RANKO R55 Maintenance Manual

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R55 Forklift

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6450 NE 14th Street

Des Moines, IA 50313

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Page 1 R55 Forklift ,r� [R!;l]�� [r!] [r!]�[r!] � � [R!;l] � [r!] OJJ � 6450 NE 14th Street Des Moines, IA 50313...
Page 2 Ranko R55 Forklift Operator's Maintenance Manual Safety Regulations SAFETY REGULATIONS Any operator shall know and follow the relevant national and local safety regulations, and the safety instructions contained in this manual can be only applied where no national or local regulations exist.
Page 3: Table Of Contents
Ranko R55 Forklift Operator's Maintenance Manual Safety Regulations Ranko R55 Forklift Operator's Maintenance Manual Table of Contents TABLE OF CONTENTS ! Warning ! SAFETY REGULATION---------------- •Any incorrect operation, maintenance or repair is dangerous and may lead to personal injury or death.
Page 4 This manual includes technical performance and parameters, operation & maintenance, safety, common faults and solutions. Due to Thank you for your purchase of the Ranko R55 Forklift! the constant improvement of product design and different customers needs of configuration, you shall obtain complete latest version of Copyright of this operation &...
Page 5: Overview
Ranko R55 Forklift Operator's Maintenance Manual Technical Performance & Parameters Ranko R55 Forklift Operator's Maintenance Manual Technical Performance & Parameters I. Overview Technical Performance & Parameters Machine Logo The nameplate is fixed on the front end of instrument carrier's left side.
Page 6: Technical Parameters
Ranko R55 Forklift Operator's Maintenance Manual Technical Performance & Parameters Ranko R55 Forklift Operator's Maintenance Manual Technical Performance & Parameters II. Technical Parameters • Advanced ergonomics technique, downsized steering wheel, larger operation and upper machine space enlarge the operation view, improve the comfort ability and reduce the operator fatigue;...
Page 7: Instruments & Buttons
I. Instruments & buttons 5511 Rated capacity (lb) Load center distance (in) 9.84 Max. lifting height (ft) The Ranko forklift is well-designed for you by p roviding a pleasant I· Free lifting height (in) and comfortable operation environment. � - Mast tilt angle...
Page 8 Ranko R55 Forklift Operator's Maintenance Manual Operation &Use Ranko R55 Forklift Operator's Maintenance Manual Operation &Use Operation & Instruments Instruments Fig. 2 Diagram of Gauge Board 1. Fuel level gauge 2. Left turn indicator 3. Oil water separator indicator (for imported engine) 4.Preheater indicator...
Page 9 I Attention I Ranko R55 Forklift Operator's Maintenance Manual Operation &Use Ranko R55 Forklift Operator's Maintenance Manual Operation &Use Oil-water sep aration indication light (for forklift with imported Attention: if the light keeps on or twinkling during the operation, it means engine) abnormal charge which needs an immediate check.
Page 10 Ranko R55 Forklift Operator's Maintenance Manual Operation &Use Ranko R55 Forklift Operator's Maintenance Manual Operation &Use Lamp switch This is a push-pull two-gear switch. The O gear means power on, the 1 gear little light is on with width lamp, the 2 gear big light is on with width Speed shift lever 8 (for mechanical truck) lamp.
Page 11 Ranko R55 Forklift Operator's Maintenance Manual Operation &Use Ranko R55 Forklift Operator's Maintenance Manual Operation &Use Warning Others Before moving the load, be sure forks or attachment is locked Steering wheel adjusting handle The tilt angle of the steering column is adjustable to meet needs of the operator. If you pull the Fuel tank cap handle upwards, the steering column will be locked;...
Page 12 Ranko R55 Forklift Operator's Maintenance Manual Operation &Use Ranko R55 Forklift Operator's Maintenance Manual Operation &Use Running-in of New Forklift sound pressure meter in the operator's compartment and a sound level tires meter outside the vehicle. (The may impact the noises to a certain extent if the floor is uneven.)
