Doosan DE12 Series Operation & Maintenance Manual
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Doosan DE12 Series Operation & Maintenance Manual

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950106-029004EN
Operation &
Maintenance Manual
DIESEL VEHICLE ENGINE
DE12

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Summary of Contents for Doosan DE12 Series

  • Page 1 950106-029004EN Operation & Maintenance Manual DIESEL VEHICLE ENGINE DE12...
  • Page 3 Doosan Infracore's DE12 series (DE12, DE12T, DE12TI and DE12TIS) diesel engine. To provide the best engine to our customers, DE12 series (DE12, DE12T, DE12TI and DE12TIS) diesel engine is designed to satisfy all requirements for low noise, economic fuel consumption, high speed and durability with our latest technology and quality.

  • Page 5: Table Of Contents

    CONTENTS 1. GENERAL INFORMATION 1.1. General Repair Instructions ........................1 1.2. Engine Characteristics ........................... 2 1.3. Engine Specifications ..........................3 1.4. Engine Assembly ..........................12 2. MAJOR MAINTENANCE 2.1. Preventive Maintenance ........................18 2.2. Diagnosis and Remedy ........................26 2.3. Engine Inspection ..........................36 3.

  • Page 7: General Information

    4. The use of proper tools and special tools where specified is important to efficient and reliable service operation. 5. Use genuine DOOSAN Infracore 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.

  • Page 8: Engine Characteristics

    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.

  • Page 9: Engine Specifications

    1.3. Engine Specifications 1.3.1. Specification Engine model DE12 DE12T DE12TI DE12TIS Items 4 cycle in-line, 4 cycle in-line, 4 cycle in-line, Engine type Water-cooled type Water-cooled type Water-cooled type Naturally aspirated Turbo charged Turbo charged & intercooled Combustion chamber type Direct injection type Cylinder liner type Replaceable dry liner...
  • Page 10 Engine model DE12 DE12T DE12TI DE12TIS Items °C Thermostat type Wax pallet type (83 ~ 95 Air compressor type & capacity (cc/rev) Gear driven type, Truck : 220 , Bus : 318 Power steering pump (lit/bar) Bus : 16 / 100 , Truck : 18 / 125 Alternator (voltage - capacity) (V -A) Truck : 24 - 45 , Bus : 24 - 150...
  • Page 11 1.3.3. Performance curve 1) DE12-235PS kg m g/kW h g/ps.h 1000 1400 1800 2200 DL112001A Description ISO 1585 (SAE J1349) Power Output max. 173 kW (235 ps) / 2,200 rpm Torque max. 799 N.m (81.5 kg.m) / 1,400 rpm Fuel consumption min.
  • Page 12 2) DE12T-300PS kg m 1100 1000 g/kW h g/ps.h 1000 1400 1800 2200 DL112002A Description ISO 1585 (SAE J1349) Power Output max. 220 kW (235 ps) / 2,200 rpm Torque max. 1,078 N.m (110 kg.m) / 1,300 rpm Fuel consumption min.
  • Page 13 3) DE12T-310PS 1 000 1400 1600 1800 1200 2000 2200 DL112003A Description KS - R0071 Power Output max. 310 ps / 2,100 rpm Torque max. 125 kg.m / 1,260 rpm Fuel consumption min. 143 g / ps.h - 7 - GENERAL INFORMATION...
  • Page 14 4) DE12TIS - 290PS 1400 1600 1800 1200 2000 2200 EB8O1003 Description ISO 1585 (SAE J1349) Power Output max. 223 kW (290 ps) / 2,100 rpm Torque max. 1,127 N.m (115kg.m) / 1,260 rpm Fuel consumption min. 186 g/kW.h (143 g / ps.h) GENERAL INFORMATION - 8 -...
  • Page 15 5) DE12TIS - 320PS 1 000 1400 1600 1800 1200 2000 2200 DL112003A Description KS - R0071 Power Output max. 320 ps / 2,100 rpm Torque max. 135 kg.m / 1,260 rpm Fuel consumption min. 143 g / ps.h - 9 - GENERAL INFORMATION...
  • Page 16 6) DE12TIS - 340PS 1200 1400 1600 1800 2000 2100 EB8O1002 Performance ISO 1585 (SAE J1349) Power Output max. 250 kW (340 ps) / 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) GENERAL INFORMATION - 10 -...
  • Page 17 7) DE12TIS- 360PS 1400 1600 1800 1200 2000 2200 EB8O1001 Performance ISO 1585 (SAE J1349) Power Output max. 265 kW (360 ps) / 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) - 11 - GENERAL INFORMATION...

