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2.2 Mechanical transmission, speed reducer, differential

2.2.1 Technical data

Model

JDS30(2-3.5t)/JDS37(3.8t)

Gear shift type

Manual gear shift, lubrication-type synchromesh

Gear no.

Forward 2 gear, reverse 2 gear

Transmission

forward

1/2 gear

3.252/1.407

Speed ratio

reverse

1/2 gear

3.204/1.387

Reduction gear

Spiral bevel gear

Speed reducer

Reduction ratio

2.1

Reduction gear

Straight gear

differential

Reduction ratio

6.182

Reduction gear

Straight bevel gear

Code,grade code

GL-4,85W/90

Lubrication oil

Oil volume

Filling method

Fill through air hole of driving axle casing

2.2.2 Overview

2~3.St mechanical transmission forklift adopts introduced technology JDS30 /JDS37

mechanical transmission which consists of gear-shifting speed change, speed reducer and differential

with function of gear shifting, speed reducing and realizing differential transmission. The

transmission is installed with synchronizer, which realizes soft and stable gear shifting, crash

prevention, noise reduction and extends service life of gear.

The transmission structure, working theory, disassembly and installation, and operation &

maintenance please refer to <JDS30 mechanical transmission operation & maintenance manual>.

2.2.3 JDS30 Mechanical Transmission Structure Diagram ( Fig. 2-2)

Fig. 2-2 Mechanical Transmission Structure Diagram

1 , clutch casing

2, bolt M10*28

3, washer 10

washer 6

7, mechanical

6, clutch cap

8, bearing seat

bolt

transmission casing

11, air plug

12, backup light switch

13, shim

14, box cap

16,

bolt M10*16 17, pin 812*20

18, shim

19, armshaft

21,

bolt M18*20

22, washer 8

23,

bolt M l0*45

24, nutMIO

26, 0 ring 20*2.4

27, taper thread hexagon

28, sliging bolt

29, 0 ring28*3.5

Screw ZGI/2"

31, gear-shifting

32, gear shift yoke

33, spring

34, steel ball

lever

36, 0 ring22*2.4

37, wooddruffkey5*19

38, snap ring

2.2.4 Failure diagnosis & solutions

phenomenon

Possible reason

solution

strong vibration

Looseness of locking bolt in

tighten

installation connection

change

bolt M6*16

10, lock plate

15, box cap shim

20, 0 ring35*3. I

25, plug

30, snap ring

35, dwang

Oil overheat

Fill or reduce

a. Deterioration of gear oil

Oil level is abnormal

Clamping of rotational parts

adjust

Ranko R55 Forklift

Operator's Maintenance Manual

Common Faults & Solutions

Ranko R55 Forklift

Operator's Maintenance Manual

Common Faults & Solutions

Содержание R55

Страница 1: ...R l r r r r R l r OJJ L R55 Forklift 6450 NE 14th Street Des Moines IA 50313...

Страница 2: ...his manual and explai ned where any risk exi sts duri ng the operati on Warning boards have been attached to the machines thus you can identify where special risks exist If you neglect them any injury...

Страница 3: ...ICAL PARAMETERS 2 4 OPERATION us _____________________6 I INSTRUMENTS BUTTONS 6 II BREAKING IN THE NEW FORKLIFT 15 Ill DRIVING OPERATION 17 SAFETY OPERATION__________________32 I SAFETY MARK 32 II SAF...

Страница 4: ...of Operation Use introduces basic operation skills instructive information for daily maintenance And it helps the operator learn right inspection start operation shut down and maintenance intervals Th...

Страница 5: ...forklift truck It is equipped with a PSI engine which is one of most powerful engines in the market with features of easy start low fuel consumption big horsepower and high power reserve coefficient...

Страница 6: ...y or environment full of poisonous gas Operations Forbidden Operators without training qualification During non special circumstance suddenly hit the brakes when the forklift is loaded Travel with loa...

Страница 7: ...base E ft 5 25 Min ground clearance ft 0 5 Fork distance outside Min F Max G mm 244 1040 Front overhang in 18 5 Rear overhang in 21 06 Min turning radius R ft 7 35 Weight without load lb 7980 5 Opera...

