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Daewoo Doosan DE12T Diesel Engine Service Repair Manual

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Daewoo Doosan DE12T Diesel Engine Service Repair Manual

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  1. 65.99897-8057 MAINTENANCE MANUAL DIESEL ENGINE DE12 DE12T DE12TI DE12TIS PS-MMA0507-E1A

  2. DE12/T/TI/TIS MAINTENANCE MANUAL FOREWORD This maintenance manual is designed to serve as a reference for DAEWOO Heavy Industries Ltd's (here after DAEWOO’s) customers and distributors who wish to gain basic product knowledge on DAEWOO's DE series diesel engines (DE12, DE12T, DE12TI and DE12TIS) These economical and high-performance diesel engines (6 cylinders, 4 strokes, in-line, direct injection type) have been so designed and manufactured to be used for overland transport industrial purpose. That meets all the requirements such as low noise, fuel economy, high engine speed, and durability. To maintain the engine in optimum condition and retain maximum performance for a long time, CORRECT OPERATION and PROPER MAINTENANCE are essential. In this manual, the following symbols are used to indicate the type of service operations to be performed. Removal Adjustment Installation Cleaning Disassembly Pay close attention-Important Reassembly Tighten to specified torque Align the marks Use special tools of manufacturer's Directional Indication Lubricate with oil Inspection Lubricate with grease Measurement During engine maintenance, please observe following instructions to prevent environmental damage; Take old oil to an old oil disposal point only. Ensure without fail that oil and diesel fuel will not get into the sea or rivers and canals or the ground. Printed in Mar. 2001 PS-MMA0507-E1A

  3. DE12/T/TI/TIS MAINTENANCE MANUAL Treat undiluted anti-corrosion agents, antifreeze agents, filter element and cartridges as special waste. The regulations of the relevant local authorities are to be observed for the disposal of spent coolants and special waste. If you have any question or recommendation in connection with this manual, please do not hesitate to contact our head office, dealers or authorized service shops near by your location for any services. For the last, the content of this maintenance instruction may be changed without notice for some quality improvement. Thank you. DAEWOO Heavy Industries & Machinery LTD. Mar. 2001 Printed in Mar. 2001 PS-MMA0507-E1A

  4. DE12/T/TI/TIS MAINTENANCE MANUAL 1. GENERAL INFORMATION 1.1. General Repair Instructions 1. Before performing service operation, disconnect the grounding cable from the battery for reducing the chance of cable damage and burning due to short-circuiting. 2. Use covers for preventing the components from damage or pollution. 3. Engine oil and anti-freeze solution must be handled with reasonable care as they cause paint damage. 4. The use of proper tools and special tools where specified is important to efficient and reliable service operation. 5. Use genuine DAEWOO parts necessarily. 6. Used cotter pins, gaskets, O-rings, oil seals, lock washer and self-lock nuts should be discarded and new ones should be prepared for installation as normal function of the parts can not be maintained if these parts are reused. 7. To facilitate proper and smooth reassemble operation, keep disassembled parts neatly in groups. Keeping fixing bolts and nut separate is very important as they vary in hardness and design depending on position of installation. 8. Clean the parts before inspection or reassembly. Also clean oil ports, etc. using compressed air to make certain they are free from restrictions. 9. Lubricate rotating and sliding faces of parts with oil or grease before installation. 10. When necessary, use a sealer on gaskets to prevent leakage. 11. Carefully observe all specifications for bolts and nuts torques. 12. When service operation is completed, make a final check to be sure service has been done property. 1 GENERALINFORMATION Printed in Mar. 2001 PS-MMA0507-E1A

  5. DE12/T/TI/TIS MAINTENANCE MANUAL 1.2. Engine characteristics 1.2.1. OMEGA combustion bowl The OMEGA combustion bowl is a unit designed to perform high efficiency, low emission combustion. As the rim around the combustion bowl port of the upper of the piston has been machined in a smaller size than the interior of the combustion bowl, strong swirl is produced in the combustion bowl and strong squish flow makes the fuel be mixed more sufficiently with air. Due to the application of OMEGA combustion system and optimal utilization of intake and exhaust port configuration within the cylinder head, the DE12 series diesel engines discharge very low level of hazardous exhaust gases such as smoke, nitrogen oxide, hydrocarbon, or carbon monoxide and thus ensure high performance and low fuel consumption. M1041A 2 GENERALINFORMATION Printed in Mar. 2001 PS-MMA0507-E1A

