Doosan DE12T, DE12TI, DE12TIA, DE12TIS User Manual
FOREWORD
This manual is designed to serve as a reference for DAEWOO Heavy Industries & Machinery Ltd's
(here after DAEWOO’s) customers and distributors who wish to gain basic product knowledge on
DAEWOO's DE12T, DE12TI, DE12TIA and DE12TIS diesel engines.
These economical and high-performance diesel engines (6 cylinders, 4 strokes, in-line type) have been
so designed and manufactured to be used for the industrial application.They meet 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 will not get into the sea or rivers and canals or the ground.
•
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.
Feb.2005
CONTENTS
1. SAFETY REGULATIONS & ENGINE SPECIFICATIONS ......................................................... 1
1.1. General Notes 1.5.
Notes on Safety in Handling Used Engine Oil
1.2. Regulations Designed to Prevent Accidents 1.6. General Repair instructions
1.3. Regulations Designed to prevent Damage 1.7. Engine Specification
to Engine and Premature Wear 1.8. Engine Assembly
1.4. Regulations Designed to Prevent Pollution
2. TECHNICAL INFORMATION ................................................................................................... 16
2.1. Engine Model and Serial Number 2.12. Cylinder Compression Pressure
2.2. Engine Type 2.13. Injection Nozzle
2.3. Engine Timing 2.14. Fuel Injection Nozzle
2.4.Valves 2.15. Battery
2.5. Lubrication System 2.16. Air Removal of Fuel System
2.6. Fuel System 2.17. Fuel Supply Pump
2.7. Cooling System 2.18.Turbocharger
2.8. Fan Belt 2.19. Starting Motor
2.9. Air Cleaner 2.20. Electrical Equipment
2.10. Intercooler 2.21. Diagnosis and Remedy
2.11.Valve Clearance Adjust Procedure 2.22. Engine Inspection
3. DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS ....................................... 48
3.1. Disassembly 3.3. Reassembly
3.2. Inspection and Measurement
4. COMMISSIONING AND OPERATION ..................................................................................... 99
4.1. Preparation 4.4. Operation in Winter Time
4.2. Breaking-In 4.5. Tuning the Engine
4.3. Inspections After Starting
5. MAINTENANCE AND CARE ................................................................................................. 103
5.1. Periodical Inspection and Maintenance 5.4. Replacement of Fuel Filter
5.2. Lubrication System 5.5. Fuel System Checks
5.3. Adjustment of Valve Clearance 5.6. Injection Nozzle Maintenance
6. MAINTENANCE OF MAJOR COMPONENTS ...................................................................... 111
6.1. Fuel Injection Pump 6.4.Turbocharger
6.2. Cooling System 6.5. Air Intake System
6.3. Lubricating System 6.6.V-belts
7. SPECIAL TOOL LIST ............................................................................................................. 174
•
Appendix
•
Part & After service center
•
Applications for Daewoo Engine
•
Worldwide Network
1. SAFETY REGULATIONS & ENGINE SPECIFICATIONS
1.1. General Notes
Day-to-day use of power engines and the service products necessar y for running them presents
no problems if the persons occupied with their operation, maintenance and care are given suitab le
training and think as they work
This summary is a compilation of the most important regulations. These are broken down into
main sections which contain the information necessary for preventing injury to persons, damage
to property and pollution. In addition to these regulations those dictated by the type of engine
and its site are to be observed also.
Important :
If, despite all precautions, an accident occurs, in particular through contact with caustic
acids, fuel penetrating the skin, scalding from oil, antifreeze being splashed in the eyes
etc., consult a doctor immediately.
1.2. Regulations Designed to Prevent Accidents
1.2.1. During commissioning, star ting and operation
Before putting the engine into operation for the first time, read the operating instructions
carefully and familiarize yourself with the “critical” points, If you are unsure, ask your DAEWOO
representative.
•
For reasons of safety we recommend you attach a notice to the door of the engine room
prohibiting the access of unauthorized persons and that you draw the attention of the
operating personal to the fact that they are responsible for the safety of persons who enter
the engine room.
•
The engine must be started and operated only by authorized personnel. Ensure that the
engine cannot be started by unauthorized persons.
