JLG SKYTRAK 5522 Operator'S And Safety Manual Download

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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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Summary of Contents for SKYTRAK 5522

Page 1: ...nual Model 5522 S N 7D5269 After 8990118 FEBRUARY 1988 ANSI Operators and Safety Manual Model 5522 S N 7D5269 After 8990118 FEBRUARY 1988 ANSI G o t o D i s c o u n t E q u i p m e n t c o m t o o r d...

Page 2: ...e needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulotte Barreto Power Blanket Nifty Lift Atlas Copco...

Page 3: ...HE 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 re...

Page 4: ...Check 48 7 Hydraulic Oil and Filters 49 8 Transfer Case Oil 52 Operation 8 General 8 9 Axle Oil 53 10 Wheel End Oil 54 Controls 9 11 Wheels and Tires 56 Instruments 18 12 Battery 56 Warning Lights 20...

Page 5: ...2 IMPORTANT The replacement of any part on this product by other than the manufacturer s authorized replacement part may adversely affect the performance durability or safety of this product IMPORTANT...

Page 6: ...Warning The signal word Warning signifies that a potentially hazard ous situation to a person on or near the forklift exists which could result in death or serious injury if the recommended precaution...

Page 7: ...closed area Fumes from engine exhaust can cause injury ordeath 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...

Page 8: ...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 awa...

Page 9: ...orklift 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 plac...

Page 10: ...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 groun...

Page 11: ...__ _flf rtJI _rrt MollAII Mff IT t l ll Figure 1 Forklift Signals Page 8 Transmission The 5522 SkyTrak is equipped with a two speed forward and reverse hydrostatic transmission consisting of a variabl...

Page 12: ...m automatically levels the forks A single cylinder 5522 Origin 2 88 is used to extend the boom Extending the cylinder will either extend the reach of the forks or the height of the forks de pending up...

Page 13: ...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 knob all the way out This stops the fl...

Page 14: ...edal in the operators cab 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 Brak...

Page 15: ...Range move the lever to the right and down High Range move the lever to the left and down When the travel select lever is shifted into either High or Low REVERSE the back up alarm will automatically s...

Page 16: ...Wiper Switch is located on the lower panel of the control console The wiper is activated by pressing the switch rearward Light Switch Figure 6 The Light Switch is a three position rocker type switch...

Page 17: ...ased Page 14 Headlights ON Headlights and Parking Lights are lit When the lever is positioned to the right the Low Beam headlights are ON When the lever is moved to the left the Hi Beam headlights are...

Page 18: ...l and twist the adjusting lever handle so the minus mark on the handle is facing forward The adjusting leverwill now work like a ratchet to turn the adjusting screw counter clockwise and soften the su...

Page 19: ...ling the lever back raises the boom NOTE The higher the engine RPM the faster the boom will operate Boom Extend Retract Control Lever Figure 8 Extends and retracts the telescopic boom Pushing the cont...

Page 20: ...tract the pins for attachment removal Operation of Lever with a Side Tilt Carriage Pushing the Auxilliary Hydraulic Control Lever forward will tilt the carriage to the right Pulling the lever back wil...

Page 21: ...dow latch over the stud guide and locking it into the rubber catch on the ROPS See Figures 10 and 11 Hourmeter Figure 12 Figure 10 Page 18 The Hourmeter indicates the total elapsed hours of forklift o...

Page 22: ...boom angle when reading the capacity chart See Using The Capacity Chart 5522 Origin 2 88 Rear View Mirrors Two Rear View Mirrors are provided to aid the operator in rear vision A rectangular mirror i...

Page 23: ...on exists These conditions are Figure 14 Page 20 g la Alternator Charging Indicates that the alternator is not charging Engine Water Temperature Indicates high engine coolant temperature Air Restricti...

Page 24: ...he level of residue in the air pre cleaner bowl Empty the bowl if required 2 Check and add engine oil if required 3 Check radiator for coolant Add coolant if required and remove debris orother foreign...