  6. DE12/T/TI/TIS MAINTENANCE MANUAL 1.3. Engine Specification 1.3.1. Specification Engine Model DE12 DE12T DE12TI DE12TIS Items 4 cycle in-line, Water-cooled type Naturally aspirated 4 cycle in-line, Water-cooled type Turbo charged Direct injection type 4 cycle in-line, Water-cooled type Turbo charged & intercooled Engine type Combustion chamber type Cylinder liner type Replaceable dry liner Timing gear system Gear driven type No. of piston ring Compression ring 2, oil ring 1 3 GENERALINFORMATION Printed in Mar. 2001 PS-MMA0507-E1A

  7. DE12/T/TI/TIS MAINTENANCE MANUAL 1.3.2. Engine power Production tolerance : 5% Engine Model Performance Remark Injection timing (BTDC º) High idle (rpm) Power (PS / rpm) Torque (kg.m / rpm) Low idle (rpm) Model Suffix EBGBA EBGBB EBGBC EBGBD EBGBR EBGBE EBGBF EBGBJ EBGBK EBGBL EBGBM EBGBO EBGBQ 12 225 / 2,200 81.5 / 1,400 600-650 2420 50 DE12 10 230 / 2,200 81 / 1,400 600-650 2420 50 8 228 / 2,200 81.5 / 1,400 600-650 2420 50 EBGCA 12 225 / 2,200 81.5 / 1,400 600-650 2420 50 EBHBA EBHBC DE12T 8 300 / 2,200 110 / 1,300 600-650 2420 50 EBIBA 12 340 / 2,100 135 / 1,260 600-650 2,320 50 EBIBB 9 300 / 2,100 120 / 1,260 600-650 2,320 50 EBIBC 9 280 / 2,100 115 / 1,260 600-650 2,320 50 DE12TI EURO-I EBIBD 9 310 / 2,100 125 / 1,260 600-650 2,320 50 EBICA/ B/C/E/I/ L/M ECIBA ECICA ECICB ECICD ECIBD 12 340 / 2,100 135 / 1,260 600-650 2,320 50 340 / 2,100 1 145 / 1,260 335 / 2,100 2,350- 2,400 ECICC 1 320 / 2,100 135 / 1,260 DE12TIS 600 25 EURO-II ECIBB 1 310 / 2,100 125 / 1,260 1 290 / 2,100 115 / 1,260 ECIBC 1 360 / 2,100 145 / 1,260 ECIBE * Note : All data are based on operation without cooling fan at ISO 1585(SAE J1349). 4 GENERALINFORMATION Printed in Mar. 2001 PS-MMA0507-E1A

  8. DE12/T/TI/TIS MAINTENANCE MANUAL 2) DE12TIS – 340PS Performance ISO 1585 (SAE J1349) Output (max.) 250 kW (340PS) / 2,100 rpm Torque (max) 1,421 N.m (145 kg.m) / 1,260 rpm Fuel consumption (min.) 186 g/kW.h (143 g / PS.h) 6 GENERALINFORMATION Printed in Mar. 2001 PS-MMA0507-E1A

  9. DE12/T/TI/TIS MAINTENANCE MANUAL 3) DE12TIS - 290PS Performance ISO 1585 (SAE J1349) Output (max.) 223 kW (290PS) / 2,100 rpm Torque (max.) 1,127 N.m (115 kg.m) / 1,260 rpm Fuel consumption (min) 186 g/kW.h (143 g / PS.h) 7 GENERALINFORMATION Printed in Mar. 2001 PS-MMA0507-E1A

  10. DE12/T/TI/TIS MAINTENANCE MANUAL 1.4. Engine Assembly 1.4.1. Engine sectional view (longitudinal) 3 4 5 6 7 8 9 10 2 1 11 12 13 14 15 16 17 18 19 1 4 7 10 13 16 19 Cooling water pump Valve spring Push rod Chamber Oil pump Connecting rod Flywheel 2 5 8 11 14 17 Fuel filter Oil filler Piston pin Crank shaft pulley Crank shaft Cam shaft 3 6 9 12 15 18 Valve Tappet Piston Vibration damper Oil pan Flywheel housing 8 GENERALINFORMATION Printed in Mar. 2001 PS-MMA0507-E1A

  11. DE12/T/TI/TIS MAINTENANCE MANUAL 1.4.2. Engine sectional view (cross) 7 8 9 10 6 11 5 12 4 13 3 2 1 14 1 2 3 4 5 6 7 Oil filter Cylinder block Fuel injection pump Alternator Oil cooler Cooling water outlet Fuel injection nozzle 8 9 10 11 12 13 14 Rocker arm Cylinder head cover Cylinder head Exhaust manifold Piston ring Turbocharger Oil suction pipe 9 GENERALINFORMATION Printed in Mar. 2001 PS-MMA0507-E1A