•
When the engine is running, do not get too close to the rotating parts. Wear close-fitting
clothing.
•
Do not touch the engine with bare hands when it is warm from operation risk of burns.
•
Exhaust gases are toxic. Comply with the installation instructions for the installation of
DAEWOO diesel engines which are to be operated in enclosed spaces. Ensure that there
is adequate ventilation and air extraction.
•
Keep vicinity of engine, ladders and stairways free of oil and grease.
Accidents caused by slipping can have serious consequences.
- 1 -
SAFETY REGULATIONS & ENGINE SPECIFICATIONS
1.2.2. During maintenance and care
•
Always carry out maintenance work when the engine is switched off.If the engine has to be
maintained while it is running, e.g. changing the elements of change-over filters, remember
that there is a risk of scalding. Do not get too close to rotating parts.
•
Change the oil when the engine is warm from operation.
Caution :
There is a risk of burns and scalding.Do not touch oil drain valve or oil filters with bare
hands.
•
Take into account the amount of oil in the sump.Use a vessel of sufficient size to ensure that
the oil will not overflow.
•
Open the coolant circuit only when the engine has cooled down. If opening while the engine
is still warm is unavoidable, comply with the instructions In the chapter entitled “Cooling”.
•
Neither tighten up nor open pipes and hoses (lube oil circuit, coolant circuit and any additional
hydraulic oil circuit) during the operation.The fluid which flow out can cause injury,
•
Fuel is inflammable. Do not smoke or use naked lights in its vicinity.The tank must be filled
only when the engine is switched off.
•
Keep service products (anti-freeze) only in containers which can not be confused with drinks
containers.
•
Comply with the manufacturer’s instructions when handling batteries.
Caution :
Accumulator acid is toxic and caustic. Battery gases are explosive.
1.2.3.When carr ying out checking, setting and repair work
•
Checking, setting and repair work must be carried out by authorized personnel only.
•
Use only tools which are in satisfactory condition. Slip caused by the worn open-end wrench
could lead to Injury.
•
When the engine is hanging on a crane, no-one must be allowed to stand or pass under it.
Keep lifting gear in good condition.
•
When checking injectors, do not put your hands under the jet of fuel.
Do not inhale at atomized fuel.
•
When working on the electrical system disconnect the battery ear th cable first.
Connect it up again last in prevent short circuits.
- 2 -
SAFETY REGULATIONS & ENGINE SPECIFICATIONS
1.3. Regulations Designed to Prevent Damage to Engine and Premature Wear
(1) Never demand more of the engine than it was designed to yield for its intended purpose.
Detailed information on this can be found in the sales literature.The injection pump
must not be adjusted without prior written permission of DAEWOO.
(2) If faults occur, find the cause immediately and have it eliminate in order to prevent more serious
of damage.
(3) Use only genuine DAEWOO spare parts. DAEWOO will accept no responsibility for damage
resulting from the installation of other parts which are supposedly “just as good”.
(4) In addition to the above, note the following points.
•
Never let the engine run when dry, i.e. without lube oil or coolant. Use only DAEWOO
approved service products (engine oil, anti-freeze and anticorrosion agent).
•
Pay attention to cleanliness, The Diesel fuel must be free of water. See “Maintenance and
care”.
•
Have the engine maintained at the specified intervals.
•
Do not switch off the engine immediately when it is warm, but let it run without load for
about 5 minutes so that temperature equalization can take place.
•
Never put cold coolant into an overheated engine. See “Maintenance and care”.
•
Do not add so much engine oil that the oil level rises above the max. marking on the dipstick.
Do not exceed the maximum permissible tilt of the engine. Serious damage to the engine
may result if these instructions are not adhered to.
•
Always ensure that the testing and monitoring equipment (for battery charge, oil pressure,
and coolant temperature) function satisfactorily.
•
Comply with instructions for operation of the alternator. See “Commissioning and operation”.
•
Do not let the water pump run dry.If there is a risk of frost, drain the water when the engine
switched off.
1.4. Regulations Designed to Prevent Pollution
1.4.1. Engine oil, filter catridge , fuel filter
•
Take old oil only to an oil collection point.Take strict precautions to ensure that oil does not
get into the drains or into the ground.