Page 25: ...nuously for more than 15 seconds This will avoid starter motor overheating Page 22 8 After engine starts run engine at about 1200 RPM for 30 to 60 seconds before operating machine Return to idle befor...

Page 26: ...the engine starts release the ignition key to the R RUN position 5522 Origin 2 88 10 If engine does not start in 15 seconds return the start key to the H THERMO START position for 10 seconds and then...

Page 27: ...3 Use the accelerator pedal to control ground speed IMPORTANT Checkgauges and indicators frequently dur ing operation Any abnormal indications or machine mal function should be corrected as soon as po...

Page 28: ...ausethe forklift to tip and possibly lose the load This is particularly true in 4 wheel steering mode Use a lower range or a slower speed when turning Origin 2 88 4 Wheel Steering Figure 15 The front...

Page 29: ...l steer type forklift A conventional steer type forklift will have to move back and forth several times in order to line up at the exact spot in front of the loading location Page 26 Figure 17 The for...

Page 30: ...brake 5522 Origin 2 88 3 Extend the boom about 10 feet and tilt the carriage rearward NOTE Before removing a carriage type attachment spread the forks out on the carriage shaft This will give the carr...

Page 31: ...de supports Page 28 4 Raise the boom until the hooks have contacted the attachment cross bar Pull the Fork Tilt Lever back This will roll the quick attach rearward hooking the attachment to the quick...

Page 32: ...f the front tires to a point 24 in front of the heel of the fork The boom extend numbers indicate true horizontal distance oniy when the boom is parallel to the ground 3 The height of the structure wh...

Page 33: ...away from the machine The operator should move the machine closer to the structure to assure that the machine will not exceed the maximum limits for placing the load Page 30 10 3 0 5 1 5 OFT OM 2 5 7...

Page 34: ...bled and cannot be moved under engine power the machine can be towed by another piece of equipment Due to excessive pressures that exist in the hydraulic travel system the forklift cannot be towed unl...

Page 35: ...forklift with the engine running Contact with moving parts can cause serious injury or death Page 32 Inspect the following safety equipment daily Safety Belt Check for frayed or cut webbing damaged b...

Page 36: ...e needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulotte Barreto Power Blanket Nifty Lift Atlas Copco...

Page 37: ...Maintenance 5 WARNING Parking Brake 6 WARNING Jump Start 5522 Origin 2 88 7 _ WARNING Read Manual 8 _ Lift Capacity Chart g _ WARNING Stay Inside 10 _ WARNING No Riders 11 _ Control Levers 12 Bracket...

Page 38: ...ING Engine Radiator Cool 4 Diesel Fuel 5 DANGER Electric Power Lines 6 Fork Lift Signals 7 Hydraulic Oil Level 8 Hydraulic Oil 9 WARNING Boom Figure 22 5522 Origin 2 88 G o t o D i s c o u n t E q u i...

Page 39: ...Level X 42 Hydraulic Oil Level and System leaks X 49 Brake Fluid X 61 Tires for pressure and wear X 56 Hydraulic Oil Cooler X X 52 At First 50 Hours of Use Reference Check Change Clean Page Fan Belt...

Page 40: ...Page Axle Steer Knuckles X 38 Drive Shaft Slip Universal Joints X 38 Rear Axle Pivot Pins X 38 Axle Steer Cylinder Ball Joints X 38 Battery Level X 56 Fan Belt Tension X 48 Axle Oil Level X 53 Wheel...

Page 41: ...ange Clean Page Hydraulic Oil Filter X 50 Travel System Oil Filter X 50 Wheel End Oil X 55 Axle Oil X 54 Transfer Case Oil X 53 Annually Reference Check Change Clean Page Hydraulic Oil Suction Straine...

Page 42: ...pin 1 point A Figure 23 Page 38 Lubricate the following grease fittings using Multi Purpose Grease MPG every 250 hour interval Figs 23 and 24 E Axle steer knuckles 8 points F Axle steer cylinder ball...