  • Page 18: Engine Assembly

    1.4. Engine Assembly 1.4.1. Engine sectional view (longitudinal) EQM8018I 1. Cooling water pump 8. Piston pin Oil pan 2. Fuel filter 9. Piston Connecting rod 3. Valve 10. Chamber Cam shaft 4. Valve spring 11. Crank shaft pulley Flywheel housing 5.
  • Page 19 1.4.2. Engine sectional view (cross) EQM8019I 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.
  • Page 20 1.4.3. Engine assembly views 1) DE12 (Bus) EQM8007I 1. Fly wheel 11. Oil level gauge Air pipe 2. Flywheel housing 12. Pilot bearing Cooling water pump 3. Oil pressure unit 13. Oil filter Air compressor 4. Lifting hook 14. Oil drain plug Exhaust manifold 5.
  • Page 21 2) DE12TI (Bus) 14 15 EQM8008I 1. Fly wheel 12. Pilot bearing Air pipe (Air cleaner to turbocharger) 2. Flywheel housing 13. Oil filter 3. Oil pressure unit 14. Oil drain plug Turbocharger 4. Lifting hook 15. Oil pan Exhaust manifold 5.
  • Page 22 3) DE12TI (Truck) 28 29 38 39 EQM8009I 1. Flywheel housing 15. Fuel injection pump Turbocharger 2. Oil cooler 16. Engine mounting bracket Exhaust elbow 3. Breather hose 17. Power steering pump Cooling delivery pipe 4. Fuel filter 18. Alternator Engine mounting bracket 5.
  • Page 23 4) DE12TIS (Bus) 14 15 EQM8008I 1. Fly wheel 12. Pilot bearing Air pipe (Air cleaner to turbocharger) 2. Flywheel housing 13. Oil filter 3. Oil pressure unit 14. Oil drain plug Turbocharger 4. Lifting hook 15. Oil pan Exhaust manifold 5.
  • Page 24 GENERAL INFORMATION - 18 -...

  • Page 25: Major Maintenance

    For the improper control might give the fatal damage to the cooling water pump and cylinder liners, detail care is needed. Since DE12/T/TI and DE12TIS (diesel engine of DE12 series) cylinder liner is dry type, particularly the cooling water control should be applied thoroughly.
  • Page 26 (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.
  • Page 27 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.
  • Page 28 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. Oil filter (Cartridge) Oil filter head EQM4010I 2.1.5. Fuel filter Drain water in cartridge with loosening the cock under filter manually (6) from time to time.
  • Page 29 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.
  • Page 30  No. 1 Cylinder is located at the side where flywheel was installed. Cooling fan Flywheel Intake valve Exhaust valve Cylinder no. EA8O6001 2.1.9. Cylinder compression pressure  Stop the engine after warming up, and take out nozzle holder assembly. EFM1004I ...
  • Page 31 2.1.10. Injection nozzle Normal Abnormal Abnormal EFM1006I EFM1006I Install a nozzle on the nozzle tester. If the inspected injection pressure is less than the specified value, adjust using the adjusting shims. Engine model DE12 DE12T DE12TI DE12TIS Injection nozzle 1st : 160kg 1st : 160kg 220kg 220kg...
  • Page 32 2.1.13. Air removal of fuel system The suction room of fuel injection pump has the function of air removal continuously during the operation through a relief valve. In case that the suction room lacks fuel at all, for instance, in case of new installation of injection pump, after loosening the air removing screws of cartridge filter respectively, remove the air by operating the manual pump of fuel supply pump until bubble will disappear.

  • Page 33: Diagnosis And Remedy

    2.2. Diagnosis and Remedy The following description summarizes the probable cause of and remedy for general failure by item. DE12TIS inspect the electrical parts problem with SCAN 200 and refer diagnostic manual. Immediate countermeasures should be taken before a failure is inflamed if any symptom is detected. 1.
  • Page 34 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 35 3. Output Insufficient Installation improper Engine 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 36 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 37 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 38 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 39 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 charging discharge damage liquid's standard Inspect generator Charging Replace Voltage regulator...
  • Page 40 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 Cylinder head gasket's leak Replace gasket Wear of piston, piston ring or liner Adjust...
  • Page 41 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. grind crankshaft Lopsided wear of crankshaft Grind or replace...
  • Page 42 Condition Causes Remedies 7) Oil consumption excessive (1) Oil level elevated Clearance between cylinder liner & piston Replace Wear of piston ring, ring groove Replace piston, piston ring Piston ring’s damage, stick, wear Replace piston ring Piston ring opening’s disposition Correct position improper Piston skirt part damaged or abnormal...

