Page 1 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.
Page 3 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.
Page 4 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...
Page 5 1.2. Regulations Designed to Prevent Accidents 1.2.1. During commissioning, starting 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. •...
Page 6 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. •...
Page 7 “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). •...
Page 8 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.
Page 9 4. The use of proper tools and special tools where specified is important to efficient and reli- able 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 dis- carded and new ones should be prepared for installation as normal function of the parts can not be maintained if these parts are reused.
Page 10 1.7. Engine Specification 1.7.1. Specification Engine Model DE12T DE12TI/A DE12TIS Items 4 cycle in-line, 4 cycle in-line, Engine type Water-cooled type Water-cooled type Turbo charged Turbo charged & intercooled Combustion chamber type Direct injection type Cylinder liner type Replaceable dry liner...
Page 11 Suffix timing (PS / rpm) (kg.m / rpm) (rpm) (rpm) (BTDC ˚) EBHEA 252 / 1,950 104 / 1,400 1,000~1,025 2,350~2,410 DE12T EBHLA 216 / 2,200 86 / 1,400 975±25 2,420±50 EBIEA 216 / 1,950 86 / 1,400 975±25 2,095~2,195...
Page 12 1.7.3. Performance curve 1) DE12TIS : S470 EXCAVATOR 1000 1500 2000 REVOLUTION (rpm) EE6OM001 Performance ISO 1585 (SAE J1349) Output (rated) 323 ps / 2,000 rpm Torque (max.) 135 kg.m / 1,400 rpm Fuel consumption (rated) 160 g / ps.h SAFETY REGULATIONS &...
Page 13 2) DE12TIS : S420 EXCAVATOR 1000 1500 2000 REVOLUTION (rpm) EE6OM002 Performance ISO 1585 (SAE J1349) Output (rated) 297 ps / 2,000 rpm Torque (max.) 120 kg.m / 1,400 rpm Fuel consumption (rated) 158 g / ps.h SAFETY REGULATIONS & ENGINE SPECIFICATIONS - 9 -...
Page 14 3) DE12TIS : S340 EXCAVATOR 1000 1500 2000 REVOLUTION (rpm) EE6OM003 Performance ISO 1585 (SAE J1349) Output (rated) 260 ps / 1,900 rpm Torque (max.) 110 kg.m / 1,400 rpm Fuel consumption (rated) 155 g / ps.h SAFETY REGULATIONS & ENGINE SPECIFICATIONS - 10 -...
Page 15 4) DE12TIS : M400 - V LOADER 1000 1400 1800 2100 REVOLUTION (rpm) EE6OM004 Performance ISO 1585 (SAE J1349) Output (rated) 285 ps / 2,100 rpm Torque (max.) kg.m / 1,200 rpm Fuel consumption (rated) 160 g / ps.h SAFETY REGULATIONS & ENGINE SPECIFICATIONS - 11 -...
Page 16 1.8. Engine Assembly 1.8.1. Engine sectional view (longitudinal) EE6OM018 1. Cooling water pump 7. Piston pin 13. Crank shaft 2. Valve 8. Piston 14. Oil suction pipe 3. Valve spring 9. Piston chamber 15. Connecting rod 4. Oil filler 10. Crank shaft pulley 16.
Page 17 1.8.2. Engine sectional view (cross) EE6OM019 1. Oil filter 7. Rocker arm 2. Cylinder block 8. Cylinder head cover 3. Fuel injection pump 9. Exhaust manifold 4. Oil cooler 10. Piston ring 5. Fuel filter 11. Air pipe 6. Fuel injection nozzle SAFETY REGULATIONS &...
Page 18 1.8.3. Engine assembly views 1) DE12TI / A 10 12 11 EE6OM005 1. Fly wheel 9. Oil filter 17. Cooling water pump 2. Flywheel housing 10. Oil drain plug 18. Exhaust manifold 3. Lifting hook 11. Oil pan 19. Crank shaft pulley 4.
Page 19 2) DE12TIS 11 13 12 EE6OM006 1. Fly wheel 9. Oil filler cap 18. Turbocharger 2. Flywheel housing 10. Oil filter 19. Exhaust manifold 3. Lifting hook 11. Oil drain plug 20. Crank shaft pulley 4. Oil cooler 12. Oil pan 21.
Page 20 They are also referred to as engine model and serial number because of their location. EE6OM020 • Engine serial No. (example 2 : DE12T) DE12T 5 00001 EA Engine Suffix(EBHEA) Serial No. Production Year (2005) Engline Model •...
Page 21 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 efficien- cy, low emission combustion.
Page 22 2.3. Engine Timing Camshaft, oil pump and injection pump are driven by a gear train arranged at the front end. Injection pump gear Camshaft gear Water pump gear (Z = 72) (Z =72) (Z =29) Idle gear (Z = 52) Crankshaft gear (Z = 36) Oil pump idle gear...
Page 23 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 DE12T/TI/TIA Construction equipments every 250hr DE12TIS • The following oils are also recommended...
Page 24 Total Vehicle Max. Min. model (lit) (lit) (lit) Excavator DE12T/TI/TIA/TIS Loader 2.5.2. Oil filter • Check for oil pressure and oil leaks, and repair or replace the oil filter if necessary. • Oil filter (Cartridge) Change the oil filter cartridge simulta- neously at every replacement of engine oil.
Page 25 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.
Page 26 500 hours . 2.6.3. Fuel requirements DAEWOO diesel engines was 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.
Page 27 Fuel Oil Selection Chart General Fuel ASTM No. 1 No. 2 DIN 51601 Classification Test ASTM 1-D ASTM 2-D ˚ Gravity, D 287 40 ~ 44 33 ~ 37 0.815 ~ 0.855 Flash Point D 93 100 (38) 125 (52) 131 (55) ˚...
Page 28 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.
Page 29 • 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. •...
Page 30 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.
Page 31 2.7.3. Cleaning of the cooling inside system circuit ( by authorized specialist personnel ) When the cooling system circuit are fouled with water scales or sludge particles, the cooling efficiency will be lowered. Investigations have shown that in many cases the poor condition of the coolant and /or the cool- ing system accounts for damage to the water pump mechanical seal, The poor condition of the cooling system is normally due to use of unsuitable or no anti-freezing agents and corrosion inhibitor or defect, not early enough replaced covers for filler neck and working valves.
Page 32 2.8. Fan Belt • V-belt - Use a fan belt of specified dimen- Press here sions, and replace if damaged, "Y" frayed, or deteriorated. - Check the fan belt for belt tension. If belt tension is lower than the Water pump pulley specified limit, adjust the tension by Alternator...
Page 33 2.10. 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.
Page 34 • As for the valve clearance, adjust it when in cold, as follow. Model Intake Valve Exhaust Valve DE12T DE12TI 0.3 mm 0.3 mm DE12TIA DE12TIS 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.
Page 35 • Install a nozzle on the nozzle tester. • If the inspected injection pressure is less than the specified value, adjust using the adjust- ing shims. Engine model DE12T/TI/TIA DE12TIS Injection nozzle 220 kg/cm 160 / 220 kg/cm Pressure •...
Page 36 2.14. Fuel Injection Nozzle • Check the housing crack, damage etc. and replace it if abnormal. • Check if the idle operation and speed regulating lever’s sealing is removed. • The adjustment and testing of fuel injection pump should necessarily be done at the test bench.