•
The drinking water supply may be contaminated.
•
Oil and fuel filter elements are classed as dangerous waste and must be treated as such.
1.4.2. Coolant
•
Treat undiluted anti-corrosion agent and / or antifreeze as dangerous waste.
•
When disposing of spent coolant comply with the regulations of the relevant local authorities.
- 3 -
SAFETY REGULATIONS & ENGINE SPECIFICATIONS
1.5. Notes on Safety in Handling Used Engine Oil
Prolonged or repeated contact between the skin and any kind of engine oil decreases the skin.
Drying, irritation or inflammation of the skin may therefore occur.Used engine oil also contains
dangerous substances which have caused skin cancer in animal experiments. If the basic rules
of hygiene and health and safety at work are observed, health risks are not to the expected as
a result of handling used engine oil.
Health precautions
•
Avoid prolonged or repeated skin contact with used engine oil.
•
Protect your skin by means of suitable agents (creams etc.) or wear protective gloves.
•
Clean skin which has been in contact with engine oil.
- Wash thoroughly with soap and water, A nailbrush is an effective aid.
- Certain products make it easier to clean your hands.
- Do not use petrol, Diesel fuel, gas oil, thinners or solvents as washing agents.
•
After washing apply a fatty skin cream to the skin.
•
Change oil-soaked clothing and shoes.
•
Do not put oily rags into your pockets.
Ensure that used engine oil is disposed of properly.
- Engine oil can endanger the water supply -
For this reason do not let engine oil get into the ground, waterways, the drains or the sewers.
Violations are punishable.Collect and dispose of used engine oil carefully.
For information on collection points please contact the seller, the supplier or the local authorities.
- 4 -
SAFETY REGULATIONS & ENGINE SPECIFICATIONS
1.6.
General Repair Instructions
1. Before performing ser vice 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 impor tant to efficient and reliable service operation.
5. Use genuine DAEWOO parts necessar ily.
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 chec k to be sure service has been done
property.
- 5 -
SAFETY REGULATIONS & ENGINE SPECIFICATIONS
1.7.
Engine Specification
1.7.1. Specification
- 6 -
SAFETY REGULATIONS & ENGINE SPECIFICATIONS
Engine Model
Items
Engine type
Combustion chamber type Direct injection type
Cylinder liner type Replaceable dry liner
Timing gear system Gear driven type
No.of piston r ing 2 Compression ring , 1 oil ring
No.of cylinder-bore x stroke (mm) 6 - 123 x 155
Total piston displacement (cc) 11,051
Compression ratio 17.1 : 1 16.5 : 1 19.5 : 1
Engine dimension (length x width x height)
(mm)
1,317 x 847 x
1,379 x 1,017 x 1,310
1,064
Engine weight (kg) 909 900
Rotating direction (viewed from flywheel)
Counter clockwise
Fuel injection order 1 - 5 - 3 - 6 - 2 - 4
Injection pump type Mechanical Mechanical Mechanical
Governor type RSV RSV / RFD RSV
Injection nozzle type
Multi-hole (5-N0.31) Multi-hole(5-N0.31) Multi-hole(5-N0.29)
Fuel injection pressure (kg/cm2) 220 220 160 / 220
Compression pressure (kg/cm2) 28 (at 200rpm)
Intake and exhaust valve clearance(at cold)
(mm) 0.3
Intake valve
Open at 18˚ (B.T.D.C)
18.2˚ (B.T.D.C)
Close at 34˚ (A.B.D.C)
32.2˚ (A.B.D.C)
Exhaust valve
Open at 46˚ (B.B.D.C)
69.8˚ (B.B.D.C)
Close at 14˚ (A.T.D.C)
29.8˚ (A.T.D.C)
Lubrication method Full forced pressure feed type
Oil pump type Gear type driven by crankshaft
Oil filter type Cartridge type
Lubricating oil capacity (max./min)
(liter) 25/17
Oil cooler type Water cooled
Water pump Centrifugal type driven by gear
Cooling method Fresh water forced circulation
Cooling water capacity (engine only)
(liter) 21
Thermostat type (opening temperature) Wax pallet type (71 or 85 ˚C)
Alternator voltage - capacity (V - A) 24V - 50A
Starting motor voltage - output(V - kW) 24 - 6.6
DE12T DE12TI/A DE12TIS
4 cycle in-line,
Water-cooled type
Turbo charged
4 cycle in-line,
Water-cooled type
Turbo charged & intercooled
1.7.2. Engine power
* Note : All data are based on operation without cooling fan at ISO 1585 (SAE J1349).