Страница 8: ...ndicator Water thermometer 8 Battery charge control lamp 9 Hour meter 10 Alarm light for engine oil pressure Fuel level gauge It Indicates the fuel volume in the tank When the pointer is at the left s...

Страница 9: ...harge indicating light It indicates the state of battery charge This light will be on when the start switch is placed in ON and will go out after the engine starts 9 Attention if the light keeps on or...

Страница 10: ...lift Fig 7 Reverse control handle for fluid Forklift Fig 8 Pedal two reverse gear Please step on the clutch pedal before shifting gear and please stop the Forklift when shifting direction The backup l...

Страница 11: ...ter 180 rotations so that you can move around the fork ffi _1 1 is adjusted to the most suitable position of the I FJ When adjusting the forks the center of the load to be recognizedcorresponds to the...

Страница 12: ...ory which shall not be adjusted at will by the user in the operation lest an overpressure should cause damages to the whole system and the hydraulic elements The noise surrounding the Forklift shall n...

Страница 13: ...here might be troubles with the tires Find out the cause and eliminate it The air pressure of tires shall be maintained in normal status Low air pressure will shorten the working life of tires and dif...

Страница 14: ...pressure for wear and tear 19 for Check the wheel nuts for tightness Check the cooling water Check the overhead guard for distortion and cracks Checkthe cooling oil level Attention 1 check the hydraul...

Страница 15: ...art again after an interval of 2 minutes In the event that the atmosphere temperature is lower than 41 F the preheating system may be used if startup is difficult Turn the startup key to Preheat posit...

Страница 16: ...tep on the clutch and operate the gear shifting lever Loosen the hand brake Step on the accelerator pedal and slowly loosen the clutch pedal at the same time to make the Forklift move forward 23 Step...

Страница 17: ...nce between the two forks based on cargo s dimension pull out the position pin and push the forks left or right Make the forklift directly face the cargo in order to load it When using the forks to fe...

Страница 18: ...is forklift failure you shall report to management and call Ranko Service Department Items must be done after daily work Check the fuel reserve Check the oil level of engine oil pan and clean If the o...

Страница 19: ...ment in anti freezing solution instructions 29 Precautions for using battery I Attention I When the temperature goes down the battery volume will also go down and the electrolyte may freeze Try best t...

Страница 20: ...pter will introduce the positions where the marks are pasted and there illustration Properly protect the safety marks If there is any loss damage of the marks or unclear characters graphs please make...

Страница 21: ...ing Position mast and counterwieght s 33 Mark fuel mark Position filling port of FUEL Dangerous keep away from the fan Position on the engine where is near th fan Mark hydraulic oil mark Position fill...

Страница 22: ...l the rules and regulations during operation and learn all the signals during work to make sure understand all the meaning of signal flags signals and marks as soon as you see them When the operator w...

Страница 23: ...ohibited to have anyone stand on the forks while traveling Please observe the traffic regulations on the driving path Do not cause any obstacle to road traffic especially on road crossing make sure a...

Страница 24: ...personnel in charge of guiding 39 People can easily have visual illusion on judgment of distance or altitude of ground at night Please keep a speed which is proper for lighting Make sure the large lig...

Страница 25: ...ling on the ramp if the engine flames out you must immediately and fully step on the brake pedal then operate the stop brake to stop the forklift If the engine flames out on the ramp grade 20 please i...

Страница 26: ...ks When turning tbe forklift give out signals if there are pedestrians or vehicles Sharp turning at high speed is prohibited because it can cause tip over due to the loss of transverse stability of th...

Страница 27: ...erate c arefully when loading the c argo in strong wind and prevent the Forklift from rolling over When the mast is lifted up to the maximum height please operate disc reetly The movement of lifting t...

Страница 28: ...prevent it from sliding backward When placing the load the mast may be slightly tilted forward to deploy the load and draw back the fork Never drastically engage a load and operate the forks to crash...

Страница 29: ...If the electrolyte in the battery has frozen do not charge the battery or 49 use other power to start the engine It can be very dangerous and cause fire When you charge the battery or use other power...

Страница 30: ...some medicine if necessary 27 make sure you know what to do if fire or injury happens 51 Mark some contact numbers of some personnel like doctor first aid center or fire station in order get in touch...