Page 37 2.18. Turbocharger The turbocharger needs not arty special equipment. Every time of engine replacement, a leakage or clogging of oil pipes should be inspected. Air cleaner should be maintained carefully for nut or foreign material not to get in. Periodic inspec- tion should be applied on the compressed air and exhaust gas pipes, For leaking air will bring the overheat engine, an immediate repair must be done.
Page 38 2.20. Electrical Equipment 2.20.1. Starting of winter Caution : 1. Preheating devices are attached to the engine for improving the starting abilities at extremely low temperature. 2. Do not actuate the starter for longer than 10 seconds. If starting fails regardless of the preheating, start the preheating again after 30 seconds.
Page 39 2.20.2. Alternator a) Alternator ( 24V x 45A ) The alternator is fitted with integral silicon rectifiers. A transistorized regulator mounted on the alternator body interior limits the alternator voltage. The alternator should not be operated except with the regulator and battery connected in circuit to avoid damage to the rectifier and regulator.
Page 40 2.20.3. Starting motor The sliding-gear starter motor is flanged to the rear of the flywheel housing on the left-hand side. As parts of every engine overhaul, the starter pinion and ring gear should be cleaned with a brush dipped in fuel and then a coat of grease should be applied again. 24V X 6.6KW Switch terminal Battery terminal(+)
Page 41 2.21. Diagnosis and Remedy • The following description summarizes the probable cause of and remedy for general failure by item. • Immediate countermeasures should be taken before a failure is inflamed if any symptom is detected. 1. Engine Starting Impossible Starting motor operation poor Starting motor revolution Inspection of battery electorlytic...
Page 42 2. Engine Overheated Operating state 1. Overload 2. Radiator core clogged Fuel unit Cooling unit 3. Continuous over-run Check coolant Inspect fuel quality Fuel excessive supply Normal Too low Poor Check fan belt Clean and replace Repair Check injection nozzle tension wear with specified fuel Replace...
Page 43 3. Output Insufficient Engine Installation improper Check for coupling Others Fuel unit alignemnt Inspect air cleaner Check for air mixing Adjust or replace in fuel coupling Normal Clean Relpace Inspect fuel supply pump Inspect engine control Inspect air leakage rod, link, cable, etc. Normal Clean Replace of air piping line...
Page 44 4. Oil pressure lowered Check if oil pressure gauge indicates wrongly Check oil amount Too low Normal Use recommended oil Check cooling (replenish) temperature Too high Normal Refer to engine overheat Inspect oil quality Normal Check oil relief Water & fuel mixed Improper valve in oil...
Page 45 5. Fuel Consumption Excessive Causes according to Use Conditions 1. Overload 2. Frequent use of low gear position at high speed 3. Frequent use of high gear position at low speed 4. Clutch slip 5. Too low tire inflation pressure Inspect fuel leakage Normal Oil leakage...
Page 46 6. Oil Consumption Excessive Cause according to use conditions 1. Excessive oil infusing 2. Continuous operation in low speed or extremely cold state Inspect oil leakage Inspect air cleaner Normal Clean Replace Oil leakage Check oil quality Internal External Retighten Replace with Check compressed Replace...
Page 47 8. Battery Discharge Generator Wiring, Switch Battery Inspect cut wire Check fan belt Check electrolytic shorts and loose tension & damage liquid amount connections Repair Replace Normal Battery over Battery self Battery room Electrolytic discharge charging damage liquid’s standard Inspect generator Charging Replace Voltage regulator...
Page 48 Condition Causes Remedies 1) Starting difficult • (1) Starting motor trouble Refer to diagnostics • (2) Fuel system trouble Refer to diagnostics • (3) Compression pressure lack Valve’s poor shut, stem distortion Repair or replace • Valve spring damage Replace valve spring •...
Page 49 Condition Causes Remedies 5) Engine noisy For noises arise compositely such as rotating parts, lapping parts etc., there is necessity to search the cause of noises accurately. • (1) Crankshaft As the wear of bearing or crankshaft Replace bearing & progress, the oil clearances increase.
Page 50 Condition Causes Remedies 7) Oil Consumption Excessive • (1) Oil level elevated Clearance between cylinder liner Replace & piston • Wear of piston ring, ring groove Replace piston, piston ring • Piston ring’s damage, stick, wear Replace piston ring • Piston ring opening’s disposition improper Correct position •...
Page 51 2.22. Engine Inspection 2.22.1. Stopping engine After checking the engine for any unusual condition at the idling speed, then turn the key switch to stop the engine. 2.22.2. General engine inspection cycle : Check & adjust : Replace Every Every Every Every Every...
Page 52 3. DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 3.1. Disassembly 3.1.1. General precautions • Maintenance operation should be carried out in a bright and clean place. • Before disassembly, provide parts racks for storage of various tools and disassembled parts. • Arrange the disassembled parts in the disassembly sequence and use care to prevent any damage to them.
Page 53 3.1.3. Engine oil • Take out the oil level gauge. • Remove the oil drain plug of oil pan and drain out the engine oil into a pre- pared container. • Reassemble the drain plug with the oil pan after draining out the engine oil. EQM3001I 3.1.4.
Page 54 3.1.7. Fuel filter • Remove fuel hoses connected to the fuel injection pump, take off the bracket fixing bolts, then disassemble the fuel filter. EE6OM029 3.1.8. Breather • Loosen the clamp screw to remove the rubber hose. 3.1.9. Intercooler • Tear down the various hoses and air pipes from the inter cooler •...
Page 55 3.1.11. Air heater • Remove the electrical wiring for the air heater. • Disassemble the intake pipes by loosening the nuts installed thereon. • Disassemble the air heater and gas- ket. 3.1.12. Intake manifold • Remove the air hose connected to the fuel injection pump.
Page 56 3.1.14. Exhaust manifold • Release the exhaust manifold fixing bolts, disassemble the exhaust mani- fold, then remove the heat shield and gasket. NOTE : Make sure to release the nuts one after another because the exhaust manifold will be removed if you unscrew two nuts simultaneously.
Page 57 3.1.18. Fuel injection pump • Remove the oil supply pipe and return pipe connected to the fuel injection pump. • Unscrew the bolts connecting the coupling and drive shaft, loosen the injection pump attaching bolts, then disassemble the injection pump. NOTE : EAMD021I Place the No.1 cylinder in ‘OT’...