  • Page 43: Engine Inspection

    2.3. Engine Inspection 2.3.1. Stopping engine After checking the engine for any unusual condition at the idling speed, then turn the key switch to stop the engine. 2.3.2. General engine inspection cycle : Check & adjust : Replace Inspection time (Hr) Inspection Daily Remark...

  • Page 44: Disassembly And Reassembly Of Major Components

    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. 3.1.2.
  • Page 45 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 prepared container. Reassemble the drain plug with the oil pan after draining out the engine oil. EQM3001I 3.1.4.
  • Page 46 3.1.6. Air con. compressor Remove the air con. compressor fixing bolts and disassemble the air con. compressor. Remove the tension adjusting bolt and bracket. EQM3007I 3.1.7. Oil level gauge guide tube Loosen the flange nut installed on the ladder frame to remove the guide tube. EQM3005I 3.1.8.
  • Page 47 3.1.10. ntercooler Tear down the various hoses and air pipes from the inter cooler Remove the intercooler fixing bolts and tear it down. EA6M2001 3.1.11. Fuel injection pipe Unscrew the hollow screws to disassemble the fuel return pipe. Remove the nuts installed on the fuel injection pump and nozzles, then disassemble the injection pipe.
  • Page 48 3.1.14. Turbo charger Release the clamp screw of the rubber hose connected to the intake manifold, and take off the intake pipes both simultaneously. Unscrew the exhaust pipe bracket fixing bolts, release the nuts installed on the turbocharger, then disassemble the exhaust pipe. Remove the turbocharger after removing the oil supply pipe and return pipe and releasing the fixing nuts.
  • Page 49 3.1.18. Cooling water pump Remove the water pipe connected to the expansion tank. Remove the water pipe and hoses connected to the water pump. Unscrew the water pump fixing bolts and remove the water pump. 3.1.19. Air compressor Remove the oil hoses, water pipe, air pipe connected to the air compressor.
  • Page 50 3.1.21. Oil filter Using a filter remover wrench, remove the oil filter cartridge. Remove the pipe connected to the oil cooler. Loosen the oil filter fixing bolts and disassemble the oil filter head from the cylinder block. 3.1.22. Idle pulley Remove the bolts and disassemble the fan drive pulley.
  • Page 51 3.1.25. Timing gear case cover Unscrew the pulley fixing bolts and disassemble the pulley-vibration damper assembly. Unscrew the vibration damper fixing bolts and disassemble the damper from the pulley. EAMD025I 3.1.26. Idle gear Unscrew the idle gear fixing bolts and disassemble the thrust washer and idle gear.
  • Page 52 3.1.29. Rocker arm Unscrew the rocker arm bracket bolts and remove the rocker arm assembly. Take off the snap rings to remove the washers and rocker arm, then unscrew the bracket fixing bolts to take off the bracket and springs. Take out the push rods.
  • Page 53 3.1.33. 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. Unscrew the oil cooler fixing bolts and remove the oil cooler from the oil cooler cover.
  • Page 54 3.1.37. Relief valve  Disassemble the relief valve. EAMD036I 3.1.38. Piston and connecting rod  Disassemble the pistons by two cylinders while turning the crankshaft.  Unscrew the connecting rod fixing bolts and take off the pistons and connecting rods in the direction of piston.
  • Page 55 3.1.39. Cylinder liner  Disassemble the cylinder liner using a liner puller. EAMD040I 3.1.40. 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.
  • Page 56 3.1.43. Cam shaft and tappet Remove the cam shaft gear. Take off the cam shaft gear and thrust washer. Take out the cam shaft care not to damage the cam shaft. Slide out the tappets by hand. EAMD044I 3.1.44. Crankshaft gear and oil pump idle gear Loosen the socket head bolts and take out the oil pump idle gear.
  • Page 57 3.1.46. Crank shaft Remove the main bearing cap fixing bolts in the opposite direction of assembling. Maintain the removed bearing caps in the order of cylinders. Temporarily install the bolts at the both side of crankshaft, and lift the shaft with a rope. NOTE : Do not mingle with the metal bearings and EAMD047S...