- 7 -
SAFETY REGULATIONS & ENGINE SPECIFICATIONS
Engine Model Performance
Model Suffix
Injection
Power Torque Low idle High idle
Remark
timing
(PS / rpm)
(kg.m / rpm)
(rpm) (rpm)
(BTDC ˚)
DE12T
EBHEA 14 252 / 1,950 104 / 1,400 1,000~1,025 2,350~2,410
EBHLA 14 216 / 2,200 86 / 1,400 975±25 2,420±50
DE12TI
EBIEA 14 216 / 1,950 86 / 1,400 975±25 2,095~2,195
EBIEB 14 286 / 2,000 114 / 1,400 1,100±25 2,200±50
EBIEC 17 320 / 2,000 128 / 1,400 1,000~1,025 2,250~2,275
EBIED 17 294 / 2,000 115 / 1,400 1,000~1,025 2,250~2,275
TIER-I
EBIEE 17 282 / 2,000 110 / 1,400 1,000~1,025 2,250~2,275
DE12TIA
EBILA 14 305 / 2,100 115 / 1,400 975±25 2,310±50
EBILB 14 302 / 2,100 132 / 1,200 1,000±25 2,380~2,410
EBILC 14 302 / 2,100 132 / 1,200 1,000±25 2,380~2,410
EBILD 17 282 / 2,100 132 / 1,200 1,000±25 2,380~2,410
ECIEA 17 282 / 2,000 132 / 1,200 1,000±25 2,380~2,410
ECIEB 6.5 ~ 7 294/ 2,000 115 / 1,400 1,000~1,025 2,250~2,275
ECIEC 5 ~ 6 257 / 1,900 105 / 1,400 1,000~1,025 2,090~2,140
DE12TIS
ECIED 6.5 ~ 7.5 282 / 2,000 110 / 1,300 1,000~1,025 2,250~2,275
TIER-II
ECILA 5 ~ 6 305 / 2,100 132 / 1,200 1,000~1,025 2,350~2,410
ECILB 5 ~ 6 235 / 2,100 112 / 1,200 1,000~1,025 2,350~2,410
ECILC 5 ~ 6 282 / 2,100 132 / 1,200 1,000~1,025 2,350~2,410
Production tolerance : ±5%
1.7.3. Performance curve
1) DE12TIS : S470 EXCAVATOR
- 8 -
SAFETY REGULATIONS & ENGINE SPECIFICATIONS
REVOLUTION (rpm)
POWER OUTPUT (ps)
1000
200
20001500
FUEL CONSUMPTION (g/ps.h)
170
130
110
TORQUE (kg.m)
160
100
300
120
150
EE6OM001
Performance ISO 1585 (SAE J1349)
Output (rated) 323 ps / 2,000 r pm
Torque (max.) 135 kg.m / 1,400 rpm
Fuel consumption (rated) 160 g / ps.h
2) DE12TIS : S420 EXCAVATOR
- 9 -
SAFETY REGULATIONS & ENGINE SPECIFICATIONS
REVOLUTION (rpm)
POWER OUTPUT (ps)
1000
200
20001500
FUEL CONSUMPTION (g/ps.h)
170
120
100
TORQUE (kg.m)
160
100
300
110
150
EE6OM002
Performance ISO 1585 (SAE J1349)
Output (rated) 297 ps / 2,000 r pm
Torque (max.) 120 kg.m / 1,400 rpm
Fuel consumption (rated) 158 g / ps.h
3) DE12TIS : S340 EXCAVATOR
- 10 -
SAFETY REGULATIONS & ENGINE SPECIFICATIONS
REVOLUTION (rpm)
POWER OUTPUT (ps)
1000
200
20001500
FUEL CONSUMPTION (g/ps.h)
170
110
90
TORQUE (kg.m)
160
100
300
100
150
EE6OM003
Performance ISO 1585 (SAE J1349)
Output (rated) 260 ps / 1,900 r pm
Torque (max.) 110 kg.m / 1,400 rpm
Fuel consumption (rated) 155 g / ps.h
4) DE12TIS : M400 - V LOADER
- 11 -
SAFETY REGULATIONS & ENGINE SPECIFICATIONS
REVOLUTION (rpm)
POWER OUTPUT (ps)
1000
250
21001400
FUEL CONSUMPTION (g/ps.h)
170
130
90
TORQUE (kg.m)
150
220
280
1800
160
110
180
150
EE6OM004
Performance ISO 1585 (SAE J1349)
Output (rated) 285 ps / 2,100 r pm
Torque (max.) 130 kg.m / 1,200 r pm
Fuel consumption (rated) 160 g / ps.h
1.8.