Page 58 3.1.21. Timing gear case cover • Disassemble the oil seal using an oil seal removing jig. • Remove the cover fixing bolts and disassemble the cover from the tim- ing gear case. EAMD025I 3.1.22. Idle gear • Unscrew the idle gear fixing bolts and disassemble the thrust washer and idle gear.
Page 59 3.1.25. Rocker arm • Unscrew the rocker arm bracket bolts and remove the rocker arm assembly. • Take off the snap rings to remove the washers rocker arm, then unscrew the bracket fixing bolts to take off the bracket and springs. •...
Page 60 3.1.29. Oil cooler • Remove the water pipe connected to the water pump. • Remove the oil pipe connected to the cylinder block and oil filter. • Unscrew the oil cooler cover fixing bolts and disassemble the oil cooler assembly from the cylinder block. •...
Page 61 3.1.33. Piston and connecting rod • Disassemble the pistons by two cylin- ders while turning the crankshaft. • Unscrew the connecting rod fixing bolts and take off the pistons and connecting rods in the direction of piston. EAMD037I • Remove the piston pin snap rings, take off the piston pin, then discon- nect the connecting rod from the pis- ton.
Page 62 3.1.35. Fly wheel • Position the engine so that the head installing surface of the cylinder block faces down. • Unscrew the flywheel fixing bolts and fit a dowel pin. • Install flywheel disassembling bolts in the bolt holes machined on the fly- wheel, and disassemble the flywheel.
Page 63 3.1.39. Crankshaft gear and oil pump idle gear • Loosen the socket head bolts and take out the oil pump idle gear. • Use a puller to remove the crankshaft gear. 3.1.40. Timing gear case • Unscrew the case fixing bolts and dis- assemble the timing gear case.
Page 64 3.1.42. Oil spray nozzle • Unscrew the fixing bolt and remove the oil spray nozzles. DISASSEMBLY - 60 -...
Page 65 3.2. Inspection and Measurement 3.2.1. Cylinder block 1) Clean the cylinder block thoroughly and make a visual inspection for cracks or damage. 2) Replace if cracked or severely damaged, and correct if slightly damaged. 3) Check oil and water flow lines for restriction or corrosion. 4) Make a hydraulic test to check for any cracks or air leaks.
Page 66 3) flatness • Measure flatness of the intake/exhaust manifolds fitting surfaces on the cylinder head using a straight edge and a feeler gauge. Standard Limit 0.05 mm 0.2 mm 4) Hydraulic test • Hydraulic test method for the cylinder head is same as that for cylinder block. 3.2.3.
Page 67 2) Valve guide • Install the valve into the valve guide and measure the clearance between them by valve movement. If the clearance is exces- sive, measure the valve and replace either Measuring the valve or the valve guide, whichever Point 측정...
Page 68 - Measure the spring inclination with a square. - Compare the measured value with the standard value to determine whether to replace or repair. EFM2039I Standard Limit Valve DE12T/TI/TIA 1.0 mm spring 2.0 mm inclination DE12TIS 1.7 mm INSPECTION AND MEASUREMENT...
Page 69 3.2.4. Rocker arm shaft assembly 1) Rocker arm shaft • Rocker arm shaft run-out Place the rocker arm shaft on two V blocks and inspect the shaft for bend using a dial gauge. • If the amount of this run-out is small, press the shaft with a bench press to correct the run-out.
Page 70 3) Tappet and push rod • Clearance Measure the clearance of the tappet and tappet holes of the cylinder block. If the value is beyond the specified limit, replace tappets. • Visual check of tappet Visually check the face of the tappets in contact with the cam for pitting, scores or cracks, and replace if severely damaged.
Page 71 3.2.5. Cam shaft 1) Cam • Cam lobe height Use a micrometer to measure the cam lobe height and journal diameter. If the measured value is less than the specified limit, the camshaft must replaced. unit : mm Standard Limit I II I II Cam lobe Intake...
Page 72 • Run-out Support the camshaft on two V blocks and check for run-out using a dial indicator. Correct or replace the cam shaft if the amount of run-out is beyond the value indicating need for servicing. Standard Limit 0.05 mm 0.2 mm EA0M4066 3) Cam shaft end play...
Page 73 • If the amount of wear is beyond the limit, have the crankshaft grind and install undersize bearings. However, if the amount of wear is within the limit, you can correct the wear using an oil stone or oiled grinding paper of fine grain size.
Page 74 3.2.7. Crank shaft bearing and connection rod bearing 1) Visual check • Visually check the crankshaft bearing and connecting rod bearing for scores, uneven wear or damage. 2) Oil clearance between crankshaft and bearing. • Main bearing clearance Install the main bearing in the cylinder block, tighten the bearing cap to spec- ified torque, then measure the inside diameter.
Page 75 • If the clearance deviates from the specified range, have the crankshaft journals and pins grind and install undersize bearings. 3) Bearing spread and crush • Inspection Check that bearing requires a considerable amount of fin- ger pressure at reassembly opera- tion.
Page 76 4) Crank shaft end play • Assemble the crankshaft to the cylin- der block. • With a dial gauge, measure crank- shaft end play. Standard Limit 0.15 ~ 0.325 mm 0.5 mm 3.2.8. Piston 1) Visual check • Visually check the pistons for cracks, scuff or wear, paying particular attention to the ring groove.
Page 77 Standard Limit Top ring 0.30 ~ 0.45 mm 1.5 mm 2nd ring 0.35 ~ 0.50 mm 1.5 mm DE12T/TI/TIA 0.30 ~ 0.50 mm Oil ring 1.5 mm DE12TIS 0.40 ~ 0.70 mm • Replace piston rings with new ones if the gap is beyond the limit 3) Piston ring side clearance •...
Page 78 3.2.10. Piston pin 1) Wear • Measure the amount of wear on the piston pin at the points as shown. • If the measured values are beyond the limit (0.005 mm or greater), replace the pin. Standard Limit N 44.995 ~ N 45.0 mm N 44.990 mm or less EA0M4031 2) Clearance...
Page 79 If the measured values are beyond the 실린더 헤드 Cylinder head limit, replace the seal ring. 노즐 튜브 Standard DE12T/TI/TIA DE12TIS Nozzle tube (Thickness of seal ring) 3.4 ~ 3.5 mm 2.4 ~ 2.5 mm (Projection of nozzle) EQM8010I...
Page 80 3.3. Reassembly 3.3.1. General precautions • Wash clean all the disassembled parts, particularly oil and water ports, using compressed air, then check that they are free from restrictions. • Arrange the general and special tools in order for engine assembly operation. •...
Page 81 • Apply engine oil to the entire face of the tappets and slide them into the tappet holes on the cylinder block. • Wet the cam bush inside diameter and camshaft with oil, and carefully assemble them while turning the camshaft.
