Clark Forklift 915, (H)Y1015 English O-299 Operator's Manual - PDF DOWNLOAD

lndustrlal Truck Division

C500 100-120 (D) C500 Yl00-150 (D)

Book No. Printing

0-299

May 79 Printing

Clark Equipment Company Customer Service Publications Department Battle Creek, Michigan 49016

INDUSTRIAL TRUCK DIVISION ILLUSTRATION OF MACHINE

C L A A K

C500(H) 100

C500(H)YIOO

C500(H)120

C500(H)Yl30 8001-33

C500(H)Y150 SEP 72

m;m m?mttl

INDUSTRIAL TRUCK DIVISION TABLE OF C ONTENTS

m;m m?mttl

Description BOO! B003

Illustration of machine Specifications OPERATIONS

cooo

C002 C103 C203 c303

Overall controls Instrument Indicators Starting instructions Reserve fuel cut-in valve Safety precautio�s LUBRICATION ANO PREVENTIVE MAINTE·NANCE

(

Time Interval (H-Hours)

Number (0000-)

Description

H 8H 8H 8H 8H 8H 8H 8H 8H 8H

001 000 003 103 203 303 403 503 602 604

Index 8 Hour Lubrication and Preventive Maintenance Pictorial Index Engine crankcase check Engine cooling system check Instrument indicators check Brake pedal free travel, parking brake check Air cleaner check Hydraulic sump and control levers check Tire and rim maintenance Directional tread tires

!OOH !OOH 100H !OOH !OOH !OOH !OOH !OOH !OOH 100H IOOH

000 003 103 203 302 305 403 503 603 701 702

100 Hour Lubrication and Preventive Maintenance Pictorial Index Engine crankcase and oil filter check Cooling system check Fan and generator drive belt check Brake pedal free travel check Brake system check Lifting mechanisms check Hydraulic sump tank breather Battery check Lubrication Chart Key Lubrication Chart

500H 500H 500H 500H 500H 500H

000 003.

103 202 302 403

Lubrication and Preventive Maintenance Pictorial Index Transmission oil filter check Hydraulic sump tank and filter check Steering gear adjust Steering axle and 1 inkage adjustments Manifolds check

1000H 1000H 1000H 1000H 1000H 1000H 1000H 1000H 1000H 1000H 1000H 1000H 1000H 1OOOH

000 603 713 803 805 912 1002 1103 1202 1210 1517 1703 1705 1793

Lubrication and Preventive Maintenance Pictorial Index Starting motor Alternator Steer wheel bearings lubrication Axle ends lubrication Brake bleeding procedure Brake Adjusters Hand brake adjustment Cooling system inspect and clean Thermostat Removal Power Steering Pressure Check Transmission stall and pressure checks Transmission checks Neutral starting switch

•

Page

AOOJ-33

JAN 71

INDUSTRIAL TRUCK DIVISION TABLE OF CONTENTS

., .. : .. · . \

LUBRICATION AND PREVENTIVE MAINTENANCE Time Interval (H-Hours)

Number (0000-)

Description

1000H

1803

Lift and upright adjustments

Page

TROUBLE SHOOTING GUIDE Page

Description

Page

Description

TS TS TS TS TS TS TS

Engine Fuel system Cool ing system Ignition system Starting motor Generator troubles Battery, 1 ights and horn

TS TS TS TS TS TS

Drive axle

001 251 321 341 361 381 401

483 521 531 541 653 963

Steering axle

Steering

Brakes

Hydraulic system Transmission, converter and adaptor (hydratork drive)

axle

I\

AUG 70

A004-19

INDUSTRIAL TRUCK DIVISION

®

CLARKLIFT S00

DIMENSIONAL SPECIFICATIONS

C500-(HJ 100D Rated for 10000 Lbs. 24" Load Center

CAPACITY CHART WITH UPRIGHT VERTICAL

10 00

OVI RHIAO GUARD RCMOVIO roR Ol�(hSIONINC. ruRrOS[S

9

50 OV(RALL WIDIH SID

I

111

•

�

�1

�'-' 6 0

5H rsu

I� ..

..l!i

�a00or.-:-±::-±�c:--:-:E+.,-,+::-:-t-:+fr.c��

s FOR BASIC RICHI ANCU Sl•CKINC AISU ADD LOAD LINCIH

Lo.ad ctntt, 1n 1ncho lrom tronl f.act of fo,h C1p.ac,11u Uto•n .abon ,,, comcuiled ""11h up r,atits ,n .,.,t,ul powt1on l.•lh �bove 162' on St,and,1'd 140 on rSU rN&llfflHT'I to,._ llt•IM cont.a,1 Sou,flc up.ac,11u •1UtttWtC)llon on lfuc, l\imepf.llt

MINIMUM INT£RSCC11NC AISI l WITH•8 •41 IOAO i1

'""°''

UPRIGHT DIMENSION TABLE nu LIFT

MAX. fOH HllCHT

Clark products and SJH.:."t.�11k·n110J1s :in• SUbJ<"C1 to impn)\ (lllWlllS and chat1.).:f'S w1thuu1 not1c-1.�.

r--1

e-;i �, I I

n

10 16

AOIUSIABL(-----< -------:--+--+�

&HJ

I I

11 \I

1

;;I

\ 1 \

STD.

