the warranty period, assuring
that your claims during the warranty period will be honored
and processed expediently. To guarantee you full warranty
service, make sure your distributor has filed this report with
TRAK International.
The manufacturerreservesthe right to makechangeson and
to add improvements upon its products at any time without
noticeorobligation. The manufactureralso reservesthe right
to discontinue manufactureof any product at its discretion at
any time.
5522
Origin 2/88
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Safety Practices
This symbol means "Attention! Become Alert! Your
Safety
is Involved !" The symbol is used in conjunctionwith
the following signal words to attract your attention to safety
messagesfound throughout this manual. The message that
follows the symbol contains important information about
Safety. To avoid injury and possible death, carefully read
the message! Be sure you fully understand the causes of
possible injury
or death.
A Danger
The signal word "Danger'' signifies that an imminently haz-
ardoussituationto apersonon
ornearthe forklift exists. This
dangerto persons
is suchthat it will result in a high likelihood
of death or permanent injury if the recommended precau-
tions are not taken.
5522
Origin 2/88
A Warning
The signalword "Warning"signifiesthat apotentiallyhazard-
ous situation to a person on or nearthe forklift exists, which
could result in death or serious injury if the recommended
precautions are not taken.
A Caution
The signalword"Caution"signifiesthat apotentially hazard-
ous situation to a person on or nearthe forklift exists, which
may result
in minor or moderate injury if the recommended
precautions or unsafe practices are not taken.
The information in this manual does not replace any safety
rules and laws used in your area. Before operating this
forklift, learn the rules and lawsforyourarea. Make sure the
machine has the correct equipment according to these rules
and laws.
Your safety and the safety of others in the work area are the
result of yourknowledge of correct operating procedures for
this machine.
Paae 3
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If this machine is to be used by an employee or is loaned or
rented to someone other than the owner, make certain that
the newoperatorreads and understandsthefollowing before
operating the forklift.
1. Instructions on safe and correct use of the machine.
2. The Operator's Manual, along with the F.I.E.I. (Farm
and Industrial Equipment Institute) Safety Manualthat
are provided with the machine.
1. Always adjust the seat and fasten the seat belt se-
curely before you start the engine.
3.
4.
5.
6.
7.
2.
DO NOT get off the forklift without first: a.
·engaging the parking brake,
• lowering the boom ,
• grounding the carriage,
·turning engine off,
• unbuckling the seat belt, and
• exit the forklift using the grab bars and cab step.
Page 4
NEVER operate this forklift in an enclosed area.
Fumesfrom engine exhaustcan cause injury
or death.
Provide good ventilation to replace exhaust fumes
with fresh air.
DO NOT allow anyone to ride on the forklift with the
operator.
DO NOT use this forklift as a manlift orwork platform.
DO NOT allow anyone on the forklift carriage.
Engine fuel is flammable and can cause a fire or
an
explosion. Keep sparks, open flames and smoking
materials away from the forklift during refueling or
servicing of the fuel system.
DO NOTget under araised boom unless the boom is
blocked up. Always block up the boom before doing
any servicing which requires the boom to be up.
DO NOT attempt to repair or tighten any hydraulic
hoses orfittings with the engine running or when the
hydraulicsystem
is underpressure. Escaping hydrau-
licfluid underpressure can penetrate the skin causing
serious injury ordeath.
5522
Origin 2/88
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• DO NOT use your hand to check for leaks. Use a
piece of cardboard
or paper to search for leaks.
• Hydraulic fluid can cause permanent eye injury.
Wear appropriate eye protection and stop engine
and relieve pressure before connecting ordiscon-
necting lines.
• HOT HYDRAULIC FLUID WILL CAUSE SEVERE
BURNS. Wait forfluid to cool down before discon-
necting lines.
•
If anyone is injured by or if any .hydraulic fluid is
injected into the skin, obtain medical attention
immediately or gangrene may result.
9. DO NOTwear loose clothing orjewelrythat can catch
on controls or moving parts. Wear the protective
clothing and personal safety gear devices issued or
called for by job conditions.