Page 13 Ranko R55 Forklift Operator's Maintenance Manual Operation &Use Ranko R55 Forklift Operator's Maintenance Manual Operation &Use Driving & Operation • Check the Forklift for any inclination in any direction. If any, there might be troubles with the tires. Find out the cause and eliminate it.
Page 14 • Check the locknut of the • Check the tir es and the air tilting cylinder for tightness pressure for wear and tear; Ranko R55 Forklift Operator's Maintenance Manual Operation &Use Ranko R55 Forklift Operator's Maintenance Manual Operation &Use Attention 1.
Page 15 Attention I Attention I Ranko R55 Forklift Operator's Maintenance Manual Operation &Use Ranko R55 Forklift Operator's Maintenance Manual Operation &Use If nothing abnormal, and travel brake alarm lig ht sends no alarm Attention before startup: indication, then the Forklift can be started.
Page 16 I Attention I I Attention I Ranko R55 Forklift Operator's Maintenance Manual Operation &Use Ranko R55 Forklift Operator's Maintenance Manual Operation &Use • Step on the brake pedal and operate the front-rear shifting • For safe operation of your Forklift, the above inspections must lever.
Page 17 Ranko R55 Forklift Operator's Maintenance Manual Operation &Use Ranko R55 Forklift Operator's Maintenance Manual Operation &Use • Deceleration Adjust the distance between the two forks based on cargo's Mechanical drive Forklift dimension (pull out the position pin and push the forks left or right).
Page 18 If there is forklift failure, you shall report to management • Sharp braking is prohibited in traveling with a load, except in special and call Ranko Service Department. circumstances. • In the circumstance of earring large cargo can block the view of the operator.
Page 19 Ranko R55 Forklift Operator's Maintenance Manual Operation &Use Ranko R55 Forklift Operator's Maintenance Manual Operation &Use • Traction Precautions for using battery The tolling pin at the bottom of counterweight is used for hoisting the Attention truck. When hoisting the forklift, fasten the steel wire to the drag pin •...
Page 20: Safety & Operation
Ranko R55 Forklift Operator's Maintenance Manual Operation &Use Ranko R55 Forklift Operator's Maintenance Manual Operation &Use (grease). If you do not use permanent anti-freezing solution, you must Safety & Operation release all the water in radiation system, clean the system and change new coolant liquid I.
Page 21 Ranko R55 Forklift Operator's Maintenance Manual Operation &Use Ranko R55 Forklift Operator's Maintenance Manual Operation &Use Warning: mast moving, prevent Warning: radiator is hot Mark: fuel mark Mark: hydraulic oil mark hands being nipped. Position: on the radiator Position: filling port of Position: filling port of hydraulic �...
Page 22: Safety Principles
Ranko R55 Forklift Operator's Maintenance Manual Safety & Operation Ranko R55 Forklift Operator's Maintenance Manual Safety & Operation II. Safety Principles mis operation may get yourself or other people hurt. Remember all the rules and regulations during operation and learn all the signals during work to make sure understand all the meaning of signal 1.
Page 23 Ranko R55 Forklift Operator's Maintenance Manual Safety & Operation Ranko R55 Forklift Operator's Maintenance Manual Safety & Operation careful and avoid any clamp or sliding down. • It is stric tly prohibited to have anyone stand on the forks while •...
Page 24 Ranko R55 Forklift Operator's Maintenance Manual Safety & Operation Ranko R55 Forklift Operator's Maintenance Manual Safety & Operation 13. Over-speed is strictly prohibited • People can easily have visual illusion on judgment of distance or altitude of ground at night. Please keep a speed which is proper for •...
Page 25 Ranko R55 Forklift Operator's Maintenance Manual Operation &Use Ranko R55 Forklift Operator's Maintenance Manual Safety & Operation of the gear, please step on the brake pad el to slow down. 16. Safe travel on ramp • When the forklift is traveling on the ramp, if the engine flames out, you must immediately and fully step on the brake pedal •...
Page 26 Never allow sight is blocked. anyone to stand under your forks. Ranko R55 Forklift Operator's Maintenance Manual Safety & Operation Ranko R55 Forklift Operator's Maintenance Manual Safety &...
