Daewoo Doosan DE12TI Diesel Engine Service Repair Manual.pdf
- 2. DE12/T/TI/TIS MAINTENANCE MANUAL Printed in Mar. 2001 PS-MMA0507-E1A 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.
- 3. DE12/T/TI/TIS MAINTENANCE MANUAL Printed in Mar. 2001 PS-MMA0507-E1A 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
- 4. DE12/T/TI/TIS MAINTENANCE MANUAL 1 Printed in Mar. 2001 PS-MMA0507-E1A GENERAL INFORMATION 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.
- 5. DE12/T/TI/TIS MAINTENANCE MANUAL 2 Printed in Mar. 2001 PS-MMA0507-E1A GENERAL INFORMATION 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
- 6. DE12/T/TI/TIS MAINTENANCE MANUAL 3 Printed in Mar. 2001 PS-MMA0507-E1A GENERAL INFORMATION 1.3. Engine Specification 1.3.1. Specification Engine Model Items DE12 DE12T DE12TI DE12TIS Engine type 4 cycle in-line, Water-cooled type Naturally aspirated 4 cycle in-line, Water-cooled type Turbo charged 4 cycle in-line, Water-cooled type Turbo charged & intercooled Combustion chamber type Direct injection type Cylinder liner type Replaceable dry liner Timing gear system Gear driven type No. of piston ring Compression ring 2, oil ring 1
- 7. DE12/T/TI/TIS MAINTENANCE MANUAL 4 Printed in Mar. 2001 PS-MMA0507-E1A GENERAL INFORMATION 1.3.2. Engine power Production tolerance : 5% Engine Model Performance Model Suffix Injection timing (BTDC º) Power (PS / rpm) Torque (kg.m / rpm) Low idle (rpm) High idle (rpm) Remark EBGBA EBGBB EBGBC EBGBD EBGBR 12 225 / 2,200 81.5 / 1,400 600-650 2420 50 EBGBE EBGBF EBGBJ EBGBK EBGBL EBGBM 10 230 / 2,200 81 / 1,400 600-650 2420 50 EBGBO EBGBQ 8 228 / 2,200 81.5 / 1,400 600-650 2420 50 DE12 EBGCA 12 225 / 2,200 81.5 / 1,400 600-650 2420 50 DE12T EBHBA EBHBC 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 EBIBD 9 310 / 2,100 125 / 1,260 600-650 2,320 50 DE12TI EBICA/ B/C/E/I/ L/M 12 340 / 2,100 135 / 1,260 600-650 2,320 50 EURO-I 340 / 2,100 ECIBA ECICA ECICB ECICD ECIBD 1 335 / 2,100 145 / 1,260 ECICC 1 320 / 2,100 135 / 1,260 ECIBB 1 310 / 2,100 125 / 1,260 ECIBC 1 290 / 2,100 115 / 1,260 DE12TIS ECIBE 1 360 / 2,100 145 / 1,260 600 25 2,350- 2,400 EURO-II * Note : All data are based on operation without cooling fan at ISO 1585(SAE J1349).
- 8. DE12/T/TI/TIS MAINTENANCE MANUAL 6 Printed in Mar. 2001 PS-MMA0507-E1A GENERAL INFORMATION 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)
- 9. DE12/T/TI/TIS MAINTENANCE MANUAL 7 Printed in Mar. 2001 PS-MMA0507-E1A GENERAL INFORMATION 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)
- 10. DE12/T/TI/TIS MAINTENANCE MANUAL 8 Printed in Mar. 2001 PS-MMA0507-E1A GENERAL INFORMATION 1.4. Engine Assembly 1.4.1. Engine sectional view (longitudinal) 1 Cooling water pump 2 Fuel filter 3 Valve 4 Valve spring 5 Oil filler 6 Tappet 7 Push rod 8 Piston pin 9 Piston 10 Chamber 11 Crank shaft pulley 12 Vibration damper 13 Oil pump 14 Crank shaft 15 Oil pan 16 Connecting rod 17 Cam shaft 18 Flywheel housing 19 Flywheel 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
- 11. DE12/T/TI/TIS MAINTENANCE MANUAL 9 Printed in Mar. 2001 PS-MMA0507-E1A GENERAL INFORMATION 1.4.2. Engine sectional view (cross) 1 Oil filter 8 Rocker arm 2 Cylinder block 9 Cylinder head cover 3 Fuel injection pump 10 Cylinder head 4 Alternator 11 Exhaust manifold 5 Oil cooler 12 Piston ring 6 Cooling water outlet 13 Turbocharger 7 Fuel injection nozzle 14 Oil suction pipe 1 2 3 4 5 6 7 8 9 10 11 12 14 13
- 12. DE12/T/TI/TIS MAINTENANCE MANUAL 10 Printed in Mar. 2001 PS-MMA0507-E1A GENERAL INFORMATION 1.4.3. Engine assembly views 1) DE12 (Bus) 1 Fly wheel 11 Oil level gauge 21 Air pipe 2 Flywheel housing 12 Pilot bearing 22 Cooling water pump 3 Oil pressure unit 13 Oil filter 23 Air compressor 4 Lifting hook 14 Oil drain plug 24 Exhaust manifold 5 Oil cooler 15 Oil pan 25 Crank shaft pulley 6 Intake manifold 16 Fuel injection pump 26 Vibration damper 7 Air heater 17 Mounting bracket 27 Mounting bracket 8 Cooling warning switch 18 Power steering pump 28 Starting motor 9 Thermostat 19 Alternator 29 Fuel injection nozzle 10 Oil filler cap 20 Fuel filter 30 Cooling water pipe 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 25 23 24 4 26 27 28 29 30
