Page is loading ...
DE08TS Diesel Engine
Disassembly & Assembly
D100, D120, D150
D110S-5, D130S-5, D160S-5
SB2088E02
Sep. 2011
Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary training,
skills and tools to perform these functions properly.
Improper operation, Iubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any Iubrication, maintenance or repair on this product, until you have read and
understood the operation, Iubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not
heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "WARNING" as
shown below.
The meaning of this safety alert symbol is as follows :
Attention! Become Alert! Your Safety is Involved.
The Message that appears under the warning, explaining the hazard, can be either written or pictorially presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in this publication.
DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this
publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the operation, Iubrication,
maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product.
Obtain the complete and most current information before starting any job. DOOSAN dealers have the most current
information available.
WARNING
1 of 76
Index
Air Cleaner Assembly ...........................................24
Air Cleaner Elements.............................................25
Air Compressor (if equipped).................................72
Alternator ...............................................................12
Camshaft And Camshaft Bearing ..........................61
Connecting Rod Bearings......................................48
Cooling Water Pipe................................................41
Crankshaft..............................................................69
Crankshaft Pulley...................................................63
Cylinder Head ........................................................49
Cylinder Head Cover..............................................34
Cylinder Liners.......................................................57
Electric Starting Motor............................................11
Engine And Transmission........................................5
Exhaust Manifold ...................................................33
Fan Assembly ........................................................26
Fan Belts................................................................26
Flywheel.................................................................64
Flywheel Housing...................................................68
Fuel Filter...............................................................18
Fuel Injection Lines................................................17
Fuel Injection Nozzle Assembly.............................20
Fuel Injection Pump ...............................................13
Fuel Pump..............................................................19
Fuel Strainer ..........................................................18
Intake Manifold.......................................................31
Muffler....................................................................22
OIl Cooler...............................................................39
Oil Filter..................................................................38
Oil Pan ...................................................................34
Oil Pump ................................................................42
Pistons ...................................................................53
Radiator .................................................................28
Rocker Shaft ..........................................................46
Rocker Shaft And Push Rods ................................45
Timing Gear Case..................................................60
Timing Gear Case Cover .......................................58
Timing Gears .........................................................58
Water Pump...........................................................35
Water Temperature Regulator ...............................27
Disconnect batteries before performance of any
service work
WARNING
Engine
Remove Engine And
Transmission
A10999 & D40999 - 02
Start By :
a. Remove overhead guard.*
b. Remove floorplate.*
c. Remove hood.*
d. Remove air cleaner.
e. Remove universal joint.*
* This operation is in the Vehicle Systems,
Disassembly And Assembly Manual.
1. Drain the coolant from the radiator.
2. Remove engine harness assembly (1) from the
clips of bonnet assembly (3).
3. Remove screws, washers and circuit breaker (2)
from bonnet assembly (3).
4. Remove bolt and washer that hold bonnet
assembly. Remove bonnet assembly (3) from the
frame.
5. Remove bolts (4), washers and nuts that hold
coolant reservoir on the frame. Set coolant
reservoir (5) aside.
6. Disconnect two hoses (6) from the fuel tank.
7. Disconnect wiring harness (7) from fuel sender.
8. Remove tube (8) from the tube of air compressor
(if equipped).
5 of 76
DE08TS Diesel Engine Disassembly and Assembly
Tools Needed A
Link Bracket 1
IEED001P
IEED002P
IEED003P
IEED004P
2
5
4
7
6
3
8
1
9. Remove two bolts washers (9) and hydraulic filter
assembly (10). Set hydraulic filter assembly (10)
aside.
10. Disconnect battery cable (11) from the starting
motor.
11. Disconnect transmission neutral switch connector
(12).
12. Disconnect ground cable (13) from the alternator.
13. Disconnect three hoses (14) from the hydraulic
pump.
NOTE : Plug and cap all hydraulic connectors and hoses
to avoid debris and contamination from entering the
system.
14. Remove bolts (15) and washers that hold the
muffler expansion on exhanst manifold of the
engine.
6 of 76
DE08TS Diesel Engine Disassembly and Assembly
IEED005P IEED008P
IEED009P
IEED010P
IEED006P
IEED007P
9
11
14
15
12
10
13
15. Disconnect two transmission cooling hoses (16)
from the transmission.
16. Disconnect transmission oil temperature switch
wiring (17).
17. Disconnect two engine cooling hoses (18 ) from
the engine.
18. Remove bolts (19), washers, nuts from the two
engine support (20), one on both side of the
engine.
19. Remove bolts (21), washers and nuts from the
two transmission support.
NOTE : At this point, make a final check to be sure all
removals and disconnections have been made from
the engine and the transmission.
20. Install the tool (A) to the transmission. Fasten tool
(A) to the engine and transmission as shown.
21. Remove engine and transmission (22) from the
lift truck.