Engine Assembly
1.8.1. Engine sectional view (longitudinal)
- 12 -
SAFETY REGULATIONS & ENGINE SPECIFICATIONS
1. Cooling water pump
2.Valve
3.Valve spring
4. Oil filler
5.Tappet
6. Push rod
7. Piston pin
8. Piston
9. Piston chamber
10. Crank shaft pulley
11.Vibration damper
12. Oil pump
13. Crank shaft
14. Oil suction pipe
15. Connecting rod
16. Cam shaft
17. Flywheel
EE6OM018
1
234 5 6 78 9
10 11 12 13 14 15 16 17
1.8.2. Engine sectional view (cross)
- 13 -
SAFETY REGULATIONS & ENGINE SPECIFICATIONS
EE6OM019
1
2
3
4
5
678
9
10
11
1. Oil filter
2. Cylinder block
3. Fuel injection pump
4. Oil cooler
5. Fuel filter
6. Fuel injection nozzle
7. Rocker arm
8. Cylinder head cover
9. Exhaust manifold
10. Piston ring
11. Air pipe
1.8.3. Engine assembly views
1) DE12TI / A
- 14 -
SAFETY REGULATIONS & ENGINE SPECIFICATIONS
d
a
e
k
i
3456 7 1516
18
9 10121113 19 2021 22 1 2
14
17
8
24
23
(VALVE CLEAR AT CO LD)
¹è±â(EX):0.3mm
Èí±â(IN):0.3mm
¹ë ºê ˚£ ±Ø
9
0
1
.
9
0
1
.
9
0
1
.
9
0
1
.
9
0
1
.
9
0
1
.
9
0
1
.
9
0
1
.
9
0
1
.
9
0
1
.
9
0
1
.
9
0
1
.
EE6OM005
1. Fly wheel
2. Flywheel housing
3. Lifting hook
4. Oil cooler
5. Intake manifold
6. Air heater
7.Water outlet
8. Oil filler cap
9. Oil filter
10. Oil drain plug
11. Oil pan
12. Fuel injection pump
13. Mounting bracket
14. Alternator
15. Fuel filter
16. Air pipe
17. Cooling water pump
18. Exhaust manifold
19. Crank shaft pulley
20.Vibration damper
21. Mounting bracket
22. Starting motor
23. Fuel injection nozzle
24. Cooling water pipe
2) DE12TIS
- 15 -
SAFETY REGULATIONS & ENGINE SPECIFICATIONS
d
a
e
k
i
(VALVE CLEAR AT COLD)
¹è±â(EX):0.3mm
Èí±â(IN):0.3mm
¹ë ºê ˚£ ±Ø
9
0
1
.
9
0
1
.
9
0
1
.
9
0
1
.
9
0
1
.
EE6OM006
3 4 5 6 7 8 16 18
19
10 11 13 12 14 20 21 22 23 1 2
15
17
924
25
1. Fly wheel
2. Flywheel housing
3. Lifting hook
4. Oil cooler
5. Intake manifold
6. Air heater
7. Air pipe
(Intercooler to intake manifold)
8.Water outlet
9. Oil filler cap
10. Oil filter
11. Oil drain plug
12. Oil pan
13. Fuel injection pump
14. Mounting bracket
15. Alternator
16. Fuel filter
17. Cooling water pump
18.Turbocharger
19. Exhaust manifold
20. Crank shaft pulley
21.Vibration damper
22. Mounting bracket
23. Starting motor
24. Air pipe
(Turbocharger to intercooler)
25. Fuel injection nozzle
2.TECHNICAL INFORMATION
2.1. Engine Model and Serial Number
The engine model and serial number is
located on the engine as illustrated.These
numbers are required when requesting
warranty and ordering parts.They are also
referred to as engine model and serial
number because of their location.
