Format: PDF (Printable Document)
File Language: English
File Pages: 1600
File Size: 113.50 MB (Speed Download Link)
Brand: Clark
Model: C60, C70, C75, C80D Doosan Engine Truck Forklift
Book No: SM1157
Part No: 8162025
Type of Document: Service Manual
$ 40
These Clark C60–C80D trucks usually live in rough yards, loading docks, and warehouses, moving heavy pallets and steel all day. This service manual helps you trace faults, strip components in the right order, and put everything back together cleanly on trucks fitted with the Doosan engine. If, for example, the machine starts losing power under load and smoking, this is what you’d use to work through the fuel and air systems step by step, test what’s suspect, and confirm what actually needs to be repaired instead of just guessing.
Applications & Use Cases
FAQ
Q: Can I use this manual on a tablet or laptop in the shop?
A: Yes, it works well digitally so you can zoom diagrams and search quickly while you’re at the truck.
Q: Is it worth printing parts of it?
A: Many techs print only the pages for the job they’re doing and keep them by the machine to avoid getting devices dirty.
Safety Note
Always follow the lockout, blocking, and lifting instructions in this manual before working under or around a raised truck.
SM-1157
CONTENTS
GROUP SA SAFE MAINTENANCE
Section 1 Safety
Section 2 Lifting, Jacking, and Blocking the Truck
Section 3 Towing
GROUP PS PERIODIC SERVICE
Section 1 Maintenance Schedules
Section 2 The Planned Maintenance Program
GROUP 00 ENGINE (Diesel Engine – Model : D34P (DooSan)
Section 1 General and Performance
Section 2 Regular Inspections
Section 3 General Engine Information
Section 4 Cooling System
Section 5 Lubrication System
Section 6 Fuel System
Section 7 Intake / Exhaust System
Section 8 Cylinder Block / Head
Section 9 Electrical System
Section 10 Other / Driving System
Section 11 DCU Error Code List
Section 12 ECU Error Code List
GROUP 01 ENGINE COOLING SYSTEM
Section 1 Specifications and Description
Section 2 Troubleshooting
Section 3 Testing and Maintenance
Section 4 Radiator Removal and Replacement
GROUP 03 INTAKE AND EXHAUST SYSTEM
Section 1 Specifications and Description
Section 2 Troubleshooting
Section 3 Intake System Service
Section 4 Exhaust Systems
GROUP 07 TRANSMISSION – Model : 3WG-94EC (for Diesel Truck)
Section 1 Layout (3WG-94C)
Section 2 Measuring Points and Connections
Section 3 Disassembly
Section 4 Reassembly
Section 5 Removal and Installation
Section 6 AEB Setting of T/M Controller Clutch & Inching Calibration
Section 7 Troubleshooting
GROUP 13 ELECTRICAL SYSTEM
Section 1 Electrical System Cautions
Section 2 Specifications and Features
Section 3 Electrical Circuit Diagram & Electrical Parts Arrangement
Section 4 Instrument Pod
Section 5 Electrical Components Specification and Operation
Section 6 Air Conditioning System (Option)
GROUP 20 (D) DRIVE AXLE
Section 1 System Operation
Section 2 Differential Carrier Assembly
Section 3 Drive Axle
Section 4 Problem and Cause
Section 5 Disassembly and Reassembly
Section 6 Removal and Installation
GROUP 22 WHEELS AND TIRES
Section 1 Specifications and Description
Section 2 Pneumatic Wheels and Tires
GROUP 23 BRAKE SYSTEM
Section 1 Braking / Inching System Specifications and Description
Section 2 Service Brake Troubleshooting
Section 3 Brake / Inching Pedals and Linkages Adjustments
Section 4 Brake System Bleeding
Section 5 Brake Valve Service
Section 6 Parking Brake Service
GROUP 25 STEERING COLUMN AND GEAR
Section 1 Specifications and Description
Section 2 Troubleshooting
Section 3 Steering Column and Component Removal and Replacement
Section 4 Steering System Relief Pressure Check and Adjustment
Section 5 Steering Gear Overhaul
GROUP 26 STEER AXLE
Section 1 Specifications and Description
Section 2 Steer Axle Bearing Maintenance and Adjustment
Section 3 Removal and Replacement
Section 4 Overhaul
Section 5 Steer Cylinder Removal and Replacement
Section 6 Steer Cylinder Overhaul
GROUP 29 HYDRAULIC SUMP, FILTERS, AND PUMP
Section 1 Specifications and Description
Section 2 Main Hydraulic Pump Troubleshooting
Section 3 Main Hydraulic Pump Removal and Installation
GROUP 31 HYDRAULIC CONTROL VALVE (DAESUNG NACHI)
Section 1 Operation of Hydraulic Control Valve
Section 2 Hydraulic Circuit
Section 3 Disassemblying Hydraulic Valve
Section 4 Assemblying Hydraulic Control Valve
Section 5 Hydraulic System Pressure Checks and Adjustments
Section 6 Hydraulic Control Valve Removal and Replacement
Section 7 Testing Hydraulic Valve
Section 8 EHL Valve Disassembly and Assembly
GROUP 32 TILT CYLINDERS
Section 1 Specifications and Description
Section 2 Checks and Adjustments
Section 3 Removal and Replacement
Section 4 Overhaul
GROUP 34 UPRIGHTS
Section 1 Specifications and Description
Section 2 Troubleshooting
Section 3 Inspection
Section 4 Carriage and Upright Roller Clearance Checks and Shim Adjustments
Section 5 Cylinder Removal, Shimming, Overhaul, and Replacement
Section 6 Chain Inspection, Adjustment, and Replacement
Section 7 Fork and Carriage Removal and Replacement
Section 8 Removal and Replacement
GROUP 38 COUNTERWEIGHT AND CHASSIS
Section 1 Specifications and Description
Section 2 Removal and Replacement
Section 3 Overhead Guard / Operator’s Cell Removal and Replacement
Section 4 Floorboard, Cowls, and Seat Deck Removal and Replacement
Section 5 Operator’s Seat Removal and Replacement
GROUP 40 SPECIFICATIONS
Section 1 Nameplates and Decals
Section 2 General Specifications
Section 3 Hydraulic Fitting Tightening Procedure