- 13. DE12/T/TI/TIS MAINTENANCE MANUAL 11 Printed in Mar. 2001 PS-MMA0507-E1A GENERAL INFORMATION 2) DE12TI (Bus) 1 Fly wheel 12 Pilot bearing 23 Air pipe (Air cleaner to turbocharger) 2 Flywheel housing 13 Oil filter 24 Turbocharger 3 Oil pressure unit 14 Oil drain plug 25 Exhaust manifold 4 Lifting hook 15 Oil pan 26 Crank shaft pulley 5 Oil cooler 16 Fuel injection pump 27 Vibration damper 6 Intake manifold 17 Mounting bracket 28 Mounting bracket 7 Air heater 18 Power steering pump 29 Starting motor 8 Air pipe (Turbocharger to intercooler) 19 Alternator 30 Air pipe (Intercooler to intake manifold) 9 Thermostat 20 Fuel filter 31 Cooling water pipe 10 Oil filler cap 21 Cooling water pump 32 Fuel injection nozzle 11 Oil level gauge 22 Air compressor 1 2 3 4 5 6 7 8 9 10 11 19 20 21 22 23 24 25 30 31 32 26 27 28 29 12 13 14 15 16 17 18
- 14. DE12/T/TI/TIS MAINTENANCE MANUAL 12 Printed in Mar. 2001 PS-MMA0507-E1A GENERAL INFORMATION 3) DE12TIS (Truck) 1 Flywheel housing 15 Fuel injection pump 28 Turbocharger 2 Oil cooler 16 Engine mounting bracket 29 Exhaust elbow 3 Breather hose 17 Power steering pump 30 Cooling delivery pipe 4 Fuel filter 18 Alternator 31 Engine mounting bracket 5 Intake manifold 19 Lifting hook(Front) 32 Ladder frame 6 Air heater 20 Cooling water pump 33 Starting motor 7 Air pipe (Intercooler to intake manifold) 21 Oil hose(Power steering pump) 34 Fly wheel 8 Thermostat 22 Fan guide bracket 35 Pilot bearing 9 Air-con. Compressor 23 Oil drain plug 36 Exhaust manifold 10 Fan guide 24 Fan clutch 37 Cylinder head cover 11 Cooling fan 25 Air pipe (Turbocharger to intercooler) 38 Fuel injection nozzle 12 Oil filter 26 Air compressor 39 Cooling water pipe 13 Oil pan 27 Air pipe 40 Oil pressure unit 14 Oil level gauge (Air cleaner to turbocharger) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 22 23 21 20 19 18 26 27 28 29 30 25 24 31 32 33 35 36 37 38 39 40 34
- 15. DE12/T/TI/TIS MAINTENANCE MANUAL 15 Printed in Mar. 2001 PS-MMA0507-E1A MAJOR MAINTENANCE 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) Cooling water (%) Anti-freeze (%) Over -10 -10 -15 -20 -25 -30 -40 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)
- 16. DE12/T/TI/TIS MAINTENANCE MANUAL 16 Printed in Mar. 2001 PS-MMA0507-E1A MAJOR MAINTENANCE 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 10 minutes for oil drain into the crankcase before checking oil level. The oil level must be between Max and Min. lines on the gauge. Engine oil should be changed at the specified intervals. Oil in the oil filter should be changed simultaneously. First oil change After 1,000km (50hr) operation DE12/T/TI every 10,000km 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. DE12/T/TI SAE 15W40 above CD or CE DE12TIS SAE15W40 SAE10W40 ACEA-E2 or ACEA-E3 (API CH-4) * If long oil change intervals are to be used, ACEA-E3 oil must be used. Engine Oil capacity Engine oil capacity in Oil pan Engine model Vehicle Max. (lit) Min. (lit) Total (lit) Bus 17 14 21 DE12 DE12T DE12TI Truck 17 14 21 DE12TIS Bus Truck 17 14 21
- 17. DE12/T/TI/TIS MAINTENANCE MANUAL 17 Printed in Mar. 2001 PS-MMA0507-E1A MAJOR MAINTENANCE 2.1.4. Oil filter Check for oil pressure and oil leaks, and 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. 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. G1019 EQM4010I
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- 19. DE12/T/TI/TIS MAINTENANCE MANUAL 18 Printed in Mar. 2001 PS-MMA0507-E1A MAJOR MAINTENANCE 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. 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 Intake Valve Exhaust Valve DE12 DE12T DE12TI DE12TIS 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 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)
- 20. DE12/T/TI/TIS MAINTENANCE MANUAL 19 Printed in Mar. 2001 PS-MMA0507-E1A MAJOR MAINTENANCE 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. 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. Standard value 28kg/cm2 over Limit value 24kg/cm2 Difference between each cylinder Within ± 10 % Condition : Water temperature 20 C, Engine rotation 200rpm (10 rotations) G1048 Flywheel Intake Valve Exhaust Valve Cylinder No. Cooling Fan