  12. DE12/T/TI/TIS MAINTENANCE MANUAL 1.4.3. Engine assembly views 1) DE12 (Bus) 4 5 6 7 8 20 21 9 3 19 10 2 22 11 1 12 13 14 15 16 17 18 23 24 4 29 30 25 26 27 28 1 2 3 4 5 6 7 8 9 10 Fly wheel Flywheel housing Oil pressure unit Lifting hook Oil cooler Intake manifold Air heater Cooling warning switch Thermostat Oil filler cap 11 12 13 14 15 16 17 18 19 20 Oil level gauge Pilot bearing Oil filter Oil drain plug Oil pan Fuel injection pump Mounting bracket Power steering pump Alternator Fuel filter 21 22 23 24 25 26 27 28 29 30 Air pipe Cooling water pump Air compressor Exhaust manifold Crank shaft pulley Vibration damper Mounting bracket Starting motor Fuel injection nozzle Cooling water pipe 10 GENERALINFORMATION Printed in Mar. 2001 PS-MMA0507-E1A

  13. DE12/T/TI/TIS MAINTENANCE MANUAL 2) DE12TI (Bus) 20 4 5 6 7 8 9 3 19 10 2 21 1 11 12 13 14 15 16 17 18 30 22 23 24 25 31 32 26 27 28 29 23 Air pipe (Air cleaner to turbocharger) Turbocharger Exhaust manifold Crank shaft pulley Vibration damper Mounting bracket Starting motor Air pipe (Intercooler to intake manifold) Cooling water pipe Fuel injection nozzle 1 Fly wheel 12 Pilot bearing 2 3 4 5 6 7 Flywheel housing Oil pressure unit Lifting hook Oil cooler Intake manifold Air heater Air pipe (Turbocharger to intercooler) Thermostat Oil filler cap Oil level gauge 13 14 15 16 17 18 Oil filter Oil drain plug Oil pan Fuel injection pump Mounting bracket Power steering pump 24 25 26 27 28 29 30 8 19 Alternator 9 10 11 20 21 22 Fuel filter Cooling water pump Air compressor 31 32 11 GENERALINFORMATION Printed in Mar. 2001 PS-MMA0507-E1A

  14. DE12/T/TI/TIS MAINTENANCE MANUAL 3) DE12TIS (Truck) 5 6 7 3 4 8 19 9 2 18 10 11 1 20 21 12 17 22 23 13 14 15 16 26 38 39 36 37 27 28 29 30 25 40 24 35 31 32 34 33 1 2 3 4 5 Intake manifold 6 Air heater 7 Air pipe (Intercooler to intake manifold) 8 Thermostat 9 Air-con. Compressor 10 Fan guide 11 Cooling fan Flywheel housing Oil cooler Breather hose Fuel filter 15 16 17 18 19 20 21 Fuel injection pump Engine mounting bracket Power steering pump Alternator Lifting hook(Front) Cooling water pump Oil hose(Power steering pump) 28 29 30 31 32 33 34 Turbocharger Exhaust elbow Cooling delivery pipe Engine mounting bracket Ladder frame Starting motor Fly wheel 22 23 24 25 Fan guide bracket Oil drain plug Fan clutch Air pipe (Turbocharger to intercooler) Air compressor Air pipe (Air cleaner to turbocharger) 35 36 37 38 Pilot bearing Exhaust manifold Cylinder head cover Fuel injection nozzle 12 13 14 Oil filter Oil pan Oil level gauge 26 27 39 40 Cooling water pipe Oil pressure unit 12 GENERALINFORMATION Printed in Mar. 2001 PS-MMA0507-E1A

  15. DE12/T/TI/TIS MAINTENANCE MANUAL NOTE: However, it should not elapse longer than 75 sec, and if it did, the hue would change. (4) Make the numerical value by comparing the test paper which hue has changed with the color list of label on storage bottle. (5) By comparing the hue changed into yellowish green or so with the green color indication of test paper storage bottle, confirm the density. (Then, the density indication must be in the hue range of 33% to 50%). (6) The brown at the middle of test paper and the lower pink color indication represent the additive state for rust prevention, and the proper range is that the meeting numerical value of brown (vertical) and pink color (horizontal) locates in the range of 0.3 to 0.8 at the color list of label on the test paper storage bottle. (7) In case of less than 0.3, replenish the additive for rust prevention (DCA4), and in case of more than 0.8, pour out the cooling water about 50% and then readjust the density after refilling with clean fresh water. Amount of Anti-freeze in winter Ambient temperature ( C) Over -10 -10 -15 -20 -25 -30 -40 Cooling water (%) Anti-freeze (%) 85 80 73 67 60 56 50 15 20 27 33 40 44 50 2.1.2. Fan belt Use a fan belt of specified dimensions, and replace if damaged, frayed, or deteriorated. Check the fan belt for belt tension. If belt tension is lower than the specified limit, adjust the tension by relocating the alternator. (specified deflection: 10 15 mm when pressed down with thumb) 15 MAJOR MAINTENANCE Printed in Mar. 2001 PS-MMA0507-E1A