  • Page 58: Inspection And Measurement

    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 59 3) flatness Measure flatness of the intake/exhaust manifolds fitting surfaces on the cylinder head usinga 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 60 2) Valve guide Install the valve into the valve guide and measure the clearance between them by valve movement. If the clearance is excessive, measure the valve and replace either the valve or the valve guide, Measuring Point whichever worn more. Standard Limit EA0M4052...
  • Page 61 For removal of the valve seat, apply arc welding work to two points of valve seat insert, and pull Vavle seat out the valve seat insert with inner extractor. insert Undercool a new valve seat with dry ice for about 2 hours and press the valve seat insert into position in the cylinder head using a special Cylinder head tool (bench press).
  • Page 62 3.2.4. Rocker arm 1) Rocker arm shaft Rocker arm shaft 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. Replace the shaft if the measured value exceeds the limit.
  • Page 63 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 64 3.2.5. Camshaft 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. (mm) Standard Limit I II I II ø...
  • Page 65 Run-out 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 66 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 67 3.2.7. Crank shaft bearing and connection rod bearing 1) Visual check Check the scratch or crack of the crankshaft journal and crank pin with naked eyes. 2) Oil clearance between crankshaft and bearing Main bearing clearance Install the main bearing in the cylinder block, tighten the bearing cap to specified torque, then measure the inside diameter.
  • Page 68 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 to see that the bearing requires a considerable amount of finger pressure at reassembly operation. Spread = O A - O B EDM2047I Crankshaft bearing crush...
  • Page 69 4) Crank shaft end play Assemble the crankshaft to the cylinder block. With a dial gauge, measure crankshaft 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. 2) Clearance between the piston and cylinder liner With an outside micrometer, measure the piston outside diameter at a point 18mm away...
  • Page 70 3.2.9. Piston rings 1) Visual check Replace the piston rings with new ones if detected worn or broken when the engine is overhauled. 2) Piston ring gap  Insert the piston ring into the upper portion of the cylinder liner bore so that it is held at a right angle to the cylinder liner wall.
  • Page 71 3.2.10. Piston pin 1) 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 ø ø ø 44.990 mm or less 44.995 ~ 45.0 mm 2) Clearance...
  • Page 72 3) Wear Assemble the connecting rod to the crankshaft and measure connecting rod big end side clearance using a feeler gauge. Assemble the connecting rod to the piston and measure connecting rod small end side clearance. If the measured values are beyond the limit, replace the connecting rod.

  • Page 73: Reassembly

    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. To wet each sliding part, prepare the clean engine oil. Prepare service materials such as sealant, gaskets, etc.
  • Page 74 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. Check to see that the camshaft rotates smoothly. EDM2060I 3.3.5.
  • Page 75 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. Install the bearing and thrust washers to the bearing cap and apply oil to the bearing and thrust washers.
  • Page 76 Apply oil to the entire part of the bearing cap bolts, then tighten in tightening sequence to specified torque. Torque 30 kgf • After semi-tightening both bolts evenly, tighten them diagonally to about 15kg.m for the first stage and 25 kg m for the second stage •...
  • Page 77 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 assembly 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 78 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 79 3.3.12. Fuel injection pump drive gear Mount gasket by aligning the bolt holes with the pin holes on the bearing housing. Tighten the fixing bolts in the direction of fuel injection pump. EAMD027I 3.3.13. Timing gear case cover Install dowel pin on the timing gear\ case. Mount a gasket by aligning the fixing bolt holes with those on the gasket.
  • Page 80 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 connecting rod with the piston.
  • Page 81  Identify the mark “Y” or “TOP” on the ring end to prevent the top and bottom of the piston ring from being interchanged and make the marked portion face upward. Marked with the name of piston ring manufacturing company EAMD090I ...
  • Page 82  Semi-tighten the fixing bolts with hand, tighten them to specified torque using a torque wrench as follows. <Tightening sequence> 1) Step 1 : Apply engine oil to the top of the bolts. 2) Step 2 : Temporarily install the bolts so that only 1 ~ 2 threads are engaged. 3) Step 3 : Use a torque wrench to tighten them to around 8 kg.m 4) Step 4 : Use a torque wrench to tighten them to around 60°.
  • Page 83 3.3.19. Oil pump and oil pipe  Install a dowel pin in the No.7 bearing cap, then assemble the oil pump with specified torque. Torque 4.4 kg •  Assemble the oil suction pipe with the delivery pipe, then install the bracket on the bearing cap.
  • Page 84  After installing valve springs and spring retainer, press the retainer with a jig, then install cotter pin.  Tap the valve stem lightly with a rubber hammer to check that the valve is assembled correctly. Compress the spring EA0M4007 3.3.22.
  • Page 85 Install the spring, rocker arm, bracket, rocker arm, spring, washer, and snap ring in the described sequence. Install the rocker arm and bracket in the same direction. EA8M3008 3.3.24. Cylinder head Install the injection nozzle fixing stud bolts and water pipe fixing stud bolts. Clean the head bolt holes on the cylinder block with compressed air to remove foreign substances and thoroughly clean the gasket...
  • Page 86 Tighten the head bolts in proper sequence to the specified torque. <Cylinder Head Bolts> Type 3 Type 1 Type 2 (12.9T) Type 12.9T 10.9T M14X1.5X153 M14X1.5X150 M14X1.5X150 EAMD102I 1st : 6 kg 1st : 6 kg • • Tighten 24.5 kg 2nd : 180°...
  • Page 87  No. 1 Cylinder is located at the side where flywheel was installed. Cooling fan Flywheel Intake valve Exhaust valve Cylinder no. EA8O6001  Adjust valve clearance with a feeler gauge and tighten the fixing nuts to specified torque. Valve clearance adjust Torque 4.4 ±...
  • Page 88 3.3.27. Oil cooler Install the oil cooler onto the oil cooler cover. Carefully apply the gasket to prevent oil leakage. Do not damage the gasket and install the cover onto the cylinder block. Connect a connection pipe between the water pump and oil cooler.
  • Page 89  Turn the flywheel until No. 1 piston is placed in Timing the “OT” position of notch marks on the flywheel, Check hole and then turn again the flywheel clockwise until showing the notch mark of the right figure corresponding to the injection timing is aligned ↓...
  • Page 90 3.3.31. 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. Torque 13.4 kg • 3.3.32. Idle pulley Install the fan drive pulley onto the timing gear case cover.
  • Page 91 3.3.35. Exhaust manifold Install the exhaust manifold gasket over the stud bolts by aligning the gasket with the exhaust port on the cylinder head so that the face and back of the gasket can be positioned correctly. Semi-assemble the exhaust manifold and install the heat resisting plate.
  • Page 92 3.3.39. Intake manifold Fit a gasket on the intake manifold before assembling the intake manifold. Mount the air heater gasket on the intake manifold, then assemble the air heater with the intake manifold. Connect the air hoses to the boost compensator mounted on the fuel injection pump.
  • Page 93 3.3.42. Cylinder head cover Assemble the cover packing with the cover, install the cover on the head, then tighten the fixing bolts in sequence to specified torque. Torque 1.2 kg • Assemble the breather hose with PCV valve. EAMD126I 3.3.43. Air con. compressor Install the air con.
  • Page 94 3.3.46. V- belt Install the V-belt on the crank pulley and alternator pulley. Alternator Adjust the V-belt tension using the tension adjusting bolt. Air con. compressor EQM8013I Alternator EQM8012I 3.3.47. Cooling fan guide Install the three fan guide brackets then assemble the fan guide and bracket.

