Table of Contents
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Table of Contents
Related Manuals for Doosan DE12TI
Summarization of Contents
1. General Information
1.1. General Repair Instructions
Instructions for performing service operations on the engine.
1.2. Engine Characteristics
Description of the OMEGA combustion bowl for high efficiency and low emissions.
1.3. Engine Specifications
Detailed specifications for DE12 engine models including dimensions, power, and timing.
1.3.2. Engine Power
Technical data on engine power output for different models, including PS and torque.
1.3.3. Performance Curve
Graphical representation of engine performance characteristics.
1.4. Engine Assembly
Overview of engine assembly with longitudinal, cross, and detailed views.
2. Major Maintenance
2.1. Preventive Maintenance
Procedures for maintaining the engine to prevent issues and ensure longevity.
2.1.1. Cooling water
Maintenance of the engine's cooling water system, including fluid checks and density.
2.1.2. Fan belt
Inspection and maintenance of the engine's fan belt, including tension adjustment.
2.1.3. Engine oil
Procedures for checking, changing, and maintaining engine oil and filter.
2.1.4. Oil filter
Maintenance and replacement of the engine oil filter cartridge.
2.1.5. Fuel filter
Maintenance of the engine fuel filter, including draining water.
2.1.6. Air cleaner
Maintenance, cleaning, and replacement of the air cleaner elements.
2.1.7. Intercooler
Maintenance and importance of the intercooler for engine performance.
2.1.8. Valve clearance adjust procedure
Procedure for adjusting engine valve clearances to ensure proper operation.
2.1.9. Cylinder compression pressure
Procedure for measuring cylinder compression pressure for engine health.
2.1.10. Injection nozzle
Inspection and testing of engine injection nozzles for proper spray pattern and pressure.
2.1.11. Fuel Injection nozzle
Maintenance and inspection of the fuel injection nozzle for damage or wear.
2.1.12. Battery
Inspection and maintenance of the engine battery, including electrolyte level and gravity.
2.1.13. Air removal of fuel system
Procedure for removing air from the fuel system to ensure proper fuel delivery.
2.1.14. Fuel supply pump
Maintenance of the fuel supply pump, including cleaning the fuel strainer.
2.1.15. Turbocharger
Maintenance and inspection of the turbocharger for leaks, clogging, and contamination.
2.1.16. Starting motor
Maintenance of the engine starting motor, including cleaning gears and lubrication.
2.2. Diagnosis and Remedy
Troubleshooting guide for common engine issues like starting, overheating, and output problems.
1. Engine Starting Impossible
Troubleshooting steps for engine starting failures related to motor, engine, or fuel.
2. Engine Overheated
Troubleshooting guide for engine overheating issues related to cooling or fuel units.
3. Output Insufficient
Troubleshooting for insufficient engine output due to engine, fuel, or other system issues.
4. Oil pressure lowered
Troubleshooting for low engine oil pressure caused by various factors like oil amount or relief valve.
5. Fuel Consumption Excessive
Troubleshooting for excessive fuel consumption related to engine or fuel system conditions.
6. Oil Consumption Excessive
Troubleshooting for excessive engine oil consumption due to leaks or worn parts.
7. Engine Knocking
Troubleshooting for engine knocking issues caused by combustion or timing problems.
8. Battery Discharge
Troubleshooting for battery discharge problems related to the battery, wiring, or generator.
2.3. Engine Inspection
General inspection cycle and procedures for the engine, including part usage.
2.3.1. Stopping engine
Procedure for safely stopping the engine after checking for unusual conditions.
2.3.2. General engine inspection cycle
Table outlining periodic engine inspection intervals and actions.
2.3.3. Use of original parts for repair and replacement
Importance of using genuine parts for engine repair to maintain performance and prevent failure.
3. Disassembly and Reassembly of Major Components
3.1. Disassembly
General precautions and step-by-step procedures for disassembling engine components.
3.1.1. General precautions
General safety and preparation guidelines for engine disassembly operations.
3.1.2. Cooling water
Procedure for draining the engine's cooling water, including cautions for hot coolant.