  16. DE12/T/TI/TIS MAINTENANCE MANUAL 2.1.3. Engine oil Check oil level with the oil level gauge and replenish if necessary. Check the oil level with the engine cooled. If the engine is warm, allow time for 5 level must be between Max and Min. lines on the gauge. 10 minutes for oil drain into the crankcase before checking oil level. The oil Engine oil should be changed at the specified intervals. Oil in the oil filter should be changed simultaneously. After 1,000km (50hr) operation First oil change every 10,000km DE12/T/TI Short-distance operation vehicle (city bus, dump truck) DE12TIS every 20,000km DE12/T/TI every 15,000km Long-distance operation vehicles (express bus, cargo truck) DE12TIS every 30,000km The following oils are also recommended Recommend oil Engine model SAE No. API No. SAE 15W40 above CD or CE DE12/T/TI SAE15W40 SAE10W40 ACEA-E2 or ACEA-E3 (API CH-4) DE12TIS * If long oil change intervals are to be used, ACEA-E3 oil must be used. Engine Oil capacity Engine oil capacity in Oil pan Max. (lit) Engine model Total (lit) Vehicle Min. (lit) DE12 DE12T DE12TI 17 14 21 Bus 17 14 21 Truck Bus Truck DE12TIS 17 14 21 16 MAJOR MAINTENANCE Printed in Mar. 2001 PS-MMA0507-E1A

  17. DE12/T/TI/TIS MAINTENANCE MANUAL 2.1.4. Oil filter Check for oil pressure and oil leaks, and EQM4010I repair or replace the oil filter if necessary. Change the oil filter cartridge simultaneously at every replacement of engine oil. 2.1.5. Fuel filter Drain water in cartridge with loosening the cock under filter manually (6) from time to time. G1019 2.1.6. Air cleaner. In case that elements are deformed, damaged or if the air cleaner has a crack, replace it. By the definite interval, the elements must be cleaned and replaced. 17 MAJOR MAINTENANCE Printed in Mar. 2001 PS-MMA0507-E1A

  18. Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.

  19. DE12/T/TI/TIS MAINTENANCE MANUAL 2.1.7. Intercooler The intercooler is air to air type and has a large cooling fan capacity. The intercooler life and performance depends on the intake air condition greatly. Fouled air pollutes and clogs the air fins of intercooler. As a result of this, the engine output is decreased and engine malfunction is occurred. So you always check whether the intake air systems like air filter element are worn or polluted. Air/air intercooler with radiator (combined radiator) Air flow by cooling fan Hot air by turbo charger compressor Cooled air to intake manifold (max. 50 C) 2.1.8. Valve clearance adjust procedure After letting the #1 cylinder's piston come at the compression top dead center by turning the crankshaft, adjust the valve clearances. Loosen the lock nuts of rocker arm adjusting screws and push the feeler gauge of specified value between a rocker arm and a valve stem and adjust the clearance with adjusting screw respectively and then tighten with the lock nut. As for the valve clearance, adjust it when in cold, as follow. Model DE12 DE12T DE12TI DE12TIS Intake Valve Exhaust Valve 0.3 mm 0.3 mm 1) Rotate the crankshaft to overlap the intake and the exhaust valves of #6, then #1 cylinder become the compression state of top dead center. 2) Therefore adjust the valve clearance corresponding to “ ” of lower figure. At this time there are no force on the push rods of #1 cylinder. 3) Rotating the crankshaft by one revolution, #6 cylinder become the compression 18 MAJOR MAINTENANCE Printed in Mar. 2001 PS-MMA0507-E1A

  20. DE12/T/TI/TIS MAINTENANCE MANUAL state of top dead center. 4) Thereafter adjust the valve clearances corresponding to “ ” of lower figure. 5) After reinsuring the valve clearances, retighten if necessary. No. 1 Cylinder is located at the side where flywheel was installed. Cylinder No. Flywheel Intake Valve Exhaust Valve Cooling Fan G1048 2.1.9. Cylinder compression pressure Stop the engine after warming up, and take out nozzle holder assembly. Install the special tool (compression gauge adapter) at the nozzle holder hole, and connect the compression pressure gauge there. 28kg/cm2 over 24kg/cm2 Standard value Limit value Difference between each cylinder Condition : Water temperature 20 C, Engine rotation 200rpm (10 rotations) Within ± 10 % 19 MAJOR MAINTENANCE Printed in Mar. 2001 PS-MMA0507-E1A

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