II

84 90

96

102 108 114 120 MAXIMUM fORK HClCHI LOAD!O

f•

--

-

112

Ill

-

144

:

-

150

\ '

fR[[ llfl rrt1lSU LESSLOAO BACKR(Sl UlCNSION

l

-

156

•162 168

-114

•a

l

fR([ LIFT Sl�NOARO

-

180

186

-192 -

198

104 210 216

18

t 1 • 11 IJ

TSU

--

., ol

11& ll5 1 44 153 162

11 14 11 80

-

8l

86 aa 91 92

111 180

-

-

2,1 252

261

Ill 127 136 IJ0 IJ9 115

--

281

-

-

, ,.,

-

58 25 6115

-

66 25

16 15

69 25

-

1615

-

7415

1615

8221 -

-

1615

16 75

-8525 -90 25 -9125 -9815

1615

-

1615

-

1675

16 75

-

101 25

1675

-

109 25 -

106 25

1615

Ill l4J

14 15

50 25 5325

-

m

-219

4115

H ll

-

95 99 99 104 102 107 106 111 109 115 112 120 116 121 119 128

-11• -110

TSU

--

16 IS lo15 16 ll 16a 1615 1615 l&n 1615 1615 1615

96

189

-191 -201 -216 -125

rn,

STD.

16 7l 1615 16 75

-

Pteltutcl ,1ano,,o he11hu

-;------66 ------;......--------106 25

OYUALL HUCHT LOWUED

rn,

t 6 • 1!1 DUALS

AOO 1 10 IH(S! DIM(NSIONS FOR IR1Pl( SIAC( UPRICHI

fCN Dvt,.111 flttrn1 1.11\fO ltU INO �c.lt.rnl Ultn11on .100 Ult lo� IO•una 10 fN.l1Mum lorlt. ht11t11 31 5 hw ,anc,rd vi,1•1hl and 11 aa ,., Hl rsu

UNDUCLUONCU J .u

Ot1vt Arlt

Counltf¥tt•lh1

' 1�

Ct.tClt Clu11inu

JI,

P11ntt0 1n U S A

B011-8

AUG 72

-,

INDUSTRIAL TRUCK DIVISION SPECIFICATIONS RP M Governed Speed (No Load).... 2600 Maximum H.P . @ 2600 RPM .. ·.:-:-"""7".:--;8,...7_-:-:- ­ Maximum torque@ 1500 RPM� lb.--::ft.

1-3-4-2 Firing Order....

GENERAL: 1 0_ 0_ _ 0 _____ _ Vehic1e••••_____C5� 0-'- _0�(H�)�....

Draw Bar Pul1: HYORATORK

Crankcase Capacity:

HYORACOOL

With Filter....______ 8 __Qts. _

Orawbar pull@ .9 c.f. loaded•••.•.••.•.••• 7,900 lbs. 6,900 lbs.

Orawbar pull@ .9 c.f. empty.•..•.•••.•.•,.. 4,340 lbs. 4,340 lbs.

Fuel Tank Capacity..•• ___ ___ 1 8--__G=..... a1.

Travel Speeds (Loaded):

15� Cooling System Capacity•••. _ _ _ ___ 0_t=s.

Lubrication System.•.• {Type)

_ "-MPH 5 '----' Hydratork ••.••• ---�9""'...,.____ MPH 10.1 Hydracool •.••• • Gradeabi I i ty Hydracool (Loaded): Either Trans. W /0 Load•.•. """'25�....2_____ -:-- :"' @ .9 coefficient of friction.

.

Fan Belt Deflection .•.•-----·""5""'0-------'-'in -'-'Torque Converter: 11 Diameter....

Torque Multiplication....

.,_.%

STANDARD

...1JL

FFL-TSU

..:J!L 60 80

60 80

TILT CYLINDER DRIFT: .38(9,6) of tilt cylinder drift, maximum allowable, in 5 minutes with rated load, starting with load raised 12.00(304,8) from floor and upright in full back tilt position.

Value is with 120 Deg. F. oil temperature and Clark MS 68 oi1.

4 to 6 degrees per second rate of tilt at maximum engine R.P.M. and rated load.

16 Deg. 9 Deg. 7 Deg.

TOTAL TILT TIME LIMITS FWD (SEC.) REAR (SEC.) 3.89 2. 19 1.70

3.26 3.30 2.77 1.83 1.86 1.56 1.43 1.45 1.21

NOTE: Specific High Lift Uprights may have slower rate of Tilt Speed.