3.1.3. Engine oil
Procedure for draining engine oil from the oil pan and replacing the drain plug.
3.1.4. Cooling fan
Procedure for removing the cooling fan and its flange.
3.1.5. V-Belt
Procedure for loosening tension adjusting nuts and removing the alternator belts.
3.1.6. Air con. compressor
Procedure for removing the air conditioning compressor and its adjusting bolt.
3.1.7. Oil level gauge guide tube
Procedure for removing the oil level gauge guide tube by loosening a flange nut.
3.1.8. Fuel filter
Procedure for removing fuel hoses and bracket fixing bolts to disassemble the fuel filter.
3.1.9. Breather
Procedure for removing the breather hose by loosening the clamp screw.
3.1.10. Intercooler
Procedure for removing the intercooler by detaching hoses and bolts.
3.1.11. Fuel injection pipe
Procedure for disassembling fuel injection pipes by unscrewing hollow screws.
3.1.12. Air heater
Procedure for removing electrical wiring, intake pipes, and gasket of the air heater.
3.1.13. Intake manifold
Procedure for removing the intake manifold by detaching air hoses and fixing bolts.
3.1.14. Turbo charger
Procedure for removing the turbocharger by detaching hoses, pipes, and fixing nuts.
3.1.15. Exhaust manifold
Procedure for removing the exhaust manifold, including heat shield and gasket.
3.1.16. Thermostat
Procedure for removing the thermostat housing and the thermostat itself.
3.1.17. Starter
Procedure for disassembling the starter motor by unscrewing fixing bolts.
3.1.18. Cooling water pump
Procedure for removing the cooling water pump, including pipes and bolts.
3.1.19. Air compressor
Procedure for removing the air compressor by detaching hoses, pipes, and bolts.
3.1.20. Fuel injection pump
Procedure for removing the fuel injection pump, including pipes, coupling, and bolts.
3.1.21. Oil filter
Procedure for removing the oil filter cartridge and oil filter head.
3.1.22. Idle pulley
Procedure for removing the idle pulley and fan drive pulley.
3.1.23. Power steering pump
Procedure for removing the power steering pump and its oil hoses.
3.1.24. Vibration damper
Procedure for disassembling the vibration damper assembly from the pulley.
3.1.25. Timing gear case cover
Procedure for disassembling the timing gear case cover.
3.1.26. Idle gear
Procedure for removing the idle gear, thrust washer, and idle gear pin.
3.1.27. Fuel injection pump drive
Procedure for removing the fuel injection pump drive assembly.
3.1.28. Cylinder head cover
Procedure for removing the cylinder head cover, keeping bolts and gaskets intact.
3.1.29. Rocker arm
Procedure for removing the rocker arm assembly, including bracket and push rods.
3.1.30. Injection nozzle and tube
Procedure for removing injection nozzles and tubes using a removing jig.
3.1.31. Cylinder head
Procedure for removing the cylinder head and its gasket.
3.1.32. Valve and stem seal
Procedure for removing valves, springs, retainers, and stem seals.
3.1.33. Oil cooler
Procedure for removing the oil cooler assembly and its cover.
3.1.34. Oil pan
Procedure for removing the oil pan, including stiffeners.
3.1.35. Oil pump and pipe
Procedure for removing the oil pump and its suction/feeding pipes.
3.1.36. Ladder frame
Procedure for disassembling the ladder frame.
3.1.37. Relief valve
Procedure for disassembling the relief valve.
3.1.38. Piston and connecting rod
Procedure for disassembling pistons and connecting rods, including rings and pins.
3.1.39. Cylinder liner
Procedure for disassembling cylinder liners using a liner puller.
3.1.40. Fly wheel
Procedure for disassembling the flywheel, including fixing bolts and dowel pins.
3.1.41. Oil seal
Procedure for removing oil seals using a disassembling jig.
3.1.42. Flywheel housing
Procedure for disassembling the flywheel housing by loosening fixing bolts.
3.1.43. Cam shaft and tappet
Procedure for removing the camshaft gear, tappets, and camshaft.