Page 43: ...r to clean filter element 4 Clean primary filter element with compressed air or by washing 5522 Origin 2 88 PRECLEANER CLEAN MARKS Figure 25 If using compressed air direct no more than 100 psi from th...

Page 44: ...can cause severe burns or eye injury Wear safety glasses Always turn the cap slowly to the first stop and allow the pressure to escape before removing the cap completely 3 4 5 With the engine cool slo...

Page 45: ...removing the cap completely 1 Turn the engine off and wait for the engine coolant to cool Remove locking hardware from lock cover and pivot cover open Figure 26 2 Remove radiator cap Figure 26 and op...

Page 46: ...ground the carriage shut off engine and engage the parking brake 2 Remove dipstick Figure 29 and check mark on dip stick Figure 30 Oil should be between the full and add mark 3 If oil is below the ad...

Page 47: ...ntervals may be required in dusty condi tions 1 Operate engine until warm approximately 5 minutes 2 Park forklift on a level surface ground the carriage shut off engine and engage the parking brake 3...

Page 48: ...Stop engine Let the oil drain back for a few minutes Check oil level on dipstick Figure 29 and check for leaks at filter and drain plug Retighten filter or drain plug if necessary Page 44 14 Add oil...

Page 49: ...32 5522 Origin 2 88 FUEL PRE FILTER DRAIN COCK II Figure 33 2 Change fuel filter element every 500 hours of operation Pull and release access door latch on the right rear engine access door Raise door...

Page 50: ...ding Fuel Sys tem Raise engine access door all the way up then lower the door and use the door latch to secure the door in place Page 46 NOTE Marginal fuel cleanliness conditions will require fuel sys...

Page 51: ...ver Figure 36 Figure 36 5522 Origin 2 88 2 Loosen the injection pump vent screw on the side of the fuel injection pump Figure 36 3 Pull and release access door latch on the left rear engine access doo...

Page 52: ...r until fuel free from air comes from the injector and Thermo Start fuel line fittings Turn ignition switch OFF Tighten all fittings Page 48 INJECTOR HIGH PRESSURE LINE FITTINGS Figure 38 THERMO START...

Page 53: ...ace A Level Check Daily or 1oHour Intervals 1 Be sure all cylinders are fully retracted 2 Park forklift on a level surface ground the carriage shut off engine and engage the parking brake 5522 Origin...

Page 54: ...e hydraulic oil must be changed when a hydraulic component has contaminated the system 1 Be sure all cylinders are fully retracted 2 Park forklift on a level surface ground the carriage shut off engin...

Page 55: ...ent into heads Tighten 1 2 turn after initial contact 5522 Origin 2 88 7 If hydraulic oil is to be changed remove the locking hardware from the locking fill cap Place a receptacle underthe reservoir d...

Page 56: ...ulic Oil Cooler Daily or 10 Hour Intervals 1 The hydraulic oil cooler is located behind the rear grille to the right of the radiator 2 Clean all dirt and debris off the cooler using com pressed air Pa...

Page 57: ...ase to level plug with 90W gear lube Capacity approx 2 1 qts 2 0 liters 7 Install fill level plug A Level Check 250 Hour Intervals 1 Clean area around the axle fill and level plug Figure 47 and check...

Page 58: ...ousing 3 Allow oil to drain completely 4 Install drain plug Page 54 5 Fill axle to level plug with 90W gear lube Axle capacity is 6 9 quarts 6 5 liters 6 Install fill and level plug Do not perform ser...

Page 59: ...e 1 000 Hour Intervals 1 Park forklift on a level surface ground the carriage shut off engine and engage the parking brake Be sure that the level drain plug on the wheel end housing Figure 49 is posti...

Page 60: ...ilation keep sparks flames and lit cigarettes away from the battery Lead acid batteries generate explosive gases when charging or when the engine is running Wear safety glasses and chemical resistant...