Page 27 When traveling on a ramp, always keep the forks pointing up to the grade, regardless the direction of traveling. Never travel across the ramp in transverse direction or spiral up a ramp. Ranko R55 Forklift Operator's Maintenance Manual Safety & Operation...
Page 28 Never drastically a hard object. It is prohibited to use the fork tip to handle loads. Ranko R55 Forklift Operator's Maintenance Manual Safety & Operation Ranko R55 Forklift Operator's Maintenance Manual Safety &...
Page 29 Dangerous Ranko R55 Forklift Operator's Maintenance Manual Safety & Operation Ranko R55 Forklift Operator's Maintenance Manual Safety & Operation is heavy, please set fenders, signal, flag or warning light, and put other use other power to start the engine. It can be very dangerous and necessary signals to make sure the passing vehicles can easily identify cause fire.
Page 30 Ranko R55 Forklift Operator's Maintenance Manual Safety & Operation Ranko R55 Forklift Operator's Maintenance Manual Safety & Operation • Mark some contact numbers of • When the Forklift is in operation, fire can easily happen if the some personnel(like doctor, first...
Page 31: Ill.transportation Safety
• It is strictly forbidden to steer on the sloping plate. If necessary, you • Do not u se attachments that are not approved by Ranko or should drive the forklift off the sloping plate and adjust the distributors appointed by Ranko. There may have safety problems direction right before you drive it up again.
Page 32 Ranko R55 Forklift Operator's Maintenance Manual Safety & Operation Ranko R55 Forklift Operator's Maintenance Manual Safety & Operation The Forklift weight: Please see the technical parameter table according to different models. When doing hoisting, please pay attention to the hoisting tool's service load limit.
Page 33: Storage
When considering other ways (loading into containers) of transporting After pulling out the key, operate the working device control lever the Forklift, it needs to be disassembled. Please contact Ranko or the slowly for 2 or 3 times in order to remove the remaining distributors appointed.
Page 34 Warning Ranko R55 Forklift Operator's Maintenance Manual Safety & Operation Ranko R55 Forklift Operator's Maintenance Manual Safety & Operation Operation of the truck after long-term storage 1. Unload the battery from the Forklift and store it at a cool dry place have it charged once a month.
Page 35: Maintenance
3. Please use the regular spare parts provided by Ranko To avoid any personal injury, lay down all the working devices during work. Stop the engine when doing repair work. Pull up the stop brake and well wedge the Forklift.
Page 36 Speed regulator or Check max. speed in techomet injection empty load condition pump Ranko R55 Forklift Operator's Maintenance Manual Storage & Maintenance Ranko R55 Forklift Operator's Maintenance Manual Storage & Maintenance 1. Table of regular maintenance plan Engine...
Page 37 I month 6months (8 hours) (166 h) (l000 h) (2000 hl Check between pedal and bottom scale operation Separation and connection operation and if it is loose Mechanical Remark: change the fluid drive oil when fluid transmission works 200 hours. element (200h) daily...
Page 38 If air exists in brake Abrasion damage pipeline Ranko R55 Forklift Operator's Maintenance Manual Storage & Maintenance Ranko R55 Forklift Operator's Maintenance Manual Storage & Maintenance Steering System Rod, Brake System...
Page 39 Looseness of riveted pin connector Out of shape or damage of Change pipes sprocket 1-2 years Looseness sprocket Ranko R55 Forklift Operator's Maintenance Manual Storage & Maintenance Ranko R55 Forklift Operator's Maintenance Manual Storage & Maintenance of brake drum Electrical System...
Page 40 (only first If these parts become abnonnal before the changing time, please immediately change them. Ranko R55 Forklift Operator's Maintenance Manual Storage & Maintenance Ranko R55 Forklift Operator's Maintenance Manual Storage &...
Page 41 Oil cup of brake liquid Cylinder cap and dust-proof cover of brake master pump and separated pump Fuel soft pipe Scalings and rubber parts inside hydraulic system Ranko R55 Forklift Operator's Maintenance Manual Storage & Maintenance Ranko R55 Forklift Operator's Maintenance Manual Storage &...