  • Page 95: Breaking-In

    3.4. Breaking-In 3.4.1. Operation of a new engine (Breaking-In) Because the sliding surfaces of a new engine are not lapped enough, the oil film can be destroyed easily by overload or overspeed and the engine life-time may be shortened. Therefore the following things must be obeyed by all means. Up to the first 1,000km(50 hours) Engine should be run at fast idling until the temperature of the engine becomes normal operating condition.
  • Page 96 <Engine Oil capacity> Engine oil capacity Recommend oil in Oil pan Engine Model Total (lit) API No. model Max. (lit) Min. (lit) DE12 API CD grade DE12T Truck DE12TI above CE grade ACEA-E2 DE12TIS ACEA-E3 (API CH-4) * If long oil change intervals are to be used, ACEA-E3 oil must be used. ENGINE DISASSEMBLY - 89 -...

  • Page 97: Maintenance Of Major Components

    4. MAINTENANCE OF MAJOR COMPONENTS 4.1. Cooling System 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 98 4.1.2. 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. With a press, remove the spline shaft and bearing. Reverse the disassembly sequence for reassembly operation.
  • Page 99 4.1.3. Thermostat General descriptions and main dataThe thermostat maintains a constant temperature of coolant (90 ~ 95 °C) and improves thermal efficiency of the engine by preventing heat loss. Namely, when the temperature of oolant is low, the thermostat valve is closed to make the coolant bypass to directly enter the water pump;...
  • Page 100 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 variation of temperature of coolant. Such relatively slow reaction is mainly due to the large heat capacity of the wax pellet type thermostat.
  • Page 101 4.1.4. 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 Fan belt fouled with oil Replace fan belt Thermostat inoperative Replace thermostat Water pump defective...

  • Page 102: Lubricating System

    4.2. Lubricating System 4.2.1. 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 injection pump in order to ensure normal engine performance.
  • Page 103 4.2.2. Oil pump Disassembly (1) Disassembly of oil pump drive gear a. Unscrew the screw and disassemble 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 cover.
  • Page 104 (3) Measuring clearance between drive shaft and bushing a. Measure the outside diameters of the drive shaft and driven shaft, and replace if themeasured values are less than the limit. ø 16.95 ~ ø 16.968 mm Standard 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 105 4.2.4. Diagnostics and troubleshooting Complaints Possible causes Corrections 1. Oil consumption excessive Poor oil Use suggested oil Oil seal or packing leaky Replace Pistons or piston rings worn Replace pistons and/or piston rings Cylinder liner worn Replace cylinder liner Piston rings sticking Replace pistons and/or piston rings Valve guide oil seals or valve...