Page 61: ...ked 5 Reinstall cell caps Make sure holes in caps are not plugged 6 Replace battery case cover and secure with the two latches Pivot battery case back into place and tighten handle to secure the batte...

Page 62: ...er over the battery by unhooking the two latches on both sides 3 Clean off the top of the battery around the cell caps 4 Remove the cell caps and check the specific gravity of the electrolyte with a t...

Page 63: ...harge a frozen battery it may explode and cause injury Let the battery warm before putting on a charger Charging rates between 3 and 50 amperes am satisfactory if excessive gassing or spewing of elect...

Page 64: ...heating 15 amp 2 Road Lights 15 amp 3 4 Way Flashers 7 5 amp 4 Horn 7 5 amp 5 Windshield Washer Optional 7 5 amp 6 Not Used 7 Circulation Fan 7 5 amp 8 Directional Signals 7 5 amp 9 Travel Range 7 5 a...

Page 65: ...ent in the brake system has been serviced 5522 a Place machine on a level surface Shut off the engine and engage the parking brake b Make sure the brake reservoir is filled to the Maximum Fluid Level...

Page 66: ...Check After First 50 Hours then When Necessary Thereafter Periodically check the parking brake to see that it will hold the forklift when parked on a grade To readjust the brake follow the procedures...

Page 67: ...f the brake still does not hold the forklift sufficiently after cable adjustment check for wear of the brake linings in the parking brake on the transfer case Replace the brake linings if worn Page 63...

Page 68: ...rthe wear pad s to center the inner boom 7 Extend th e boom fully and lubricate the outer boom slide surfaces with a Multi Purpose Lithium base grease as far into the boom as possible B Front Wear Pad...

Page 69: ...Loosen the four large lock nuts Figure 57 on the top and right side of the outer boom Tighten the wear disc adjustment plugs to bring the wear discs into contact with the boom slides Remove play evenl...

Page 70: ...STEM Differential Housing Capacity 6 9 qts 6 5 liters Capacity 9 qts 8 6 liters Wheel Ends Reducers 1 8 qts 1 75 liters Type of Fluid 50150 Ethylene Glycol and Water Type of Lubricant 90W Gear Lube HY...

Page 71: ...Maximum No Load RPM 2400 rpm Horsepower 76 HP 2200 rpm Torque 197 Lbs Ft 1300 rpm 5522 Origin 2 88 BASIC MACHINE Operating Weight 13 200 lbs 5987 kg Maximum Lift Capacity 5 500 lbs 2495 kg Length les...

Page 72: ...y traveling with no more than rated load DO NOTexceed 22o o grade 12 Figure 58 Page 68 Lateral stability traveling with no load DO NOT exceed 40 o grade 22 Fi ure 59 5522 Origin 2 88 G o t o D i s c o...

Page 73: ...turn with boom up Keep load low Figures 58 59 Longitudinal stability stacking with rated load DO NOT exceed 6 o grade 3 1 2 6 grade 3 1 2 F ure 60 Page 69 G o t o D i s c o u n t E q u i p m e n t c o...

Page 74: ...th rated load lateral stability stacking with no load DO NOT exceed 1Oo o grade 6 DO NOT exceed 0 o grade 6 F re 61 F re 62 5522 Page 70 Origin 2 88 G o t o D i s c o u n t E q u i p m e n t c o m t o...

Page 75: ...NOTES 5522 Origin 2 88 Page 71 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 76: ...NOTES 5522 Page 72 Origin 2 88 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 77: ...G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 78: ...atures In a few easy steps you can Look up prices and availability Identify parts using graphical parts manuals Enter orders using part numbers or order by selecting from graphical parts manuals Revie...

Page 79: ...e needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulotte Barreto Power Blanket Nifty Lift Atlas Copco...

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JLG SKYTRAK 5522, Operator'S And Safety Manual

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