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
i:!!!::!!!i!lil!!:lllll!!!lll!llllll,i.!l:l!!!'!:·_·~il!··l!l:!'!:l·l.··l·: _ _-::·::·!~::·::·!:::.!.·.·~!:!i.··~!:~!-·!·.·~-:·_:J.:I~·-·_.J.:'!'_:_:::·:··::, .. ~····.!~·;i::_·:.:'!::!.:l!!-1:1~·-l·i:·:::::!!i:
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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1.
2.
3.
DO NOT modify oralter orpermit anyone to modify or
alter this equipment or any of its components.
DO NOT by-pass the safety starting circuit. Consult
your dealer
if the safety start circuit is malfunctioning.
DO NOTmodifyorrepairthe Falling Object Protective
Structure (FOPS). Any repairs ormodifications (weld-
ing, drilling, etc.) to the FOPS can weaken the struc-
ture creating a hazard that can cause injury or death.
FORKLIFT * SIGNALS
• ~, •
~,
~~
1.1TW
........ LeAl
J.liWI'IlW
'1'
~
l
l.tlll, .... _..,
1.1llffl'ftULI11
I.Till,_.W
• r
r:l
~
., llt.f,tMtQIOWif
._.,.~IAC:IWUI
1. ...-..:UAI~
-.n~nooo•ror.-a .. •Lut"
10..0, ___ .., ... ..,.._,_
~~~..=..~._,-
:~- ...... -......-~-,_
--~-~ ....
.. ....._,._..,...,.. .. ....,_.,.._.
--
_..,.._.,_ ____ ,..._flf .........
•.rtJI,_rrt:MollAII.Mff .. IT"'t:l"ll~
Figure 1. Forklift Signals
Page 8
Transmission
The 5522 SkyTrak is equippedwith atwo speed forward and
reverse hydrostatic transmission, consisting of a variable
flow pump and a two speed hydraulic motor. The motor
is
coupled directlyto a gearreduction box that transmits power
through drive shafts to the front and rear drive axles.
I
For the first 24 hours, avoid long distance road travel to
provide a proper running-in of the transmission system.
Axles
Both front and rear axles have a steerable type planetary
drive with a single drive line disc brake on the front axle.
Braking System
The5522 SkyTrakis equipped with both service and parking
brakes.
5522
Ori in 2/88
g
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Service Brake
A single drive line disc brake is located on the front axle
and is actuated by a foot pedal operated master cylinder
from inside the operators cab.
Parking Brake
A single drive line drum brake is located on the gear
reductionbox
anc;f ismanually controlledwith aleverinside
the operators cab.
Hydraulic System
The hydraulic system consists of a 2-:section, engine
mounted hydraulic pump, a hydraulic fluid reservoir, and
valves required to direct the fluid flow to the boom hoist,
boom extend, fork tilt, travel/range, steering wheel, steer
select valve, and steering cylinders along with the auxiliary
hydraulics.
Boom
Thetelescopic, 2-stageboomis ofwelded construction. High
strength steel
is used in all sections. Dual cylinders raise and
lower the boom. A slave cylinder attached
to the rear of the
outer boom automatically levels the forks. A single cylinder
5522
Origin 2/88
isusedto extend the boom. Extending the cylinderwill either
extend the reach of the forks or the height of the forks, de-
pending upon the angle of the boom. A special quick attach
head with hydraulically activated locking pins are provided
on the inner boom gooseneck. This allows the operator to
change attachments without leaving the operators cab.
Keys
Three keys are provided with the forklift. One key is for the
ignition. A second key isforthe operator's cab access door.
The third
is located behind the seat which isolates power
from the battery.
Ignition Switch (Figure 2.)
Using the ignition switch key, the switch may be turned
clockwise from the OFF position to the RUN, THERMO
START and START positions. The THERMO START and
START positions are spring-loaded
to return to the RUN
position and must be manually held
in place for cold starting
or normal starting.
Page 9
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Off position- The entire electrical system is shut down.
Run
position -All controls and indicators are
operable.
Thermo Start position -Energizes a cold starting aid
element
in the intake manifold to pre-heatthe intake airfor
cold starting.
Start position -Engages starter to crank the engine
when the parking brake
is engaged and the transmission
is in neutral.
Fuel Shut-Off Control (Figure 3)
The Fuel Shut-Off is located on the lower right side of the
operator's control console. The Fuel Shut-Off knob controls
the fuel delivery to the engine. To stop the engine, pull the
knoball the wayout. This stopsthe flowoffuel to the injection
pump. Push the knob all the way in after the engine has
stopped forthe next start.