  • Page 106: Fuel Injection Pump

    4.3. Fuel Injection Pump 4.3.1. 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. Fuel filter 7.
  • Page 107 1) DE12 (A) (1) Fuel injection pump : 65.11101 - 7260 (106671 - 4834 ZEXEL) - Fuel injection pump : KP - PE6P120 / 721RS3000 (106061 - 7330) - Governor : KP-EP / RFD200 / 1450PF23CHR (105489 - 4341) - Timer : KP-EP / SP800 - 1100Z6R (105636-2330) - Fuel feed pump : KP - FP / K - P (105207 - 1470)
  • Page 108 2) DE12 (B) (1) Fuel injection pump : 65.11101 - 7656 (106671 - 9460 ZEXEL) - Fuel injection pump : KP - PE6P120 / 721RS3000 (106067-1160) - Governor : KP - EP / RLD300 / 120095JFR (105923-2311) - Timer : KP - EP / SP600 - 1100Z5.5R (105636-2180) - Fuel feed pump : KP - FP / K - P (105207-1470) - Coupling...
  • Page 109 3) DE12T (1) Fuel injection pump : 65.11101-7261 (106671-921S ZEXEL) - Fuel injection pump : KP-PE6P120/721RS3000 (106067-0660) - Governor : KP-EP/RFD200/1450PF8CWR (105489-5102) - Timer : KP-EP/SP700-1100Z3R (105636-2530) - Fuel feed pump : KP-FP/K-P (105207-1470) - Coupling : 105663-0740 (2) Nozzle holder assembly : 65.10101-7300 (105160-4351 DOOWON) (3) Nozzle : 65.10102-6046 (105029-1330 DOOWON)
  • Page 110 4) DE12TI (280PS) (1) Fuel injection pump : 65.11101 - 7296 (106671 - 9430 ZEXEL) - Fuel injection pump : KP-PE6P120 / 721RS3S (106067 - 0850 ZEXEL) - Governor : KP - EP / RFD200 - 1400PF57DZR(105487 - 7010) - Timer : KP - EP / SPG700 - 110023/R (105681 - 1910) - Fuel feed pump : KP - FP / K - PS (105207 - 1540)
  • Page 111 5) DE12TI (310PS) (1) Fuel injection pump : 65.11101-7297 (106671-9430 ZEXEL) - Fuel injection pump : KP-PE6P120/721RS3S (106067-0850 ZEXEL) - Governor : KP-EP/RFD200-1400PF57DZR(105487-7010) - Timer : KP-EP/SPG700-110023/R (105681-1910) - Fuel feed pump : KP-FP/K-PS (105207-1540) - Coupling : 105663-0740 (2) Nozzle holder assembly : 65.10101-7294A (9134-153C DOOWON) (3) Nozzle : 65.10102-6043 (105029-1320 DOOWON)
  • Page 112 6) DE12TI (340PS) (1) Fuel injection pump : 65.11101-7657A (106671-9430 ZEXEL) - Fuel injection pump : KP-PE6P120/721RS3S (106067-0850 ZEXEL) - Governor : KP-EP/RFD200-1400PF57DZR(105487-7010) - Timer : KP-EP/SPG700-110023/R (105681-1910) - Fuel feed pump : KP-FP/K-PS (105207-1540) - Coupling : 105663-0740 (2) Nozzle holder assembly : 65.10101-7294A (9134-153C ZEXEL) (3) Nozzle : 65.10102-6043 (105029-1320 ZEXEL)
  • Page 113 7) DE12TIS (290PS) (1) Fuel injection pump : 65.11101-7347 (108622-4031 ZEXEL) - Fuel injection pump : NP-TC6HD120/72ARS2 (108062-4020 ZEXEL) - Governor : NP-EP/RLD250-1050T6JXR(105923-4831) - Fuel feed pump : NP-FP/KD-HD (105237-5360) - Coupling : 156643-5120 - Actuator : 159601-7720 - Plunger & barrel : 134178-5120 - Delivery valve : 134180-1220...
  • Page 114 (7) Rack curve 15.4 14.5 13.6 10.25 1050 1190 Injection pump speed (rpm) EQM8022I MAINTENANCE OF MAJOR COMPONENTS - 107 -...
  • Page 115 8) DE12TIS (310PS) (1) Fuel injection pump : 65.11101-7346 (108622-4021 ZEXEL) - Fuel injection pump : NP-TC6HD120/72ARS2 (108062-4020 ZEXEL) - Governor : NP-EP/RLD250-1050T6JXR(105923-4831) - Fuel feed pump : NP-FP/KD-HD (105237-5360) - Coupling : 105664-2490 - Actuator : 159601-7720 - Plunger & barrel : 134178-5120 - Delivery valve : 134180-1220...
  • Page 116 (7) Rack curve 15.9 15.0 12.2 10.25 1050 1190 Injection pump speed (rpm) EQM8023I MAINTENANCE OF MAJOR COMPONENTS - 109 -...
  • Page 117 9) DE12TIS (320PS) (1) Fuel injection pump : 65.11101-7339 (108622-4060 ZEXEL) - Fuel injection pump : NP-TC6HD120/72ARS2 (108062-4020 ZEXEL) - Governor : NP-EP/RLD250-1050T6JXR(105923-4831) - Fuel feed pump : NP-FP/KD-HD (105237-5360) - Coupling : 156643-5120 - Actuator : 159601-7720 - Plunger & barrel : 134178-5120 - Delivery valve : 134180-1220...