Page 82 • Semi-tighten a bolt at both sides of the crankshaft, apply engine oil to journals and pins, then assemble the crankshaft with the cylinder block by tightening the fixing bolts. • Install the oiled thrust washers with the oil groove facing outward. •...
Page 83 • Apply oil to the entire part of the bear- ing cap bolts, then tighten in tighten- ing sequence to specified torque. 30 kg . m Torque • After semi-tightening both bolts even- ly, tighten them diagonally to about EAMD079I 15kg .
Page 84 3.3.8. Flywheel • Install a guide bar into a bolt hole on the crank shaft, and lift the flywheel to align the dowel pin with the pin hole on the flywheel for temporary assem- bly operation. • Install bolts in the remaining holes, take out the guide bar, then install a bolt in the hole where the guide bar had been inserted.
Page 85 3.3.10. Timing gear case • Mount gasket using dowel pin on the cylinder block. • Install the timing gear case by aligning the dowel pin with the dowel pin hole on the timing gear case. EAMD082I 3.3.11. Timing gear • Install the oil pump idle gear onto the No.7 bearing cap.
Page 86 3.3.12. Fuel injection pump drive gear • Mount gasket by aligning the bolt holes with the pin holes on the bear- ing housing. • Tighten the fixing bolts in the direc- tion of fuel injection pump. EAMD027I 3.3.13. Timing gear case cover •...
Page 87 3.3.16. Piston and connecting rod • Use a piston heater to heat the piston approximately 100 ˚C (212 ˚F) for 5 minutes. • Align the piston pin hole with the oiled connecting rod small end and press the piston pin (by lightly tapping with a rubber hammer) to assemble the con- necting rod with the piston.
Page 88 • Identify the mark “Y” or “TOP” on the ring end to prevent the top and bottom of the piston ring from being inter- changed and make the marked por- tion face upward. 피스톤 링 제작사 표시 Marked with the name of piston ring EAMD090I manufacturing company EAMD090I...
Page 89 • Move the bearing cap with hand, and release and reassemble it if no move- ment is detected. EAMD094I 3.3.17. Relief valve • Assemble the relief valve. EAMD036I 3.3.18. Oil pump and oil pipe • Install a dowel pin in the No.7 bearing cap, then assemble the oil pump with specified torque.
Page 90 3.3.20. Intake and exhaust valves • Identify the marks of “IN” and “EX” impressed on the valve head before assembling the valve with the valve head. • Using the valve stem seal fitting jig, assemble the valve stem seal with the valve guide.
Page 91 • Apply engine oil to an expander and install it onto the special tool (guider). Expander • Tighten the bolts until the expander is forced out of the cylinder head bottom. • After mounting the nozzle tube, make a hydraulic test to check for water leaks.
Page 92 3.3.23. Cylinder head • Install the injection nozzle fixing stud bolts and water pipe fixing stud bolts. • Clean the head bolt holes on the cylin- der block with compressed air to remove foreign substances and thor- oughly clean the gasket fitting face of the cylinder block.
Page 93 • Coat the head bolts with engine oil, then tighten them in proper sequence to the specified torque. EAMD102I EAMD103I <Cylinder Head Bolts> Type 1 Type 2 Type 3(12.9T) Type 4(12.9T) Type 5(10.9T) DL08 12.9T 10.9T M14x1.5x153 M14x1.5x150 M14x1.5x153 M14x1.5x150 M14x1.5x150 1st : 6 kg.m 1st : 6 kg.m...
Page 94 • As for the valve clearance, adjust it when in cold, as follow. Model Intake Valve Exhaust Valve DE12T DE12TI 0.3 mm 0.3 mm DE12TIA DE12TIS - By cranking the engine, let #6 cylinder’s valves overlap.
Page 95 Engine model Seal ring EAMD105I DE12T/TI/TIA 1 mm DE12TIS 3 mm • Be sure to follow the specified torque. 1.0 kg . m Torque 3.3.25.
Page 96 3.3.27. Oil filter • Install the oil filter onto the cylinder block, and tighten the fixing bolts. • With the hollow screw, assemble the oil pipe connected between the oil cooler and cylinder block. • Install a connection pipe between the oil cooler and oil filter.
Page 97 • Turn the flywheel until No. 1 piston is placed in the “OT” position of notch marks on the flywheel, and then turn again the flywheel clockwise until showing the notch mark of the right figure corresponding to the injection timing is aligned with the pointer ( on the flywheel housing Timing...
Page 98 3.3.29. Vibration damper and pulley • Install the vibration damper on the crankshaft pulley. • Install the crankshaft pulley assembly on the crankshaft, then tighten the bolts and thrust washers. 13.4 kg . m Torque 3.3.30. Water pump • Mount a new O-ring. •...
Page 99 3.3.33. Air pipe • Semi-assemble the bracket to the intake pipe, connect a rubber hose between the turbocharger and intake pipe using the clamps, then assem- ble the bracket completely. EE6OM031 3.3.34. Starter • Assemble the starter in position on the flywheel housing.
Page 100 3.3.36. Injection pipe • Semi-assemble a nut at both ends of the fuel high pressure pipe and tighten them up one by one to specified torque. 3.0 kg . m Torque • Tighten hollow screws to assemble the fuel return pipe. EQM3009I •...
Page 101 3.3.39. Alternator • Install the alternator mounting brack- • Install the alternator with fixing bolts to the mounting bracket. 3.3.40. Cooling fan • Install the cooling fan and flange, then tighten the fixing bolts. EQM3106I 3.3.41. V- belt • Install the V-belt on the crank pulley and alternator pulley.
Page 102 3.3.43. Oil level gauge • Assemble the oil level gauge and guide tube on the oil pan. EQM3005I REASSEMBLY - 98 -...
Page 103 4. COMMISSIONING AND OPERATION 4.1. Preparation At the time of initial commissioning of a new or overhauled engine make sure to have observed the “Technical Information for the installation DAEWOO vehicle engines”. • Oil filler neck on cylinder head cover Before daily starting of the engine, check the fuel, coolant and oil level, replenish if necessary.
Page 104 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 1,000 km 50 hr operation DE12T/TI/TIA 250 hr Construction Equipment DE12TIS 250 hr •...
Page 105 Vehicle Max.(lit) Min.(lit) Excavator DE12T/TI/TIA/TIS Loader 4.3. Inspections After Starting During operation the oil pressure in the engine lubrication system must be monitored. If the monitoring devices register a drop in the lube oil pressure, switch off the engine immediately.
Page 106 4.4. Operation in Winter Time Pay special attention to the freezing of cooling water and the viscosity of lubricating oil. 4.4.1. Prevention against the freeze of cooling water When not using anti-freeze, completely discharge the whole cooling water after engine running. The freeze of cooling water causes the fatal damages of the engine.