Page 42 Keep the oil at a proper level; Drain out t he oil only after the more or less oil volume will do no Ranko R55 Forklift Operator's Maintenance Manual Storage & Maintenance Ranko R55 Forklift Operator's Maintenance Manual Storage & Maintenance to check the air temperature.
Page 43 No smoking and naked fi r e is allowable in refueling or maintenance of fuel system. Properly treat the oil waste. Never directly drain away the oil waste without any treatment. Ranko R55 Forklift Operator's Maintenance Manual Storage & Maintenance Ranko R55 Forklift Operator's Maintenance Manual Storage &...
Page 44 Maintenance of battery • Tighten the battery cap. • If the electrolyte of the battery has frozen, neither charge the battery The electrolyte of battery contains sulfate which generates nor use other power to start the engine which will be very dangerous hydrogen.
Page 45 Carefully move the the battery before in recharge of the battery. it should burn your skin battery shall be properly .._, Ranko R55 Forklift Operator's Maintenance Manual Storage & Maintenance Ranko R55 Forklift Operator's Maintenance Manual Storage & Maintenance • Keep daily check of tires and rims. Do not operate in low pressure.
Page 46 Ranko R55 Forklift Operator's Maintenance Manual Storage & Maintenance Ranko R55 Forklift Operator's Maintenance Manual Storage & Maintenance pressed and will affect the quality. The tire shall be rotated at least Attachment: Tightening torque of the tires: Unit: lb/ft once a month (90 °...
Page 47: Ill. Table Of Maintenance Records
Ranko R55 Forklift Operator's Maintenance Manual Storage & Maintenance Ranko R55 Forklift Operator's Maintenance Manual Storage & Maintenance please comply with related laws and regulations. Ill. Table of Maintenance Records Table of maintenance records 1. The users shall regularly keep maintenance records;...
Page 48: Common Faults & Solution
A, Step on clutch pedal to throw out the fr i ction plate. B, rotate the sliding screw on top of transmission counterclockwise to retract the driving shaft into transmission box. Ranko R55 Forklift Operator's Maintenance Manual Ranko R55 Forklift Operator's Maintenance Manual Common Faults &...
Page 49 I 6, release bearing 18, Friction Plate Ass. Pressure Plate & Cap Ass. slips. 19, Washer 20, Bolt Ranko R55 Forklift Operator's Maintenance Manual Common Faults & Solutions Ranko R55 Forklift Operator's Maintenance Manual " "t � � ' J! �;...
Page 50 Oil overheat Oil level is abnormal Fill or reduce 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 2.2 Mechanical transmission, speed reducer, differential...
Page 51 Ranko R55 Forklift Operator's Maintenance Manual Common Faults & Solutions Ranko R55 Forklift Operator's Maintenance Manual Common Faults & Solutions 2.3.2 Overview a. Bolt loose in interface tighten 2~3.5t fluid transmission forklift adopts introduced technology YQX30(A) fluid Oil leakage b.Sealings failure...
Page 52 43, coller 44, oil fi l ler pipe 45, gasket 46, bolt M8*45 47, bolt M8*35 48, gasket Ranko R55 Forklift Operator's Maintenance Manual Common Faults & Solutions Ranko R55 Forklift Operator's Maintenance Manual Common Faults & Solutions 8, oil filterl...
Page 53 The power is passed to semi-shaft through differential, and finally the hub leads ° ° Ranko R55 Forklift Operator's Maintenance Manual Common Faults & Solutions Ranko R55 Forklift Operator's Maintenance Manual Common Faults &...
Page 54 Inflation pressure 125psi (2t-2.5t) 115psi C 3t-4.0t) E, the tightening moment of the brake bottom plate installing bolt is 155-170ft/lb. ,.., Ranko R55 Forklift Operator's Maintenance Manual Common Faults & Solutions Ranko R55 Forklift Operator's Maintenance Manual Common Faults & Solutions Ill.