  • Page 118 (7) Rack curve 16.1 15.2 13.3 10.25 1050 1190 Injection pump speed (rpm) EQM8024I MAINTENANCE OF MAJOR COMPONENTS - 111 -...
  • Page 119 10) DE12TIS (340PS) (1) Fuel injection pump : 400912-00235(106671-996K DOOWON) - Fuel injection pump : KP-PE6P120/721RS3S(106067-628A DOOWON) - Governor : KP-EP/RLD300-1100P5JXR(105923-481F) - Timer : KP-EP/SPG650-900Z2.5HR(105681-435F) - Fuel feed pump : KP-FP/KD-PS(105237-547A) - Coupling : 105663-074F (2) Nozzle holder assembly : 150118-00111(105101-846A DOOWON) (3) Nozzle : 65.10102-6053 (105025-2240 ZEXEL) (4) Fuel injection pipe...
  • Page 120 (7) Rack curve 14.25 13.95 1050 1200 Injection pump speed (rpm) EQM8025I MAINTENANCE OF MAJOR COMPONENTS - 113 -...
  • Page 121 4.3.3. 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 122 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 123 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. Pull out the snap ring (20) holding the tappet (10).
  • Page 124 (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 feed pump...
  • Page 125 2) 1 - spring type (DE12, 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 (2)Reassembly After removing carbon deposit, submerge the nozzle in diesel oil and clean it. Replace all the gaskets with new ones.
  • Page 126 (4)Testing With the nozzle assembled to a nozzle tester and pressure of specified applied, check the nozzle for fuel leakage. EAMC022S 3) 2-spring type (DE12TI, DE12TIS) This inspection data is base DE12TI engine. (1)Disassembly 1. Nozzle holder body 2. Push rod 3.
  • Page 127 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 nozzle holder body in the order as described. NOTE : The secondary spring is the same one as the primary spring.
  • Page 128 g. After installing the gasket (157892-1500) on the nozzle, use 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. NOTE : Tighten the retaining nut until it resists hand tightening, then further tighten it using a torque...
  • Page 129 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 holder securely and tighten the cap nut (SW 19mm) to specified torque.
  • Page 130 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 131 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 132 Inspection of pre-lift a. If the nozzle tester handle is released with the needle valve engaged in a full lift condition, the tester pressure drops, being accompanied by decrease in the needle valve lift value (indicated value on the dial gauge). kgf / cm EQM4049I Tester pressure...
  • Page 133 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 to fully lift the needle valve.
  • Page 134 Adjusting secondary opening pressure a. In the event that the measured value deviates 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, EQM4040I...
  • Page 135 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) Torque 6.0 ~ 8.0 kg • EQM4036I Inspection at completion a.
  • Page 136 4.3.5. Diagnostics and troubleshooting Complaints Possible causes Corrections 1. Engine won’t start 1) Fuel not being pumped ① Fuel pipes clogged or air into pipe Correct out from feed pump fine ② Feed pump valve defective Replace ③ Feed pump piston or Push rod Disassemble, correct sticking 2) Fuel not being injected...
  • Page 137 6. Engine output unstable ① supply of fuel insufficient Check feed pump ② Air in fuel Bleed ③ Water in fuel Replace fuel ④ Operation of plungers unsmooth Disassemble, correct ⑤ Movement of control rack sluggish Disassemble, correct ⑥ Nozzles defective Disassemble, correct ⑦...