10. Learn where fire extinguishers are kept on the job site
and how
to use them.
11. Learn where first aid or emergency equipment
is kept
on the job site and where to get help
in a hurry.
5522
Origin 2/88
12. To avoid personal injury when checking, testing or
charging. the battery; keep sparks, flames, and lit
cigarettes away from battery. Lead acid batteries
generate explosive gases when charging orwhen the
engine
is running. Wear safety glasses when working
near batteries.
13. Severe chemical burns can result from improper
handling of battery electrolyte. Use proper protective
gearwhenhandling electrolyte;to preventcontactwith
eyes, skin or clothing.
14. Battery Electrolyte First Aid
·External Contact- Flush with water.
•Internal Contact- Drink large quantities of water.
Follow with Milk of Magnesia, beaten egg or vege-
table oil. Call a physician immediately!
Important!
In case of internal contact, DO NOTgive fluids that
would induce vomiting!
• Eyes- Flush with waterfor at least 15 minutes and
get medical attention immediately!
Page 5
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1.
2.
3.
Electrocution Hazard - To prevent serious bodily
injury:
6.
7.
NEVER operate this or any equipment in an area in
which overhead powerlines, overhead or under- a.
ground cables, or power sources exist without first
notifying the appropriate power company or utility
company to de-energize the lines or take other suit- 9.
able precautions.
Electrical cables, gas pipes, water pipes, sewers, or
other underground objects can cause injury ordeath.
Know the location of all underground hazards before
operating the forklift in a
new· work area.
Keep the machine undercontrol at all times.
Holes, obstructions, debris and other work area haz-
ards can cause injury
or death. Always walk around
and lookforthese and otherhazards before operating
the forklift
in a new work area.
DO NOT park the forklift on an incline and leave it
unattended.
DO NOT operate the forklift unless:
• all safety equipment is in proper working condition,
• all shields are in place, and
• all safety and instruction decals are in place and
readable.
(Replace all missing, illegible, or damaged safety
decals)
Always check clearances carefully before driving
under electrical lines, bridges, etc.
4. Knowthe location and function of all machinecontrols.
10. DO NOT exceed rated lift capacity loads, as unstable
and dangerous machine conditions will result.
5. Make sure all persons are away from the forklift and
thatthe Travel/Range Selector
is in the NEUTRALpo-
sition with the Parking Brake engaged before starting
the engine.
Page 6
11. DO NOTdriveacross aslope
in excessofthe machine
operating limits. Refer to Specifications.
5522
Origin 2/88
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12. Ascend or descend grades slowly and with caution.
• When ascending ordescending grades in excess of
~1°, loaded forklifts must be driven with the load
upgrade.
• Unloaded forklifts should be operated on all grades
with the carriage towards the downgrade.
·On all grades, the load must be tilted back and raised
only as far as necessary to clear the ground.
14. When operating on a downhill slope, reduce travel
speed and downshift to a lower gear to permit com-
pression braking by the engine and aid the application
of the service brakes. ,
15. Dust, smoke, fog, etc. can decrease vision and cause
an accident. Always stop or slow the forklift until the
obstruction clears and the road, traffic, orwork area
is
visible again.
16. DO NOT shift to low range at a high ground speed with
a load on the forks. You may drop the load off of the
forks due to a sudden slowing.
5522
Origin 2/88
17. Avoid jerky turns, starts, or stops. Reduce operating
speed on rough ground and slopes.
18. DO NOT travel orturn with boom up. Keep load low.
19. Sparksfrom the electrical system and engine exhaust
cancause afire or
an explosion. DO NOT operatethis
forklift in an areawithflammable dustorvapors, unless
good ventilation has removed the hazard.
20. DO NOT attempt to start the forklift engine by pushing
with anothervehicle. The powertrain design does not
allow starting in this way and the transmission may be
damaged.
21. Prevent accidents when you move the machine
around the job site. Know the rules for movement of
people and machines on the job site. Follow the
instructions of the flagman, signals and signs. See
Figure
1.
Page 7
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