1!ifilfil: Model....

4.236 Type.....

4 cycle diesel Nunber of cylinders••.• --4 -Bore....

3.875" Stroke..•• _ _ __ _ ,, ___ _ Displacement.... 235.9 cu. in.

SEP 72

Speeds.... 3 FWD/REV Gear Ratio (Forward) First.... 2.24 to----- to _____ _ Second••.. 1.26 Third•.•.• .737 to _ _ _ _ Gear Ratio (Reverse) First.... 2.13 to __ 1---to _____ I _ Second•..• 1.20 to____ Thi rd..... • 70 I-::-:,-Bevel Gears {diff)•.•. 5.286 to .L Transmission Capacity•••• _____12=.5 "" _____ 0�t=s"".

Steer Axle: Axle Alignment; Toe-in...._ ________ o deg.

1 Camber Angle.... deg. deg.

0 Caster.....

TILT SPEED:

Tl LT RANGE

in.

2 to I

Transmission (Standard):

Lifting & Lowering Speeds (FPM): Lift Loaded Empty Lower Loaded Empty

Ful 1 Pressure

HYORATORK TRANSMISSION: 2 FWD/REV Speeds....

Fwd. Lo 1.44:1 Fwd. Hi . 737.1 1,357: 1 Rev. Lo .695: 1 Rev. Hi Axle Adaptor/Transmission/P ower Steering Reservoir (Comnon Sump)••..

18 Qts. WHEELS ANO TIRES: a1 ___ _ 5-=0u : x"'c 16:-'-x'-'1"" Size, 0 rive.•• ·---=::'-2 a;,;:---/8 7 .... x1--2_-"'"1.... __x_._ Size, Steer...._---'18 =-------

SPLIT RIM WHEELS (Torque Specifications): (Ory Thread) t. b.,_ •.:,-f= 0 _ ---'- 1-=__ 0 rive Whee I •..•___ 4,"'Sc"'O:....-...:S""O-cft""".

•:....

O ___ Steer Whee I •.•. __ ....2""'""' ........

S..c. ..3 ---'-I =b.:..

90:....-

B012-7

INDUSTRIAL TRUCK DIVISION SPECIFICATIONS Steering Gear Pitman Arm Lock Nut, Torque to: 120-130 lbs.ft,

Alternator: Volts••••__ 1:...4=-----12 Field Coil Draw (ii) ___§Q_deg. F. (ii) Volts 2.2 to 2.6 AMPS. AMPS. Rated Output.... 22 00"'"0"'--_ Cold Charge (ii) 80 deg. F., (ii) _..2""" Engine RPM•..• 21 AMPS.

Steering Gear Mounting Bolts, s,o..:f_,t..... b..., Torque to: ___7._,5._-...,9:..::0'-------"-'1 ::..

HYDRAULIC SYSTEM: Sump Tank Capacity....

20 gal.

Sump Tank Filter (Replaceable) 10 micron Sump Tank Breather (Replaceable) 5 micron Hydraulic Pumps: Main Pump, (Type)....

Vane _J]_GPM (ii) 1200 Engine RPM (ii) 100

PSI

Steer Pum p, (Type)••___v__ ane_ ______ GPM(ii) 575 RPM, Idle 4.7 6 (Max.) GPM(ii) 710 Engine RPM System Pressure Relief Valve 1500 Setting....

PSI Both at 500 PSI. _§_GPM Flow Control.

Hydraulic Valve: System Pressure Relief Valve Setting.••• PSI 2000 PEDAL FREE TRAVEL:

(,1

Brake Pedal.... • 19 to .SO CI u tch Peda I • ••• • 60 in.

in.

ELECTRICAL SYSTEM: Distributor: Rotation (viewed from cap end)•... cc Point Opening•••• • 021 in. (nominal) Star t Advance (Degrees): Degree (Dist.) .3 to �deg.

Maximum Advance; Degree (Dist.) 7.5 to -9.,_S_deg.

Cam Angle Range•••• _2_2_ to _lLdeg, Distributor Brush Spring Tension (ounces): Measured(ii) Center of Contact•••• 17 to 21 oz.

Measured (ii) Back Edge of Contact•.•• 19 to 23 oz.

Spark Plugs: Gap, Standard (New)••.._-"-.0"'2:..5.___in.

Resistor.... in. .035 8at-tery: Vol ts••••___ ...;..1..:;:.2___ N umber of Cells .... __ -'6"'--_ N umber of Plates••••__2"'3..__ 172 Ampere Hours __1-7""2'-- Hour Rate Starting Motor: No Load Test: Draw Current (Amps.) __5Q__ to ___§Q_ Volts••••__�-max.

Speed (RPM) 5500 min. 9000 B013-6

SEP 72

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