Page 55: Steering System
3 .2 Overview 3.6 Failure diagnoisis & solutions 3.3 Steering Cylinder 3 .4 inspection after reinstallation of steering system 3.5 Steering Axle Ranko R55 Forklift Operator's Maintenance Manual Common Faults & Solutions Ranko R55 Forklift Operator's Maintenance Manual Common Faults & Solutions...
Page 56 40, ES type centripetal joint bearing 41, adjusting shim 42, washer14 �3, boltM14'45 44, washer I 0 14s, shim 46, shim Ranko R55 Forklift Operator's Maintenance Manual Common Faults & Solutions Ranko R55 Forklift Operator's Maintenance Manual Common Faults & Solutions ">- '-.
Page 57: Brake System
(Fig. 4-1 brake master pump) Ranko R55 Forklift Operator's Maintenance Manual Common Faults & Solutions...
Page 58 G, Engine flames out. The hand brake device is of mechanical hand pulling soft shaft mechanism. It shares the brake shoe and brake drum together with foot brake. Ranko R55 Forklift Operator's Maintenance Manual Common Faults & Solutions Ranko R55 Forklift Operator's Maintenance Manual Common Faults &...
Page 59: Hydraulic System
Possible reason solution a.Brake system leaks oil. repair Forklift model 60hp 2.4L PSI model Ranko R55 Forklift b.There is air in brake system. Release air type Gear type Main c.Gap between brake shoes is not d1iving Engine power output gear driving Adjust regulator adjusted correctly.
Page 60 (rear chamber) of tilt cylinder, with the other side communicating with low pressure, in order to make mast finish the movement of tilting backward or forward. Ranko R55 Forklift Operator's Maintenance Manual Common Faults & Solutions...
Page 61 Fig. 5-3 Lift cylinder Protection ring 23, Cotter pin Cylinder body M24x2 Shaft sleeve Ranko R55 Forklift Operator's Maintenance Manual Common Faults & Solutions Ranko R55 Forklift Operator's Maintenance Manual Common Faults & Solutions 5.6 Lift cylinder, tilt cylinder diagram (Fig. 5-3, 5-4) �,...
Page 62: Lifting System
Reset fails Operation mechanism is stuck. Adjust Components at the reset position are Reassmble and keep coaxial misaligned Ranko R55 Forklift Operator's Maintenance Manual Common Faults & Solutions Ranko R55 Forklift Operator's Maintenance Manual Common Faults & Solutions 5.7 Failure diagnoisis & solutions phenomeno VI.
Page 63 (ISO) for general use and convient change. of slide f!llide. 5. Inner mast tilts or fork carriae:e is bent. Reoair or reolace. Ranko R55 Forklift Operator's Maintenance Manual Common Faults & Solutions Ranko R55 Forklift Operator's Maintenance Manual Common Faults &...
Page 64 Front signal light Rear combination light 7 .2.2 Preheat Start Switch check the continuity of switch line by universal meter (set ohm) when the switch is at all places Ranko R55 Forklift Operator's Maintenance Manual Common Faults & Solutions Ranko R55 Forklift Operator's Maintenance Manual Common Faults &...
Page 65 Ranko R55 Forklift Operator's Maintenance Manual Common Faults & Solutions Ranko R55 Forklift Operator's Maintenance Manual Common Faults & Solutions 7.2.5 Fuse preheat location function Line color Fuse rated current (A) close horn/brake light White/blue start Working light 7.2.3...
Page 66 The sta1ting period of starter shall not exceed 5 seconds, with 2 minutes interval. If it fails to make engine work the third time, you shall inspect the malfi m ction and do not stai1 again m1til the problem is solved. Ranko R55 Forklift Operator's Maintenance Manual Common Faults & Solutions...
Page 67 13.5V, the problem is on the battery. 2. Repair or replace the battery. 3. Reolace the regulator. Ranko R55 Forklift Operator's Maintenance Manual Common Faults & Solutions Ranko R55 Forklift Operator's Maintenance Manual Common Faults & Solutions...