Doosan D100 Disassembly/Assembly

Brand: Doosan

Model: D100

Category: Engine

Type: Disassembly/Assembly

This manual is also suitable for

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).

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DE08TS Diesel Engine Disassembly and Assembly

Tools Needed A

Link Bracket 1

IEED001P

IEED002P

IEED003P

IEED004P

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.

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DE08TS Diesel Engine Disassembly and Assembly

IEED005P IEED008P

IEED009P

IEED010P

IEED006P

IEED007P

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).

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DE08TS Diesel Engine Disassembly and Assembly

IEED011P IEED014P

IEED015P

IEED012P

IEED013P

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 730800 N



(540 590 lb



ft).

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DE08TS Diesel Engine Disassembly and Assembly

Tools Needed A B

Link Bracket 1

Eye Bolt 1

IEED016P IEED017P

IEED016P

IEED014P

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.

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DE08TS Diesel Engine Disassembly and Assembly

IEED013P

IEED012P

IEED011P

IEED010P

IEED009P

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.

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DE08TS Diesel Engine Disassembly and Assembly

IEED008P

IEED006P

IEED005P

IEED004P

IEED003P

IEED007P

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.

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DE08TS Diesel Engine Disassembly and Assembly

IEED018P

IEED019P

IEED002P

IEED001P

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).

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DE08TS Diesel Engine Disassembly and Assembly

IEED020P

IEED021P

IEED019P

IEED018P

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.

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DE08TS Diesel Engine Disassembly and Assembly

IEED022P

IEED166P

IEED020P

IEED021P

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.

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DE08TS Diesel Engine Disassembly and Assembly

IEED023P

IEED024P

IEED025P

IEED026P

IEED118P

IEED117P

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.

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DE08TS Diesel Engine Disassembly and Assembly

IEED028P

IEED027P

IEED028P

IEED027P

IEED024P

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.

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DE08TS Diesel Engine Disassembly and Assembly

IEED028P

IEED026P

IEED025P

IEED023P

IEED117P

IEED118P

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).

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DE08TS Diesel Engine Disassembly and Assembly

IEED029P

IEED166P

IEED022P

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.

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DE08TS Diesel Engine Disassembly and Assembly

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Doosan D100 Disassembly/Assembly

Brand: Doosan

Model: D100

Category: Engine

Type: Disassembly/Assembly

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Doosan D100 Disassembly/Assembly

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Doosan D100 Disassembly/Assembly

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