3.1.44. Crankshaft gear and oil pump idle gear
Procedure for removing crankshaft and idle gears using a puller.
3.1.45. Timing gear case
Procedure for disassembling the timing gear case by unscrewing fixing bolts.
3.1.46. Crank shaft
Procedure for removing the crankshaft, including main bearing caps and bolts.
3.1.47. Oil spray nozzle
Procedure for removing oil spray nozzles by unscrewing the fixing bolt.
3.2. Inspection and Measurement
Procedures for inspecting and measuring various engine components for wear and damage.
3.2.1. Cylinder block
Inspection and hydraulic test of the cylinder block for cracks and leaks.
3.2.2. Cylinder head
Inspection and measurement of cylinder head flatness, distortion, and cracks.
3.2.3. Valve and valve guide
Inspection of valves, valve guides, valve seats, and valve springs for wear and damage.
3.2.4. Rocker arm
Inspection of rocker arm shaft and rocker arm diameter, clearance, and wear.
3.2.5. Camshaft
Inspection of camshaft lobe height, shaft clearance, and run-out.
3.2.6. Cam shaft
Inspection for crankshaft defects, wear, and run-out, including bearing specifications.
3.2.7. Crank shaft bearing and connection rod bearing
Inspection of crankshaft and connecting rod bearings for oil clearance, spread, and crush.
3.2.8. Piston
Inspection of pistons and clearance with cylinder liners, including ring grooves.
3.2.9. Piston rings
Inspection of piston rings for gap, side clearance, tension, and width.
3.2.10. Piston pin
Inspection of piston pins for wear, clearance, and condition check.
3.2.11. Connecting rod
Inspection of connecting rods for distortion, alignment, and wear.
3.2.12. Fuel injection nozzle
Inspection of fuel injection nozzle dimensions, including seal ring thickness and projection.
3.3. Reassembly
General precautions and step-by-step procedures for reassembling engine components.
3.3.1. General precautions
General safety and preparation guidelines for engine reassembly operations.
3.3.2. Cylinder block
Preparation for cylinder block reassembly, ensuring protection from damage.
3.3.3. Oil spray nozzle
Procedure for tightening and assembling the oil spray nozzle flange.
3.3.4. Tappet and cam shaft
Assembly of tappets, camshaft, and cam bush, checking for deformation.
3.3.5. Crankshaft
Assembly of the crankshaft with main bearings, gears, and bolts, ensuring proper lubrication.
3.3.6. Flywheel housing
Installation and tightening of the flywheel housing, applying gasket and following sequence.
3.3.7. Timing gear case
Installation of the timing gear case, aligning dowel pins and mounting gasket.
3.3.8. Flywheel
Installation and tightening of the flywheel using guide bars and bolts, following torque specifications.
3.3.9. Gear system
Installation and adjustment of the gear system, including pick-up sensor and lock nut.
3.3.10. Timing gear case
Installation of the timing gear case, ensuring gasket and dowel pin alignment.
3.3.11. Timing gear
Installation and adjustment of timing gears, including backlash check and torque settings.
3.3.12. Fuel injection pump drive gear
Installation of the fuel injection pump drive gear, aligning bolt holes and tightening bolts.
3.3.13. Timing gear case cover
Installation of the timing gear case cover, aligning dowel pins and tightening bolts.
3.3.14. Front oil seal
Installation of the front oil seal onto the crankshaft using lubricating oil.
3.3.15. Cylinder liner
Installation of the cylinder liner into the cylinder block, ensuring proper cleaning and lubrication.
3.3.16. Piston and connecting rod
Assembly of pistons and connecting rods, including heating pistons, aligning pins, and installing rings.
3.3.17. Relief valve
Assembly of the relief valve.
3.3.18. Ladder frame
Installation of the ladder frame, applying silicon and tightening bolts.
3.3.19. Oil pump and oil pipe
Installation of the oil pump and its pipes, including dowel pins and torque settings.
3.3.20. Oil pan
Installation of the oil pan, including stiffeners and bolt tightening.