If the knob is not pushed in all the
way, the engine might not start, or maximum
RPM may not
be obtained.
Page 10
0
H
H
s
0- OFF
R-RUN
H- THERMO START
HS- START
Figure 2
\----'iP·-~--- FUEL SHUT
OFF CONTROL
\\\\
Figure 3 5522
Origin 2188
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Accelerator Pedal (Figure 4)
Pressing downthe acQeleratorpedal increases travel speed
of the forklift. The pedal is spring-loaded to return to idle
speed.
Inching Control Pedal (Figure 4)
This pedal controls the precise inching movement of your
machine, by destroking the travel pump. The control
is
operable in forward and reverse, in both highand low range.
Service Brake Pedal (Figure 4)
The Brake Pedal is the centerfoot pedal in the operatorscab.
Depress the brake pedal to actuate the drive line disc brake
located on the front axle. The brake pedal also activates the
brake lights at the rear of the machine.
Parking Brake (Figure 5)
The Parking Brake Lever is located on the left side of the
operator.
To applythe brake, pull the leverup. The brakewill
release when the lever is pushed down. The brake may be
adjusted by turning the knob on the top of the lever.
5522
Origin 2/88
TRAVEL/RANGE
SELECTOR
INCHING·
CONTROL
SERVICE ACCELERATOR
BRAKE
Figure 4
Page 11
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PARKING BRAKE
Figure 5
Page 12
Travel/Range Select Lever (Figure 4)
The Travel/Range Select Lever is located on the left side of
the operator's control console.
The control lever operates as follows:
Moving FORWARD:
Low Range....... move the lever to the right and up
High Range ......move the lever to the left and up
NEUTRAL:- Central position
Moving In REVERSE:
Low Range....... move the lever to the right and down
High Range ......move the lever to the left and down
Whenthe travel select lever
is shifted into eitherHigh orLow
REVERSE, the back-up alarm will automatically sound.
Use lowrange forhighesttorque and pullingpower. Use high
range for highest ground speed.
Steering Select Switch (Figure 6)
The Steering Select Switch is a three position rocker type
switch and is located on the lower panel of the control
console. 5522
Origin 2/88
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' '
' ' Crab Steer .................press forward
; -
, -2 Wheel Steer ............center position
.,
'
; ' 4 Wheel Steer ...........press rearward
Referto "Steering" under
"Operating" for more information.
4-Way Flasher Switch (Figure 6)
The4-WayFlasherSwitch is locatedonthe lowerpanelofthe
control console and
is activated by pressing ,the switch
rearward. This causes all four directional lights to flash
intermittently.
Windshield Wiper Switch (Figure 6)
The Windshield Wiper Switch is located on the lower panel
of the control console. Thewiperis activated by pressing the
switch rearward.
Light Switch (Figure 6)
The Light Switch is a three position rocker type switch and
is located on the lower panel of the control console.
5522
Origin 2/88
Lights OFF ....................press forward
Parking Lights ON ........center position
Headlights ON ..............press rearward
STEERING SELECT
SWITCH
DIRECTIONAL
FLASHER .AND
HEADLIGHT
CONTROL LEVER
LIGHT
SWITCH
WINDSHIELD CIRCULATION
WIPER SWITCH FAN
4-WAY FLASHER
SWITCH
Figure 6
Page 13
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Directional Flasher & Headlight Control
lever (Figure 6)
The Directional Flasher and Headlight Control Lever is
located on the right side of the operator's control console.
Directional Flasher Control
Push lever down to signal right turn; up for left turn. The
flashers are not self cancelling and must be
moved to the
center OFF position after indicated turn is negotiated.
Headlight Control
The Headlight Control is directlyrelated to the operation of
the Light Switch. The headlight control will operate
as
follows with respect to the positions of the Light Switch:
Lights OFF ...............Headlights and Parking Lights are
not operable.
Parking Lights ON .... Parking Lights are lit. When the
lever is moved all theway to the right
you have momentary
Hi Beam con-
trol until the lever is released.
Page 14
Headlights ON .........Headlights and Parking Lights are
lit. When the lever is positioned to
the right, the Low Beam headlights
are ON. Whenthe lever
is moved to
the left, the Hi Beam headlights are
ON. When the lever is moved all the
way to the right you have momen-
tary Hi Beamcontrol untilthe lever
is
released.