Page 107 5. MAINTENANCE AND CARE 5.1. Periodical Inspection and Maintenance In order to insure maximum, trouble-free engine performance at all times, regular inspection, adjustment and maintenance are vital. • Daily inspections in below figure should be checked every day. • The maintenance should be executed thoroughly at regular internals. ( refer to appendix “General Engine Inspection Cycle”.
Page 108 5.2.3. Oil exchange procedure While the oil is still hot, exchange oil as follows: • Take out the oil level gauge. • Remove the drain plug from oil pan, then drain out the engine oil into a container. EE6OM023 • Reassemble the drain valve with the oil pan and the drain plug with oil filter head after draining out the engine oil.
Page 109 5.2.4. Replacement of oil filter cartridge At the same times of oil exchanges, replace the oil filter cartridge. • Drain engine oil by loosening the drain plug on the filter head. Cartridge Caution : Don’t forget tightening the drain plug after having drained engine oil.
Page 110 5.3. Adjustment of Valve Clearance 5.3.1. General information The valve clearances are to be adjusted at the times of the following situations. • When the engine is overhauled and the cylinder heads are disassembled. • When severe noise comes from valve train. •...
Page 111 If the engine is equipped with a fuel water separator, drain off any water that has accumulated. Water in fuel can seriously affect engine performance and may cause engine damage. DAEWOO recommends installation of a fuel water separator on vehicles. MAINTENANCE AND CARE...
Page 112 5.5.1. Fuel contamination and water trap In the generator environment, the most likely fuel contaminants are water and microbial growth (black “slime”). Generally, this type of contamination is the result of poor fuel handling practices. Black “slime” requires water in the fuel to form and grow, so the best prevention is to keep water content to a minimum in storage tanks.
Page 113 Check injection pressure, and adjust the nozzle using the adjusting shim if the pressure does not meet the specified limit. • Check nozzle spray patterns and replace if damaged. Engine Model DE12T/TI/TIA DE12TIS Injection nozzle pressure 220 kg/cm 160 / 220 kg/cm...
Page 114 Caution : The injection lines are designed for high operating pressures and should thus be handled with particular care. • When mounting the pipes to the engine take care of good fitness. • Do not bend pipes to permanent deformation (not for replacing the nozzles either). •...
Page 115 6. MAINTENANCE OF MAJOR COMPONENTS 6.1. Fuel Injection Pump 6.1.1. General information of fuel system The fuel system consists of the fuel tank, injection pump, injection nozzle, fuel filter, and fuel lines such as pipes and hoses necessary to connect those components. EQM4011I 1.
Page 116 1) Parts no of injection system a) Injection pump assembly Engine model Part no. Suffix DE12T 65.11101-7245B EBHEA, EBHLA DE12TI 65.11101-7378 EBIEA. EBIEB 65.11101-7378 EBIED, EBIEE, EBILA 65.11101-7394 EBILB DE12TIA 65.11101-7393 EBILC 65.11101-7402 EBILD 65.11101-7368A EBIEC 65.11101-7358A ECIEA 65.11101-7361A ECIEB 65.11101-7362A...
Page 117 2) DE12T (EBHEA, EBHLA) Bellow rack curve data are standard injection pump (1) Fuel injection pump : 65.11101-7245B (106675-4083 ZEXEL) - Fuel injection pump : KP-PE6P120/720RS3000 (106061-7840 DOOWON) - Governor : KP-EP/RSV200-1300PQ39C311(105407-5063) - Fuel feed pump : KP-FP/K-P (105207-1400) - Coupling : 105663-0470 (2) Nozzle holder assembly : 65.10101-7300 (105160-4351 DOOWON)
Page 118 3) DE12TI (ECIEA, EBIEB), DE12TIA (EBIED, EBIEE, EBILA) Bellow rack curve data are standard injection pump (1) Fuel injection pump : 65.11101-7378 (106675-4690 DOOWON) - Fuel injection pump : KP-PE6P120/720RS3S (106067-6220 DOOWON) - Governor : KP-EP/RSV200-1300PQ39C311(105407-759B) - Fuel feed pump : KP-FP/K-PS (105207-1540) - Coupling : 105663-0740...
Page 119 (6) Performance curve of governor Notch : 13 Main spring set. 14 more Idle sub spring set. + _ 0.1 BCS Stroke : 2.2 12.5 + _ 0.1 (11.3) + _ 0.1 + _ 0.1 + _ 0.1 + _ 0.1 1110 1170 1150...
Page 120 4) DE12TIA (EBILB) (1) Fuel injection pump : 65.11101-7394 (106675-400A DOOWON) - Fuel injection pump : KP-PE6P120/720RS3S (106067-6220 DOOWON) - Governor : KP-EP/RFD200/1300PQ39C311(105407-7590) - Fuel feed pump : KP-FP/K-PS (105207-1540) - Coupling : 105663-0740 (2) Nozzle holder assembly : 65.10101-7300 (105160-4351 DOOWON) (3) Nozzle : 65.10102-6046 (105029-1330 DOOWON) (4) Fuel injection pipe...
Page 121 5) DE12TIA (EBILC) (1) Fuel injection pump : 65.11101-7393 (106675-300A DOOWON) - Fuel injection pump : KP-PE6P120/720RS3S (106067-6220 DOOWON) - Governor : KP-EP/RFD200/1300PQ39C311(105407-759B) - Fuel feed pump : KP-FP/K-PS (105207-1540) - Coupling : 105663-0740 (2) Nozzle holder assembly : 65.10101-7300 (105160-4351 DOOWON) (3) Nozzle : 65.10102-6046 (105029-1330 DOOWON) (4) Fuel injection pipe...
Page 122 6) DE12TIA (EBILD) (1) Fuel injection pump : 65.11101-7402 (106675-460A DOOWON) - Fuel injection pump : KP-PE6P120/720RS3S (106067-6220 DOOWON) - Governor : KP-EP/RFD200/1300PQ39C311(105407-759A) - Fuel feed pump : KP-FP/K-PS (105207-1540) - Coupling : 105663-0740 (2) Nozzle holder assembly : 65.10101-7300 (105160-4351 DOOWON) (3) Nozzle : 65.10102-6046 (105029-1330 DOOWON) (4) Fuel injection pipe...
Page 123 (6) Performance curve of governor NOTCH : ~ 11 NOTCH 14 more + _ 0.1 Boo. com stroke : 1.0 12.7 + _ 0.1 Idle sub spring set. (12.3) 10.3 + _ 0.1 + _ 0.1 + _ 0.1 (1130) 1200 1150 Pump speed(rpm) N = 550 rpm...
Page 124 7) DE12TIA (EBIEC) (1) Fuel injection pump : 65.11101-7368A (106675-4590 DOOWON) (Modified by 65.11101-7300A injection pump) - Fuel injection pump : KP-PE6P120/720RS3S (106067-6150 DOOWON) - Governor : KP-EP/RSV200-1300PQ39C311(105407-7590) - Fuel feed pump : KP-FP/K-PS (105207-1520) - Coupling : 105663-0470 (2) Nozzle holder assembly : 65.10101-7300 (105160-4351 DOOWON) (3) Nozzle : 65.10102-6046 (105029-1330 DOOWON) (4) Fuel injection pipe...
Page 125 (6) Performance curve of governor Boo. com stroke : 1000 1200 1400 Pump speed(rpm) N = 500 rpm 12.5 11.5 10.5 Boost pressure(mmHg) EE6OM037 MAINTENANCE OF MAJOR COMPONENTS - 121 -...
Page 126 8) DE12TIS - (ECIEA) (1) Fuel injection pump : 65.11101-7358A (106675-461B DOOWON) - Fuel injection pump : KP-PE6P120/720RS3S (106067-7590 DOOWON) - Governor : KP-EP/RSV200-1300PQ39C311(105407-7590) - Timer : KP-EP/SPG700-1100Z3/R (105681-1910) - Fuel feed pump : KP-FP/K-PS (105207-1540) - Coupling : 105663-0740 (2) Nozzle holder assembly : 65.10101-7298 (105101-8460 DOOWON) (3) Nozzle : 65.10102-6053 (105025-2240 DOOWON)