Страница 31: ...tes should match the wheels distance of the truck 53 Make sure the sloping plate stays still and keep same height of two sides Make sure the surface of sloping plate is clean without lubricant oil sta...

Страница 32: ...t the key No one is allowed in the cabin You can also use 4 steel wires with different length no less than 5cm to hoist according to the center of gravity Keep the Forklift horizontal after being hois...

Страница 33: ...anual 57 Daily Storage Storage Maintenance I Storage 1 Keep the forks horizontally on the flat ground chain is in loose condition to store the forklift Try best to store the Forklift in dry place indo...

Страница 34: ...ock Place two of the same wood blocks under left right sight of the Forklift frame 59 Operation of the truck after long term storage 1 Remove the anti rust oil on the exposed parts 2 Drain the machine...

Страница 35: ...g work Stop the engine when doing repair work Pull up the stop brake and well wedge the Forklift 5 If it is necessary to do the inspection and maintenance when the forks is lifted up make sure to use...

Страница 36: ...oil leakage 0 0 0 0 Lubrication Oil volume cleanness 0 0 0 0 Change engine oil X X X system Change engine oilfilter X X element Visually check leakage of oil pipe oil pump and oil 0 0 0 0 tank Check...

Страница 37: ...hs I year 166 h l000 h 2000 hl 0 0 0 0 0 0 0 0 0 0 0 0 0 0 X X X First time X X 200h 0 0 0 X First time X X 200h 0 0 0 0 0 0 0 0 0 0 0 Check the hub looseness and noise bearing 0 0 0 Wipe clean and re...

Страница 38: ...0 0 I year 2000 h brake operation enough stroke Operation perfonnance 0 0 0 0 Rod Operation perfonnance 0 0 0 0 0 inhaul If looseness of cable 0 0 0 connection Damage leakage 0 0 0 0 0 cracks pipelin...

Страница 39: ...year 1000h 2000h 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 X 1 2years Electrical System item content tool daily 1 month 6months 1 year 8 hours 166h IO00h 2000h Start Pinion 0 motor engagement every 3 0 mon...

Страница 40: ...0 0 0 0 0 0 0 0 0 0 0 time Bottom bolt of lifting 0 cylinder top bolt of piston lnspectio only first 0 0 n hammer rod U shape bolt time Cracks and abrasion of roller roller shaft and 0 0 0 welding po...

Страница 41: ...ring hydraulic system GL 5 85w 90 Axle main drive 2 gal heavy load vehicle and hub reduction gear oil 35 ethylene glycol 100 concentration Remarks the fuel shall meet the national or local standard Th...

Страница 42: ...close to open fire otherwise it will generate toxic gas which will cause poisoning 75 Drain out t he oil only after the forklift is started up and the oil is heated Overhaul of hydraulic system Keep...

Страница 43: ...raulic oil anti freezing liquid and brake fluid can be lit by open fire Please pay attention to following points IAttention I Stop the engine when filling Tuel or lubrication oil No smoking The overfl...

Страница 44: ...use cloth to wipe it Never use the gasoline dissolvent or any other organic dissolvent or detergent 79 Tighten the battery cap If the electrolyte of the battery has frozen neither charge the battery...

Страница 45: ...k if the rim linking bolts and nuts are missing and if the torque of tightened rim linking nuts meet the suggested value of manufacturer When checking the tires do not enter the place in front or behi...

Страница 46: ...he standard inflation pressure is 101psi Attention When disassembling the tires only disassemble the hub nuts item no 5 in the following figure The tire shall be inflated in safety cage In the same ti...

Страница 47: ...ern of Maintenance Records to build their own book of records Maintenance records Serial No _ _ _ _ _ _ _ _ _ Engine No User Name _________Equipment No _ _ _ _ _ _ _ _ _ _ _ _ _ Maintena Mainten mph T...

Страница 48: ...maintenance 2 1 Clutch 2 1 2 Structure Maintenance Fig 2 1 The clutch mainly consists ofpressure plate friction plate clutch casing and release bearing The pressure plate is fixed on the flywheel of...

Страница 49: ...ation of clutch obvious chick sound Use gasol ine to clean then sanding when shifting gears and difficult gear shifting Interval ofrelease bearing is too big Oil or dirt on friction plate Pedal stroke...