22. Put the engine and transmission on an
acceptable engine stand. Remove tool (A).
7 of 76
DE08TS Diesel Engine Disassembly and Assembly
IEED011P IEED014P
IEED015P
IEED012P
IEED013P
17
16
21
18
22
A
20
19
23. Support transmission (24) with fasten a strap and
remove twenty bolts(23) and washers. Remove
transmission (24) from engine (25).
Install Engine And Transmission
A10999 & C40999 - 03
1. Put transmission (24) in position in engine (25).
2. Install bolts (23) and washers that hold
transmission to the engine. Tighten bolts (23) to
torque of 55 10 N
m (40 7 lb
ft).
3. Install the tool (A) to the transmission.
4. Fasten tool (A) to engine and transmission (22) as
shown.
5. Put the engine and transmission in position on the
lift truck. Make an alignment of supports with the
frame.
6. Install bolts (21), washers and nuts that hold the
transmission support to the frame.
Tightenbolts (21) to atorque of 730800 N
m
(540 590 lb
ft).
8 of 76
DE08TS Diesel Engine Disassembly and Assembly
Tools Needed A B
Link Bracket 1
Eye Bolt 1
IEED016P IEED017P
25
23
A
22
24
IEED016P
25
23
24
IEED014P
21
7. Install bolts (19), washers and nuts that hold
engine support (20) to the frame. Tighten bolts (19)
to a torque of 280 N
m (205 lb
ft).
8. Connect two engine cooling hoses (18) and tighten
the hose clamps.
9. Connect two transmission cooling hoses (16) to
transmission.
10. Connect transmission oil temperature switch
connector (17).
11. Install bolts (15) and washers that hold the muffler
expansion to exhaust manifold of the engine.
12. Connect three hydraulic hoses (14) to the
hydraulic pump.
9 of 76
DE08TS Diesel Engine Disassembly and Assembly
IEED013P
20
19
IEED012P
18
IEED011P
17
16
IEED010P
15
IEED009P
14
13. Connect ground cable (13) to the alternator.
14. Connect transmission neutral switch connector
(12).
15. Connect battery cable(11) to the starting motor.
16. Put hydraulic filter assembly (10) in position on
the frame. Install bolts (9) and washers.
17. Install tube (8) to the air compressor (if
equipped).
18. Connect wiring harness (7) to the fuel sender.
19. Connect two fuel hoses (6) and tighten the hose
clamp.
10 of 76
DE08TS Diesel Engine Disassembly and Assembly
IEED008P
13
IEED006P
11
IEED005P
9
10
IEED004P
8
IEED003P
7
6
IEED007P
12
20. Put the coolant reservoir with bracket (5) in
position on the frame. Install bolts (4) and
washers that hold coolant reservoir (5).
21. Put bonnet assembly (3) in position on the frame.
Install the bolts and washers. Tighten the bolts to
a torque of 200 N..m (150 lb..ft).
22. Install the screws and washers that hold circuit
breaker (2).
23. Clear engine harness assembly (1).
24. Fill the cooling system. See the Maintenance
Guide for the correct level.
End By :
a. Install universal joint.
b. Install air cleaner.
c. Install hood.
d. Install floorplate.
e. Install overhead guard.
Electric Starting Motor
Remove Electric Starting Motor
A61564 - 02
Disconnect the battery before the starting motor
is removed
1. Put identification on the starting motor and
solenoid wires. Disconnect wirings (1) and battery
cable (2).
2. Remove mounting nuts (3) and then remove
starting motor (4) from the lift truck.
11 of 76
DE08TS Diesel Engine Disassembly and Assembly
IEED018P
IEED019P
1
2
4
3
IEED002P
5
4
IEED001P
2
3
1
WARNING
Install Electric Starting Motor
A61564 - 03
1. Put starting motor (4) in position on the flywheel
housing and install nuts (3) that hold it.
2. Connect wirings (2) to the starting motor and
solenoid. Connect battery positive cable (1).
Alternator
Remove Alternator B31018 - 02
1. Put identification on all wires (1) and the
disconnect them from alternator (6).
2. Disconnect ground cable (2) from alternator (6).
3. Loosen nuts (4) and then remove belt (3) from the
alternator.
4. Remove bolts (5) from the alternator’s bracket to
remove alternator (6).
12 of 76
DE08TS Diesel Engine Disassembly and Assembly
IEED020P
IEED021P
1
5
4
6
5
3
2
6
IEED019P
4
3
IEED018P
1
2
Install Alternator B31018 - 03
1. Put alternator (6) in position on its bracket and
install bolts (5) that hold it.
2. Install fan belt (3) on the alternator and tighten nuts
(4).
3. Connect all wires (1) to their respective positions.
4. Connect ground cable (2) to alternator (6).
Fuel Injection Pump
Remove Fuel Injection Pump
A25663 - 02
Start By :
a. Remove air compressor (if equipped).
b. Remove intake manifold.