Page 127 (6) Performance curve of governor NOTCH : 14 NOTCH 14 more + _ 0.1 Boo. com stroke : 1.0 Idle sub spring set. +1.2 + _ 0.1 (12.6) 11.1 + _ 0.1 + _ 0.1 (1050) 1150 1070 Pump speed(rpm) N = 550 rpm (12.6) - 1.0)
Page 128 9) DE12TIS - (ECIEB) (1) Fuel injection pump : 65.11101-7361A (106675-461A DOOWON) - Fuel injection pump : KP-PE6P120/720RS3S (106067-622A DOOWON) - Governor : KP-EP/RSV200-1300PQ39C311(105407-7590) - Timer : KP-EP/SPG700-1100Z3/R (105681-1910) - Fuel feed pump : KP-FP/K-PS (105207-1540) - Coupling : 105663-0740 (2) Nozzle holder assembly : 65.10101-7298 (105101-8460 DOOWON) (3) Nozzle : 65.10102-6053 (105025-2240 DOOWON)
Page 129 (6) Performance curve of governor NOTCH : 14 NOTCH 14 more + _ 0.1 Boo. com stroke : 1.2 Idle sub spring set. + _ 0.1 12.5 +0.4 + _ 0.1 11.5 10.1 + _ 0.1 + _ 0.2 + _ 0.1 1070 1150 1100 Pump speed(rpm)
Page 130 10) DE12TIS - (ECIEC) (1) Fuel injection pump : 65.11101-7362A (106675-461C DOOWON) - Fuel injection pump : KP-PE6P120/720RS3S (106067-622A DOOWON) - Governor : KP-EP/RSV200-1300PQ39C311(105407-7590) - Timer : KP-EP/SPG700-1100Z3/R (105681-1910) - Fuel feed pump : KP-FP/K-PS (105207-1540) - Coupling : 105663-0740 (2) Nozzle holder assembly : 65.10101-7298 (105101-8460 DOOWON) (3) Nozzle : 65.10102-6053 (105025-2240 DOOWON)
Page 131 (6) Performance curve of governor NOTCH : 14 NOTCH 14 more + _ 0.1 Boo. com stroke : 0.7 Idle sub spring set. + _ 0.1 11.4 +0.5 10.6 + _ 0.1 + _ 0.1 + _ 0.1 (1020) 1100 1040 Pump speed(rpm) N = 500 rpm...
Page 132 11) DE12TIS - (ECIED) (1) Fuel injection pump : 65.11101-7419 (106675-461E DOOWON) - Fuel injection pump : KP-PE6P120/720RS3S (106067-622A DOOWON) - Governor : KP-EP/RSV200-1300PQ39C311(105407-7590) - Timer : KP-EP/SPG700-1100Z3/R (105681-1910) - Fuel feed pump : KP-FP/K-PS (105207-1540) - Coupling : 105663-0740 (2) Nozzle holder assembly : 65.10101-7298 (105101-8460 DOOWON) (3) Nozzle : 65.10102-6053 (105025-2240 DOOWON)
Page 133 (6) Performance curve of governor NOTCH : 14 NOTCH Rack limiter 14 more + _ 0.1 Boo. com stroke : 1.35 Idle sub spring set. + _ 0.1 12.8 (11.35) + _ 0.1 10.9 + _ 0.1 7.35 + _ 0.3 5.95 + _ 0.1 1030...
Page 134 12) DE12TIS - (ECILA) (1) Fuel injection pump : 65.11101-7396 (106675-400B DOOWON) - Fuel injection pump : KP-PE6P120/720RS3S (106067-622A DOOWON) - Governor : KP-EP/RSV200-1300PQ39C311(105407-7590) - Timer : KP-EP/SPG700-1100Z3/R (105681-1910) - Fuel feed pump : KP-FP/K-PS (105207-1540) - Coupling : 105663-0740 (2) Nozzle holder assembly : 65.10101-7298 (105101-8460 DOOWON) (3) Nozzle : 65.10102-6053 (105025-2240 DOOWON)
Page 135 (6) Performance curve of governor 14 more NOTCH : 14 NOTCH + _ 0.1 Boo. com stroke : 0.8 13.0 + _ 0.1 Idle sub spring set. (12.6) 11.3 + _ 0.1 10.2 + _ 0.1 + _ 0.3 (1110) 1210 1140 Pump speed(rpm) N = 500rpm...
Page 136 13) DE12TIS - (ECILB) (1) Fuel injection pump : 65.11101-7395 (106675-300B DOOWON) - Fuel injection pump : KP-PE6P120/720RS3S (106067-622A DOOWON) - Governor : KP-EP/RSV200-1300PQ39C311(105407-759A) - Timer : KP-EP/SPG700-1100Z3/R (105681-1910) - Fuel feed pump : KP-FP/K-PS (105207-1540) - Coupling : 105663-0740 (2) Nozzle holder assembly : 65.10101-7298 (105101-8460 DOOWON) (3) Nozzle : 65.10102-6053 (105025-2240 DOOWON)
Page 137 14) DE12TIS - (ECILC) (1) Fuel injection pump : 65.11101-7403 (106675-410A DOOWON) - Fuel injection pump : KP-PE6P120/720RS3S (106067-622A DOOWON) - Governor : KP-EP/RSV200-1300PQ39C311(105407-7590) - Timer : KP-EP/SPG700-1100Z3/R (105681-1910) - Fuel feed pump : KP-FP/K-PS (105207-1540) - Coupling : 105663-0740 (2) Nozzle holder assembly : 65.10101-7298 (105101-8460 DOOWON) (3) Nozzle : 65.10102-6053 (105025-2240 DOOWON)
Page 138 (6) Performance curve of governor NOTCH : ~ 14 NOTCH 14 more + _ 0.1 Boo. com stroke : 1.0 + _ 0.1 13.4 Idle sub spring set. +1.9 11.4 + _ 0.1 + _ 0.1 + _ 0.1 + _ 0.1 (1130) 1230 1180 Pump speed(rpm)
Page 139 6.1.3. Fuel feed pump 1) General descriptions and construction The P-type injection pump is mounted with K-ADS or KP type feed pump. These pumps have the same basic construction and operation, and the general descriptions of the KP type pump are given below : The figures show its construction (right figure) and operation (below figure).
Page 140 흡입 토출 차단 Inlet side Outlet side Interruption EQM4020I The fuel pressurized as the cam rotates on flows through the check valve on the outlet side as shown in (B). If the feeding pressure increases abnormally, the spring is compressed, resulting in interrupting further delivery of fuel as shown in (C).
Page 141 • Clamp the feed pump with a vise and disassemble the plugs (30, 32), strainer (31) and gaskets (35, 36). • Take off the priming pump (25), plug (16), both gaskets (18), spring (15), and check valve (14). • Take off the prig (7), gasket (8), spring (6), and piston (5) on the piston side. •...
Page 142 (2) Delivery test Make a test with the feed pump mounted on a pump tester as illustrated. Operate the pump at the rate of 1,000 rpm and check to see if the pump delivery is more than 405 cc/15 seconds. EAMC016I (3) Sealing test Plug up the delivery port on the...
Page 143 2) 1-spring type (DE12T) (1) Disassembly 1. Cap nut 2. Adjusting screw 3. Spring 4. Push rod 5. Connector 6. Retaining nut 7. Needle valve 8. Nozzle 9. Nozzle holder EQM4025S (2) Reassembly • After removing carbon deposit, sub- merge the nozzle in diesel oil and clean it.
Page 144 (4) Testing With the nozzle assembled to a nozzle tester and pressure of specified applied, check the nozzle for fuel leakage. EAMC022I 3) 2-spring type (DE12TIS) This inspection data is base DE12TI engine. (1) Disassembly 1. Nozzle holder body 2. Push rod 3.
Page 145 c. Install the nozzle holder body (1) onto the plate with the cap nut side facing downward. EQM4031I d. Assemble adjusting shim (10), secondary spring (11), and spring seat (12) on the noz- zle holder body in the order as described. NOTE : The secondary spring is the same one as the primary spring.
Page 146 g. After installing the gasket (157892-1500) on the nozzle, use the cap nut (157892-4000 : SW22mm) to fix the nozzle onto the nozzle holder. NOTE : While tightening the cap nut, keep checking to see if the lock pin comes all the way into the nozzle.
Page 147 l. Assemble the nozzle and nozzle holder assembly to the nozzle tester (105785- 1010). EQM4039I m. Adjust the primary opening pressure to the specified pressure using the adjusting screw (4). EQM4040I n. With a monkey wrench, fix the nozzle hold- er securely and tighten the cap nut (SW 19mm) to specified torque.
Page 148 b. Install the nozzle holder on the plate with the cap nut facing upward. c. Install the holder into the cap nut. d. Install a nut (157892-1000 : SW 17mm) on the holder. e. Assemble the pin (157892-4200 or 157892-4300) to the dial gauge (157954-3800).