  • Page 138: Turbocharger

    4.4. Turbocharger 4.4.1. Main data and specifications 1) Main data and specifications Specification DE12T DE12TI DE12TIS Turbocharger Model TBP45 GT42 Air pressure at Approx. 1.15 kg Approx. 1.2 kg Approx. 1.3 kg compressor outlet Air suction volume Approx. 20.0 Approx. 22.0 Approx.
  • Page 139 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 140 4.4.2. 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 output can be obtained as a greater volume of air charged into the cylinders burns so much more fuel.
  • Page 141 4.4.4. 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 the 1) Check oil level 2) Abrupt starting of the engine causes engine 2) Crank the engine with starter to check the engine to rotate with oil not being...
  • Page 142 4.4.5. Walk-around check and servicing As the condition of turbocharger depends greatly on how well the engine is serviced, it is very important to maintain the engine in accordance with the specified maintenance procedure. 1) Intake system Pay particular attention to the air cleaner when servicing the intake system. In the case of wet-type air cleaner, if the level of oil surface is lower than specified, cleaning effect is poor;...
  • Page 143 4.4.6. 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 144 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 turbocharger.
  • Page 145 4.4.7. 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 Disassemble/repair or replace...

  • Page 146: Appendix

    Appendix  Tightening torque for major parts Screw Strength Major parts Tightening torque Remarks (Diameter × pitch) (grade) • 2nd : 180° 10.9T Dodecagon Finished : 150° (angle torque) 24.5 Cylinder head bolt M14 × 1.5 hexagon • • 2nd : 90°+ 90° Dodecagon Finished : 30°...
  • Page 147 60% or so of the standard 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 DOOSAN engine - 140 - Appendix...
  • Page 148 Maintenance specification table  (unit : mm) Stand value Limit Group Part Inspection item Correction Remark for assembly for use Measure unworn Inside diameter of Ø123 ~ portion beneath the Ø123.223 Replace liner Cylinder liner for wear rim of the upper Ø123.023 side Projected portion of...
  • Page 149 (unit : mm) Stand value Limit Group Part Inspection item Correction Remark for assembly for use Axial run-out of journal Correct with a In horizontal and 0.05 and pin grinder vertical directions Outside diameter of Ø95.966 ~ Replace Ø96 g6 Ø94.966 journal crankshaft...
  • Page 150 (unit : mm) Stand value Limit Group Part Inspection item Correction Remark for assembly for use Outside diameter of Ø56.860 ~ Ø59.52 Ø60 cam shaft Ø56.880 Clearance between 0.050 ~ 0.128 0.20 shaft cam shaft and bush Replace thrust Axial play of camshaft 0.13 ~ 0.27 0.30 place...
  • Page 151 (unit : mm) Stand value Limit Group Part Inspection item Correction Remark for assembly for use Outside diameter of intake valve Ø10.950 ~ Replace valve Ø10.87 stem Ø10.970 Replace & guide together valve guide when replacing Outside diameter of exhaust Ø10.935 ~ Ø10.84 valve...
  • Page 152 (unit : mm) Stand value Limit Group Part Inspection item Correction Remark for assembly for use 65.75 Free length *76.4 Spring tension 36.1 ~ 39.9 36.1 Replace (set length : Inner *45.1 ~ 50.1 *45.1 valve spring 34 mm) kg Straightness (against free *1.5...
  • Page 153 (unit : mm) Stand value Limit Group Part Inspection item Correction Remark for assembly for use Check oil leakage Oil pressure 4.5 or less and clearance – (at normal speed) between each part pressure Oil pressure (idling) 0.8 ~ 1.4 –...
  • Page 154 (unit : mm) Limit Stand value Group Part Inspection item Correction Remark for assembly Radiator & water pump for corrosion, damage & – – Correct or replace improper connecting Submerge in water Test for leakage (air – and replace if air Radiator pressure) (kg/cm bubbles found...

  • Page 156: Parts & After Service Center

    Parts & After Service Center ■ Parts Service Center 85-1 Palgok Ei-dong, Sangnok-gu Ansan-shi Kyunggi-do, korea Tel. : 82-31-400-2231 Fax. : 82-31-400-2255 ■ After Service Center 489, Injung-ro, Dong-gu Incheon, Korea Tel. : [Vehicle engine] 82-32-211-2242 [Industrial engine] 82-32-211-2244 [Marine engine] 82-32-211-2247 [Generator engine] 82-32-211-2246 Fax.
  • Page 158 Tel : 021-5778-3416 Fax : 021-5778-3418 Doosan Infracore U.K., Ltd. Guangzhou Engine Service Center Doosan House, Unit 6.3, Nantgarw Park, Cardiff, CF47QU, U.K. 1595 Huangpu Dong Road, Huang Qu, Guangzhou, China Tel : +44-1443-84-2273 Fax : +44-1443-84-1933 Tel : 020-8233-4458, 4459 Fax : 020-3239-7738 Doosan Infracore Germany GmbH ASIA &...

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