1. Remove two bolts (1) and washers.
2. Remove bolt (2), washers, spacer (3) and lifting
bracket (4).
3. Remove bolts (5) and washers that hold the
tension adjusting bracket on the timing gear case.
4. Remove the idle pulley and V-belt tension
adjusting bracket assembly (6) and gasket.
Discard the gasket.
13 of 76
DE08TS Diesel Engine Disassembly and Assembly
IEED022P
IEED166P
IEED020P
1
6
5
3
4
1
2
6
2
IEED021P
5
4
6
5
3
5. Remove bolts (7), washers and cover (8).
6. Make an alignment of the timing marks on fuel
injection pump gear (9) and the idle gear or put a
mark of identification on the gears for correct
installation.
7. Remove nut (10) from the injection pump coupling.
8. Remove nut (11) and injection pump coupling and
gear (9) from the injection pump.
9. Disconnect accel rod (12) and engine stop cable
(13).
10. Disconnect five hoses (14) and tubes (15) from
the injection pump.
14 of 76
DE08TS Diesel Engine Disassembly and Assembly
IEED023P
IEED024P
IEED025P
IEED026P
12
8
7
9
14
14
14
15
13
IEED118P
IEED117P
10
11
9
11. Remove four nuts (16) and washers that hold the
injection pump in place. Remove the gasket and
discard it.
12. Support injection pump (17). Remove two bolts
(18) and washers that hold injection pump (17) on
the block. Remove injection pump (17).
Install Fuel Injection Pump
A25663 - 03
1. Install the new gasket in position on the timing
gear case. Put fuel injection pump (17) in position
on the timing gear case.
2. Make sure the timing marks or the marks that were
put on the fuel injection pump gear (9) and the idle
gear are in alignment.
3. Install four nuts (16) and washers that hold the fuel
injection pump on the timing gear case.
15 of 76
DE08TS Diesel Engine Disassembly and Assembly
IEED028P
17
IEED027P
IEED028P
16
IEED027P
16
18
17
IEED024P
9
4. Put the fuel injection pump drive coupling and gear
(9) in position. Make an alignment of the key and
the groove (slot) in the coupling.
5. Install nut (11) that hold the injection pump drive
coupling and gear (9) in place. Tighten nut (11) to
a torque of 130 N
m (96 lb
ft).
6. Install nut (10) into the injection pump coupling.
7. Install cover (8), bolts (7) and washers.
8. Install bolts (18) and washers that hold the
injection pump on the block.
9. Connect three hoses (14) and tube (15) to the
injection pump.
10. Connect accel cable (12) and engine stop cable
(13) to the injection pump.
16 of 76
DE08TS Diesel Engine Disassembly and Assembly
IEED028P
IEED026P
14
14
14
15
IEED025P
12
13
18
IEED023P
8
7
IEED117P
10
IEED118P
11
9
11. Install the new gasket on the timing gear case.
12. Put the idle pulley and V-belt tension adjusting
bracket assembly (6) on the timing gear case and
install bolts (5) and washers.
13. Install lifting bracket (4), spacer (3), washers and
bolts (2) on the block.
14. Install two bolts (1) and washers.
End By :
a. Install air compressor (if equipped).
b. Install intake manifold.
Fuel Injection Lines
Remove Fuel Injection Lines
A23525 - 02
1. Disconnect fuel injection lines (1) from the fuel
injection nozzle assemblies and the fuel injection
pump.
Install Fuel Injection Lines
A23525 - 03
2. Connect fuel injection lines (1) to the fuel injection
pump and the fuel injection nozzle assemblies.
Tighten the fuel line nuts toatorque of
16 to20 N
m (12 to 15 lb
ft).
17 of 76
DE08TS Diesel Engine Disassembly and Assembly
IEED029P
1
IEED029P
1
IEED166P
5
6
IEED022P
3
4
1
2
Fuel Filter
Remove Fuel Filter A21357SE - 02
1. Loosen bolt (1). Remove bowl (2).
2. Remove fuel filter.
Install Fuel Filter A21357SE - 03
1. Install a new gasket in the filter bowl.
2. Put a new fuel filter element in position.
3. Put filter bowl (2) in position and tighten bolt (1)
that holds the bowl in position.
Fuel Strainer
Remove & Install Fuel Strainer
A21357PR - 01
1. Remove bolt (1) and washers and disconnect fuel
line (2) that connected the fuel tank.
2. Remove bolt (3), washers and fuel strainer (4) from
the injection pump.
3. Install fuel strainer (4) in reverse order of removal.
18 of 76
DE08TS Diesel Engine Disassembly and Assembly
IEED031P
IEED030P
2
1
3
4
1
2
IEED030P
2
1
/