Page 149 f. Install the dial gauge on the holder assembly so that the pin is brought into contact with the upper end of the push rod, then fix the pin with the nut. NOTE 1 : Fix the dial gauge so that a stroke of 2 mm or so can be measured.
Page 150 Inspection of pre-lift a. If the nozzle tester handle is released with the needle valve engaged in a full lift con- dition, the tester pressure drops, being accompanied by decrease in the needle valve lift value (indicated value on the dial gauge).
Page 151 c. If the measured pre-lift value deviates from the specified limit, replace the pin (14, 16), lift piece (13), spacer (15), and nozzle assembly (A) with a new “nozzle service kit”. EQM4053I Inspection of secondary opening pressure a. After confirming the pre-lift, operate the nozzle tester and increase the internal pressure up to 350 ~ 450 kgf/cm to fully lift...
Page 152 Adjusting secondary opening pressure a. In the event that the measured value devi- ates from the specified limit, readjust the primary opening pressure if the amount of deviation is small. (to the standard range of the primary opening pressure) - If the secondary opening pressure is lower than the standard value: Adjust the primary opening pressure up to the top limit of the standard vague, and then...
Page 153 Retaining nut a. Take out the dial gauge, nut, holder and gasket from the cap nut. b. Remove the adjusting retaining nut and gasket, and install the original retaining nut. (SW 19mm) 6.0 ~ 8.0 kg . m Torque EQM4036I Inspection at completion a.
Page 154 6.1.5. Diagnostics and troubleshooting Complaints Possible causes Corrections 1. Engine won’t start 1) Fuel not being pumped ® Fuel pipes clogged or air into Correct out from feed pump pipe fine ® Feed pump valve defective Replace ® Feed pump piston or Push rod Disassemble, correct sticking 2) Fuel not being injected...
Page 155 Complaints Possible causes Corrections ® 6. Engine output unstable supply of fuel insufficient Check feed pump ® Air in fuel Bleed ® Water in fuel Replace fuel ® Operation of plungers unsmooth Disassemble, correct ® Movement of control rack Disassemble, correct sluggish ®...
Page 156 6.2. Cooling System 6.2.1. General information This engine is water-cooling type. Heat from the combustion chamber and engine oil heat are cooled down by coolant and radiated to the outside, resulting in the normal operation of the engine. Looking into the cooling system, the water pumped up by the water pump circulates around the oil cooler through the water pipe to absorb the oil heat, and then flows through the water jacket of the cylinder block and water passage of the cylinder head to absorb the heat of the combustion chamber.
Page 157 6.2.3. Water pump • Loosen the bolt (14) to disassemble the housing cover (13). • Heat the impeller (5) slightly, then remove it using a puller jig. • Remove the mechanical seal. • Remove the shaft and bearing assembly from the housing. •...
Page 158 6.2.4. Thermostat • General descriptions and main data The thermostat maintains a constant To radiator temperature of coolant (90 ~ 95 °C) and improves thermal efficiency of the engine by preventing heat loss. Namely, when the temperature of coolant is low, the thermostat valve is Bypass closed to make the coolant bypass to valve...
Page 159 • Replacing thermostat and precautions for handling (1) Precautions for handling The wax pallet type thermostat does not react as quickly as bellows type one to a vari- ation of temperature of coolant. Such relatively slow reaction is mainly due to the large heat capacity of the wax pellet type thermostat.
Page 160 6.2.5. Diagnostics and troubleshooting Complaints Possible causes Corrections • • 1. Engine overheating Lack of coolant Replenish coolant • • Radiator cap pressure valve Replace cap spring weakened • • Fan belt loosened or broken Adjust or replace fan belt •...
Page 161 6.3. Lubricating System 6.3.1. General descriptions and main data • General descriptions All the engine oil pumped up from the oil pan by the gear type oil pump is filtrated through the oil cooler and oil filter, and this filtrated oil is forced through the main oil gallery in the cylinder block from where it is distributed to lubricate the various sliding parts, and fuel injec- tion pump in order to ensure normal engine performance.
Page 162 6.3.2. Oil pump • Disassembly (1) Disassembly of oil pump drive gear a. Unscrew the screw and disas- semble the oil relief valve. b. Unfold the washer for the oil pump drive gear fixing nut and remove the nut. c. Disassemble the drive gear. EQM4006I (2) Remove the oil pump cover fixing nuts and disassemble the oil pump...
Page 163 (3) Measuring clearance between drive shaft and bushing a. Measure the outside diameters of the drive shaft and driven shaft, and replace if the measured values are less than the limit. Standard 16.95 ~ 16.968 mm b. Measure the inside diameter of the pump body bushing to determine the clearance between the bushing and shaft, and compare the measured value with the standard value to determine whether to replace or not.
Page 164 6.3.4. Diagnostics and troubleshooting Complaints Possible causes Corrections • • 1. Oil consumption Poor oil Use suggested oil • • excessive Oil seal or packing leaky Replace • • Pistons or piston rings worn Replace pistons and/or piston rings • •...
Page 165 6.4. Turbocharger 6.1.1. Main data and specifications 1) Main data and specifications Specification DE12TI DE12TIA, DE12TIS Turbocharger Model GT42 Air pressure at compressor Approx. 1.2 kg/cm Approx. 1.3 kg/cm outlet maximum Approx. 22.0 Approx. 22.5 Air suction volume output /min /min Speed of turbine Approx.
Page 166 3) Construction 25,26 EQM8026I 1. Bolt 10. Lock nut 19. Seal ring 2. Clamp 11. Compressor wheel 20. Screw 3. Lock nut 12. Piston ring 21. Thrust bearing 4. V-band 13. Wheel assembly 22. Thrust collar 5. O-ring 14. Wheel shroud 23.
Page 167 6.4.2. General descriptions The engine output is determined by the fuel delivery volume and engine efficiency. To burn the supplied fuel completely to change into effective power for the engine, the volume of air enough to burn the fuel completely should be supplied into the cylinders. Therefore, the engine output is determined substantially by the cylinder capacity, and a greater volume of compressed air is charged into cylinders of given capacity, the greater engine out- put can be obtained as a greater volume of air charged into the cylinders burns so much more...