•
Engine serial No. (example 2 : DE12T)
DE12T 5 00001 EA
•
Engine serial No. (example 3 : DE12TI)
DE12TI 5 00001 EA
•
Engine serial No. (example 4 : DE12TIS)
DE12TIS 5 00001 EA
- 16 -
TECHNICAL INFORMATION
EE6OM020
Engine
Number
Engine Suffix(EBHEA)
Serial No.
Production Year (2005)
Engline Model
Engine Suffix(EBIEA)
Serial No.
Production Year (2005)
Engline Model
Engine Suffix
(ECIEA)
Serial No.
Production Year (2005)
Engline Model
2.2. Engine Type
The Engines DE12T, DE12TI, DE12TIA, DE12TIS are in-line vertical water-cooled 6-cylinder
four-stroke diesel engines with direct injection. DE12T is turbo-charged engine, and DE12TI,
DE12TIA, DE12TIS model is turbo-charged and inter-cooled engine.
2.2.1. 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.
2.2.2. Cylinder block
The cylinder block is a single piece of alloy cast iron.To increase its stiffness, it is extended to
a level below the cr ankshaft center line.The engine has replaceab le dry cylinder liners and individual cylinder heads with struck-in valve seat rings and replaceable valve guides,
2.2.3. Piston con-rod / crankshaft
The forged crankshaft is a ingrate type (Counterweight is integrated with crank shaft body).
Radial oil seal on crankshaft and flywheel are provided to seal the flywheel housing inside
penetrations.
The con-rods (connecting rods) are die-forged, diagonally split and can be removed through
the top of the cylinders together with the pistons. Crankshaft and connecting rods run in steelbacked lead bronze ready-to fit type bearings.
- 17 -
TECHNICAL INFORMATION
EA8M1001
2.3. Engine Timing
Camshaft, oil pump and injection pump are driven by a gear train arranged at the front end.
2.4.Valves
The overhead valves are actuated via chilled cast iron tappets, push rods and rocker arms from
the camshaft.
2.5. Lubrication System
The engine is equipped with force-feed lubrication.
The pressure is produced by a gear pump whose drive gear is in direct mesh with the crankshaft
gear at the front end of cylinder block.
The oil pump draws the oil from the oil sump and delivers it through the oil cooler and oil filter to
the main distributor gallery and from there to the main bearings, big-end bearings and camshaft
bearings as well as to the small-end bearings and the rocker arms.
The injection pump and the turbocharger are also connected to the engine lubricating system.
The cylinder walls and timing gears are splash-lubricated.
Each cylinder has an oil jet provided for cooling the underside of the pistons.
The lube oil is cleaned in a full-flow oil filter.
- 18 -
TECHNICAL INFORMATION
EB8O3002
Injection pump gear
(Z = 72)
Camshaft gear
(Z =72)
Crankshaft gear
(Z = 36)
Oil pump idle gear
(Z = 31)
Oil pump drive gear
(Z = 32)
Idle gear
(Z = 52)
Water pump gear
(Z =29)
2.5.1.
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.
•
The following oils are also recommended
* If long oil change intervals are to be used, ACEA-E3 oil must be used.
- 19 -
TECHNICAL INFORMATION
Valve 5bar
Valve 2bar
Valve 10bar
EQM4005L
A/C
W/P
BRG
T/C
I/P
Rocker arm
Cam shaft
Piston
Con-rod bearing
Main bearing
Main oil gallery
Relief valve
4.4bar
Oil cooler
Oil filter
Oil pump
Air compressor
Water pump
Turbocharger
Fuel injection
pump
Oil spray nozzle
1.3bar
First oil change After 1,000km (50hr) operation
Construction equipments
DE12T/TI/TIA
every 250hr
DE12TIS
Engine model
Recommend oil
SAE No. API No.