Horn Button (Figure 6)
Pressing the momentary-contact horn button on the end of
the Directional Flasherand Headlight Control Lever sounds
the forklift horn.
Circulation Fan Switch (Figure 6)
The Circulation Fan Switch is located on the lower panel of
the control console. The Circulation Fan
is only operable
when the ignition switch is in the "Run" position.
Steering Wheel (Figure 6)
Turningthe steeringwheel to the left orright steers theforklift
in the corresponding direction. Any one of three steering
modes are selectable. Refer to "Steering Select Switch".
5522
Origin 2188
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Operator's Seat Adjustment (Figure 7)
Seat Position Adjustment
To adjustthe seat position movethe locking levertothe left
and slide the seat forward or back to desired position and
release locking lever.
Seat Suspension Adjustment
To adjustthe suspension stiffer, pull andtwistthe adjusting
lever handle so the "+" plus mark on the handle is facing
forward. The adjusting leverwill now
worl< like a ratchet to
turn the adjusting screw clockwise and stiffen the suspen-
sion. To adjust the suspension softer, pull and twist the
adjusting lever handle so the
"-" minus mark on the
handle is facing forward. The adjusting leverwill nowwork
like a ratchet to turnthe adjusting screwcounter-clockwise
and soften the suspension.
Cab Heater (Optional) (Figure 7)
The cab heaterfan is only operable when the ignition switch
is in the RUN position. The heater fan switch is located on
top of the cab heater enclosure (Figure 7). The switch has
three positions; OFF, LO, and HI.
5522
Origin 2/88
NOTE: Duringsummeroperation, close the heaterline shut-
off valve, located at the left rear corner of the engine just
above the alternator.
CAB HEATER
Figure 7
Page 15
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Fork Tilt Control Lever (Figure 8)
Controls fork tilting action. Pushing the leverforward lowers
the fork tips. Pulling the lever back raises the fork tips.
NOTE: Forks are selfleveling and will retainany set angle
throughout the boom raising, lowering and extension
operations.
Boom Raise/Lower Control Lever (Figure 8)
Raises a[ld lowers the boom. Pushing the leverforward will
lower the boom. Pulling the lever back raises the boom.
NOTE: The higherthe engine RPM, the faster the boom will
operate.
Boom Extend/Retract Control Lever (Figure 8)
Extends and retracts the telescopic boom. Pushing the
control leverforward extends the boom. Pulling the control
lever back retracts the boom..
NOTE: The higherthe engine RPM, the faster the boom will
operate.
Page 16
AUXILIARY
HYDRAULIC
CONTROL LEVER
FOR'K TILT
CONTROL LEVER
BOOM RAISE/
LOWER CONTROL
LEVER
I
==~~:-.11 BOOM EXTEND/
Figure 8
RETRACT CONTROL
LEVER
5522
Origin 2/88
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Auxiliary Hydraulic Control Lever (Figure 8)
This control leveron a standard machine actuates the quick
attach locking cylinder to extend or retract the quick attach
lock pins for attachment mounting or removal. See "Quick
Attach"
in the section on "Operating"forthe procedures to
properly mount
or remove an attachment.
Thecontrol leverperformsdifferenthydraulicfunctionswhen
other Optional equipment (ie; Side Tilt Carriage, 8ft. Mast
Extension)
is attached to the forklift. When the specific
option
is completely and properly mounted the control lever
will function as follows:
Standard Operation of Lever
Pull backthe Auxilliary Hydraulic Control Lever to extend
the quick attach lock pins for attachment mounting. Push
the leverforwardto retractthe pinsforattachmentremoval.
Operation of Lever with a Side Tilt Carriage
Pushing the Auxilliary Hydraulic Control Leverforward will
tiltthe carriage to the right. Pullingthe leverbackwill tiltthe
carriage to the left.
Operation of Lever with an 8ft. Mast Extension
Pushing the Auxilliary Hydraulic Control Leverforward will
lowerthe forks. Pulling the lever back will raise the forks.
5522
Origin 2/88
Battery Isolating Switch (Figure 9)
This switch is an anti-theft device designed to isolate all
electrical operatorcontrolsfromthe battery. This meansthat
the ignition switch
is inoperable and the machine cannot be
started.
The switch is located behind the operators seat. To connect
the battery, push
in the key and turn clockwise. To discon-
nectthe battery, turn the key counterclockwise and remove.
Figure 9
\
BATTERY
SHUT OFF
KEY
SWITCH
Page 17
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