Page 168 6.4.4. Precautions for operation 1) Precautions for operation of engine The following precautions should be observed when starting, operating, or stopping the engine : Operations Precautions Reasons When starting 1) Check oil level 2) Abrupt starting of the engine caus- 2) Crank the engine with starter to the engine es the engine to rotate with oil not...
Page 169 Deteriorated engine oil affects adversely not only the engine but torso the tur- bocharger. Suggested engine oils for the turbocharger-mounted engine are as follows : Recommend oil Engine model SAE No. API No. DE12T/TI/TIA SAE 15W40 above CD or CE SAE 15W40 DE12TIS ACEA-E2 or ACEA-E3 (API CH-4) SAE 10W40 * If long oil change intervals are to be used, ACEA-E3 oil must be used.
Page 170 6.4.6. Periodical checking and servicing Make it a rule to check the turbocharger assembly for condition and contamination periodically. 1) Guide for checking the rotor for rotating condition The inspection of the rotor assembly for rotating condition should be performed by the degree of unusual sound.
Page 171 3) Guide for disassembling/cleaning and checking the turbocharger First, disassemble the turbocharger from the engine and clean/check it with the oil inlet and outlet plugged with tape and so on. 4) Precautions for reassembling the turbocharger onto the engine For reassembly of the turbocharger or handling it after reassembly operation, be sure to observe the following precautions : Especially, exercise extreme care to prevent foreign matters from entering the inside of the tur- bocharger.
Page 172 6.4.7. Diagnostics and troubleshooting Complaints Possible causes Corrections 1. Excessive black smoke 1) Air cleaner element clogged Replace or clean 2) Restrictions in air duct Check and correct 3) Leakage at intake manifold Check and correct 4) Turbocharger seized up and not rotating Disassemble/repair or replace 5) Turbine blades and compressor blades...
Page 173 6.5. Air Intake System 6.5.1. Maintenance ( only when engine is switched off ) Empty the dust bowl (7) regularly. The bowl should never be filled more than halfway with dust. On slipping off the two clamps (3), the dust bowl can be removed. Take off the cover (6) of the dust bowl and empty.
Page 174 6.5.3. Cleaning filter elements • By compressed air ( wear goggles ) - For the purpose, the air gun should be fitted with a nozzle extension which is bent 90° at the discharge end and which is long enough to reach down inside to the bottom of the element.
Page 175 • Checking the air cleaner cartridge - Before reinstalling the cartridge, it must be checked for damage e.g. to the paper pleats and rubber gaskets, or for bulges and dents etc. in the metal jacket. - Cracks and holes in the paper pleat- ing can be established by inspecting the cartridge with a flashlight.
Page 176 6.6. V-belts (1) Change the V-belts if necessary If in the case of a multiple belt drive, wear or differing tensions are found, always replace the complete set of belts. (2) Checking condition Check V-belts for cracks, oil, overheating and wear. (3) Testing by hand •...
Page 177 4) Measuring tension Lower indicator arm (1) into the scale. • Apply tester to belt at a point midway between two pulleys so that edge of contact surface (2) is flush with the V- belt. • Slowly depress pad (3) until the spring can be heard to disengage.
Page 178 7. SPECIAL TOOL LIST Part No. Figure Tool Name Remark DPN-5337 Nozzle tube insert ass’y EF.123-082 Nozzle tube extractor D2366 EF.123-015 DE12/T/TI Injection pump setting ass’y EF.123-156 DE12TIS CR : made USA EF.123-127 (up to 2000. Apr.) Oil seal insert ass’y (Front) NOK : made Japan EF.123-173 (From 2000.
Page 179 Part No. Figure Tool Name Remark EF.123-066 Valve stem seal punch EU.2-0131 Valve clearance adjust ass’y EF.123-065 Valve spring press EU.2-0647 Crankshaft gear punch EF.123-079 DE12/T/TI/TIS Piston sleeve EF.120-208 Use all engine 60.99901-0027 Feeler gauge T7610001E Snap ring plier T7621010E Piston ring plier SPECIAL TOOL LIST - 175 -...
Page 180 APPENDIX • Tightening torque for major parts Screw Strength Major Parts Tightening Torque Remarks (Diameter x pitch) (grade) 1st : 6 kg • 2nd : 180° 10.9T Dodecagon Finished : 150° (angle torque) 24.5 kg hexagon Cylinder head bolt • 1st : 6 kg •...
Page 181 For example, a screw coated with MoS2 should be tightened to 60% or so of the stan- dard value. • Tightening torque for hollow screw (4-hole) Material SM25C 13.0 18.0 30.0 *SUM22L 11.0 16.0 20.0 35.0 STS304 11.0 16.0 20.0 35.0 * : Adopted in DAEWOO engine APPENDIX - 177 -...
Page 182 • Maintenance specification table (unit : mm) Stand value Limit Group Part Inspection Item Correction Remark for assembly for use Measure unworn Inside diameter of 123 ~ 123.023 123.223 Replace liner portion beneath the Cylinder liner for wear rim of the upper side Cylinder Projected portion of liner 0.03 ~ 0.08 block &...
Page 183 (unit : mm) Stand value Limit Group Part Inspection Item Correction Remark for assembly for use Axial run-out of journal Correct In horizontal and 0.05 and pin with a grinder vertical directions Outside diameter of 95.966 ~ 94.966 Replace crankshaft 96 g6 journal 95.988...
Page 184 (unit : mm) Stand value Limit Group Part Inspection Item Correction Remark for assembly for use Outside diameter 10.950 ~ 10.87 Replace valve guide of intake valve stem 10.970 Replace valve & together when Outside diameter 10.935 ~ guide 10.84 replacing valve of exhaust valve stem 10.955...
Page 185 (unit : mm) Stand value Limit Group Part Inspection Item Correction Remark for assembly for use Rocker arm shaft 23.978 ~ 23.75 Replace for wear 23.959 valve Permissible taper Replace of push rod Clearance between Valve 0.035 ~ 0.077 0.15 Replace tappet tappet &...
Page 186 DE12TIS : 160/220 system nozzle (kg/cm Operating pressure of overflow Replace valve valve (kg/ Replace cylinder Height of projected nozzle on the DE12T/TI : DE12TIS : head, nozzle tube or cylinder head (mm) 3.4 ~ 3.5 2.4 ~ 2.5 seal ring Misalingnment between injection 0.2 or less...
Page 187 • Engine Assembly ( DE12TIS - ECIEA) EE6OM026 APPENDIX - 183 -...

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De12ti De12tia De12tis

Daewoo DE12T Manual

1 Safety Regulations & Engine Specifications

2 Technical Information

3 Disassembly and Reassembly of Major Components

4 Commissioning and Operation

5 Maintenance and Care

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Summary of Contents for Daewoo DE12T

This manual is also suitable for:

Daewoo DE12T Manual

1 Safety Regulations & Engine Specifications

2 Technical Information

3 Disassembly and Reassembly of Major Components

4 Commissioning and Operation

5 Maintenance and Care

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Summary of Contents for Daewoo DE12T

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