DE12T/TI/TIA SAE 15W40 above CD or CE
DE12TIS
SAE15W40 ACEA-E2 or ACEA-E3
SAE10W40 (API CH-4)
•
Engine Oil capacity
2.5.2.
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.
- 20 -
TECHNICAL INFORMATION
Engine oil capacity
Engine
in Oil pan
Total
model
Vehicle Max. Min.
(lit) (lit)
(lit)
DE12T/TI/TIA/TIS
Excavator 25 17 28
Loader 21 17 24
Oil filter (Cartridge)
Oil filter head
EQM4010I
Oil filter head ass’y
Cartridge
EE6OM025
2.6. Fuel System
The fuel is delivered by the fuel feed pump via the fuel filter to the injection pump and from there
to the injection nozzles.
The fuel is sprayed into the cylinders through nozzles fitted in screw-fit injection nozzle holders
in the cylinder heads.
Excessively delivered fuel and leak fuel from the nozzle flow through the return pipe back to the
tank.
A strainer is arranged ahead of the fuel feed pump.
1. Fuel filter 7. Fuel injection pipe
1a. Fuel water drain plug 8. Fuel pipe ( feed pump filter)
2. Air bleeding screw (for fuel filter) 9. Fuel tank
3. Injection nozzle 10. Fuel return pipe
4. Overflow tube 11. Suction pipe
5. Fuel pipe ( filter injection pump) 12. Feed pump
6. Overflow valve 13.Injection pump
- 21 -
TECHNICAL INFORMATION
3
8
9
4
7
6
12
13
10
11
5
21
1a
EB8O3001
2.6.1. Injection pump
The in-line injection pump is driven via gears from the crankshaft. It is connected to the force
feed lubricating system of the engine and consequently maintenance-free.
The governor flange-mounted on the pump casing is a variable range governor designed to
keep the speed set by the speed control unit constant under conditions of varying load.
2.6.2. Fuel filter
•
This fuel filter has two functions not only
oil filtering but also water separating.
•
Before entering the suction chamber of
the injection pump, the fuel is cleaned
in a strainer of fuel feed pump and a
fuel filter.
•
Drain water in cartridge with loosening
the cock under filter manually (6) from
time to time.
•
The fuel filter should be replaced at
every 500 hours.
2.6.3. Fuel requirements
DAEWOO diesel engines w as designed to use Number 2-D diesel fuel or equivalent that meets
specification DIN 51601-DK.For maximum fuel economy, Number 2-D fuel whenever possible.
When temperatures are below -7 °C (20 °F), use Number 1-D fuel.
If Number 1-D fuel is not available, the mixture of one kerosene to two gallons of Number 2-D
fuel can be used. Once kerosene has been added, the engine should be run for several minutes
to mix the fuel.
2.6.4. How to select fuel oil
Fuel quality is an important factor in obtaining satisfactory engine performance, long engine
life, and acceptable exhaust emission levels. DAEWOO engines are designed to operate on
most diesel fuels marketed today. In general, fuels meeting the properties of ASTM
Designation D975 (grades 1-D and 2-D) have provided satisfactory performance.
The ASTM 975 specification, however, does not in itself adequately define the fuel characteristics needed for assurance of fuel quality.
The properties listed in the fuel oil selection char t below have provided optimum engine
performance.Grade 2-D fuel is normally available for gener ator service.Grade 1-D fuel should
not be used in pleasure craft engines, except in an emergency.
- 22 -
TECHNICAL INFORMATION
1
5
2
3
4
6
EA2O4009
Fuel Oil Selection Chart
#) Not specified In ASTM D 975
+) Differs from ASTM D 975
Note : The cloud point should be 6
˚C
(10 ˚F) below the lowest expected fuel temperature
to prevent clogging of fuel fitters by crystals.
- 23 -
TECHNICAL INFORMATION
General Fuel ASTM No. 1 No. 2
DIN 51601
Classification Test ASTM 1-D ASTM 2-D
Gravity,˚API
#)
D 287 40 ~ 44 33 ~ 37 0.815 ~ 0.855
Flash Point
D 93 100 (38) 125 (52) 131 (55)
Min.˚F (˚C)
Viscosity, Kinematic
D 445 1.3 ~ 2.4 1.9 ~ 4.1 1.8 ~ 10
CST 100 ˚F (40 ˚C )
Cloud Point ˚F
#)
D 2500 See Note 1) See Note 1) See Note 1)
Sulfur Content
D 129 0.5 0.5 0.15
wt%, Max.