Страница 50: ...working theory disassembly and installation and operation maintenance please refer to JDS30 mechanical transmission operation maintenance manual 91 2 2 3 JDS30 Mechanical Transmission Structure Diagr...

Страница 51: ...ially bandied to improve the abrasive resistance of friction plate E The one way exceeding clutch installed in torque converter oil line improves the power transmission efficiency The fluid transmissi...

Страница 52: ...oil seal holder 4L bolt M8 20 46 bolt M8 45 Fig 2 4 Fluid transmission structure 2 filler cap 3 screw assembly 4 torque converter 5 oil supply pump IO hexagonal 7 check ring35 8 oil filterl 9 0 ring3...

Страница 53: ...I 250 1 5 lSPR 7 0 140 psi Mechanical drive forklift9L see3 2 2 4 2 Driving axle diagram Fig 2 5 2 4 3 Overview Driving axle mainly consists of axle housing hub semi shaft brake tire and rim The axle...

Страница 54: ...bolt is 155 170ft lb 99 2 4 5 2 Precautions for reinstallation of connecting bolt between driving axle and truck frame The installation of connecting bolts between driving axle and truck frame adopts...

Страница 55: ...is even and the steering is stable or not B Check whether the hydraulic pipelines is in order and the right and left steering is contrarily installed or not C Jack up the rear wheels and slowly rotat...

Страница 56: ...le 11 adjusting shim 12 U ringB85 110 20 14 nut M12 adjusting shim 15 washer14 16 bearing7221 IE 17 bearing7207E 18 nutM30 2 19 washer30 20 pin6 3 55 2L hub cover 22 hub 23 holding pin 24 nutMIO l 25...

Страница 57: ...ar chamber presses backward in the meantime all the brake liquid inside each separated pump will be compressed by brake shoe return spring and will flow back to mast pump piston front chamber through...

Страница 58: ...Brake shoe withfriction plate I 12 Brake shoe with friction plate I 13 Baseplate assembly assembly front assembly rear 14 Gap adjusting 15 Spring Fitting 16 Pressu spring pull 18 Pressure sleeve assem...

Страница 59: ...e 109 V Hydraulic System 5 I Technical data Main oil pump Multi way valve Speed limit valve Forklift model model type d1iving Rated displacement ml r pressure rated max Psi speed Cr min type Main safe...

Страница 60: ...ve Step on the speed up pedal completely to lift up the forks just in 0 12in range of height tighten again the locking nut 5 5 Hydraulic system oil line Fig 5 2 The high pressure oil coming from the m...

Страница 61: ...Shafi circlip 65 9 Bolt MJ4xJ 5x60 13 Joint bearing 17 Piston 21 Protection ring 25 Shaft sleeve Fig 5 4 Tilt cylinder 2 Guide sleeve 3 Clipping key fo1 4 Retaining collar hole 6 Step seal 7 Useal ri...

Страница 62: ...air the oil cylinder when lifting lever is in Overload valve is worn or stuck by dirt Replace or clean the overload valve the middle Reset spring is damaged or deformed Replace the spring There is dir...

Страница 63: ...distance of 2 91 2 99in guarantee the forks descend to the ground 6 5 2 Tilt the mast backward to adjust tensioning strength of lifting chain and make the tensity ofleft lifting chain and right liftin...

Страница 64: ...raulic oil is of high temperature and or stop to lower the level of oil insufficient capacity and it is also thin capacity Examine the reason of high oil temperature 8 0vcrload Lift as required 119 VI...

Страница 65: ...ss10n oil reache Normal temperature warning light transmission oil l05 C tfhe lube Indicating whether th jVoltage ha _ ow lube pressureengine lube pressure Engine lube pressure owe Normal pressure rea...

Страница 66: ...ube 4 Check and repair 4 Poor contact ofcircuit or circuit 5 Check and change fornew Unable to or break 6 Check whether the coil is in gooc difficult to start 5 Excessive wearing or poor condition whe...

Страница 67: ...if not check the exciting circuit Check whether there is 12V voltage at the B end if not check if the wiring between B end and battery is loosened Otherwise replace the voltage regulator or generator...

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