Carbon Residue
D 524 0.15 0.35 0.1
on 10%, wt%, Max.
Accelerated Stability
Total Insolubles D 2274 1.5 1.5
mg/100 ml, Max.
#)
Ash, wt%, Max. D 482 0.01 0.01
Cetane Number, Min.
+)
D 613 45 45 > 45
Distillation D 86
Temperature,
˚F(˚
C)
IMP, Typican
#)
350(177) 375(191)
10% Typical
#)
385(196) 430(221)
50% Typical
#)
45(218) 510(256) 680(360)
90%
+)
500 (260) Max. 625(329) Max.
End Point
#)
550(288) Max. 675(357) Max.
Water & Sediment
D 1796 0.05 0.05 0.05
%, Max.
2.7. Cooling System
The engine has a liquid-cooling system. The fresh water pump is a maintenance-free by gear
from the crankshaft.
Depending on the agreed extent of delivery and the design of the engine, the coolant circuit can
be equipped with temperature monitors which, in the event of loss of coolant, shut the engine
down.
•
Check the coolant level of the expansion tank by removing the expansion tank filler cap, and
add coolant if necessary.
•
When injecting antifreeze solution, first drain out the old coolant from the cylinder block and
radiator, and then clean them with cleaning solution.
•
Be sure to mix soft water with antifreeze solution.
- 24 -
TECHNICAL INFORMATION
Reserve tank
Radiator
Water pipe
Thermostat
Cylinder block
Cylinder head
Water pump
EA5M400
EA5M4001
2.7.1. Coolant pressure cap
•
Check the pressure valve opening
pressure using a expansion tank cap
tester.
•
Replace the filler cap assembly if the
measured valve does not reach the
specified limit. (pressure valve opening
pressure : 0.9 kg/cm
2
)
Caution :
Because it is dangerous to open the
pressure cap quickly when coolant is
hot, after lowering the inside pressure
of the tank by slow-opening at first
open it fully.
2.7.2.
Cooling water
•
Regarding the cooling water that is to be used for engine, the soft water not the hard water
must be used.he use of proper tools and special tools where specified is important to efficient and reliable service operation.
•
The engine cooling water can be used diluting it with antifreezing solution 40% and the additive for rust prevention (DCA4) 3 ~ 5 %.
•
The density of above solution and additive must be inspected every 500 hours to maintain it
properly.
NOTE :
The proper density control of antifreezing solution and rust preventing additive will be
able to prevent the rusting effectively and maintain the stable quality of engine. For the
improper control might give the fatal damage to the cooling water pump and cylinder
liners, detail care is needed.
•
Since DE12T, DE12TI, DE12TIA and DE12TIS (diesel engine of DE12 series) cylinder liner
is dry type, particularly the cooling water control should be applied thoroughly.
•
The density of antifreezing solution and additive for rust prevention is able to be confirmed
by the cooling water test kit (Fleetguard CC2602M) or DAEWOO No. : 60.99901-0038
•
How to use the cooling water test kit
(1) When the cooling water temp.of engine is in the range of 10 ~ 55
˚C, loosen the plug for
cooling water discharge and fill the plastic cup about a half.
- 25 -
TECHNICAL INFORMATION
Radiator Cap
Radiator
EA5O3002
NOTE :
In taking the cooling water sample, if the water in auxiliary tank were taken, it is hard to
measure the accurate density.Take the cooling water sample necessarily loosening the
cooling water discharge plug.
(2) At the state of a test paper soaked in the sampled water, after taking the paper out
through water agitation, shake off the water.
(3) Wait for about 45 sec. till the color change of test paper.
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
- 26 -
TECHNICAL INFORMATION
Ambient
Temperature (
˚C
)
Over -10
-10
-15
-20
-25
-30
-40
15
20
27
33
40
44
50
Anti-freeze (%)
Cooling water (%)
85
80
73
67
60
56
50
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