3.3.21. Intake and exhaust valves
Installation of intake and exhaust valves, ensuring correct orientation and using seal fitting jig.
3.3.22. Nozzle tube
Installation of the nozzle tube, applying sealant and O-ring, and performing hydraulic test.
3.3.23. Rocker arm assembly
Assembly of the rocker arm assembly, including lubrication and bolt tightening.
3.3.24. Cylinder head
Installation of the cylinder head, including head gasket, bolts, and alignment.
3.3.25. Injection nozzle
Installation of the injection nozzle, seal ring, and holder assembly, following torque specifications.
3.3.26. Cooling water pipe and thermostat
Installation of cooling water pipes and thermostat housing onto the cylinder head.
3.3.27. Oil cooler
Installation of the oil cooler onto the oil cooler cover and cylinder block.
3.3.28. Oil filter
Installation of the oil filter onto the cylinder block and tightening the fixing bolts.
3.3.29. Injection pump
Installation of the injection pump bracket and pump, including run-out measurement and shim adjustment.
3.3.30. Power steering pump
Installation of the power steering pump, aligning dowel pins and using hammer for gears.
3.3.31. Vibration damper and pulley
Installation of the vibration damper and crankshaft pulley assembly.
3.3.32. Idle pulley
Installation of the fan drive pulley onto the timing gear case cover.
3.3.33. Air compressor
Installation of the air compressor assembly, including gasket, pipes, and hoses.
3.3.34. Water pump
Installation of the water pump, including O-ring, pinion, pipes, and expansion tank connection.
3.3.35. Exhaust manifold
Installation of the exhaust manifold and heat resisting plate, with gasket alignment.
3.3.36. Turbocharger
Installation of the turbocharger, including gasket, oil pipes, and fixing bolts.
3.3.37. Air pipe
Installation of the air pipe, connecting rubber hose between turbocharger and intake pipe.
3.3.38. Starter
Installation of the starter motor in position on the flywheel housing.
3.3.39. Intake manifold
Installation of the intake manifold, including gasket and air heater assembly.
3.3.40. Injection pipe
Installation of injection pipes and fuel return hose, tightening nuts and screws.
3.3.41. Fuel filter
Installation of the fuel filter with air pipe bracket and fuel feed hose.
3.3.42. Cylinder head cover
Installation of the cylinder head cover, including packing and breather hose.
3.3.43. Air con. compressor
Installation of the air conditioning compressor and its mounting bracket.
3.3.44. Alternator
Installation of the alternator and its mounting bracket.
3.3.45. Cooling fan
Installation of the cooling fan and flange, tightening fixing bolts.
3.3.46. V- belt
Installation and tension adjustment of the V-belt on pulleys.
3.3.47. Cooling fan guide
Installation of the cooling fan guide brackets and assembly.
3.3.48. Oil level gauge
Assembly of the oil level gauge and guide tube on the oil pan.
3.4. Breaking-In
Procedures and precautions for the initial operation and break-in period of a new engine.
3.4.1. Operation of a new engine (Breaking-In)
Guidelines for operating a new engine during break-in, emphasizing avoiding overload and overspeed.
3.4.2. Check points for break-in
Key checks to perform during engine break-in, including oil level, oil pressure, and water temperature.
4. Maintenance of Major Components
4.1. Cooling System
Detailed information on the engine's cooling system, including specifications and troubleshooting.
4.1.1. Cooling System
Overview and specification of the cooling system, including water pump and thermostat.
4.1.2. Water pump
Disassembly, inspection, and reassembly of the water pump, including gap maintenance.
4.1.3. Thermostat
Inspection, replacement, and handling precautions for the thermostat based on climate.
4.1.4. Diagnostics and troubleshooting
Troubleshooting common cooling system issues like overheating, overcooling, lack of coolant, and noise.
4.2. Lubricating System
Overview of the engine's lubricating system, including specifications and troubleshooting.
4.2.1. General descriptions and main data
General information and specifications for the lubricating system, oil pump, and filter.
4.2.2. Oil pump
Disassembly, inspection, and correction of the oil pump, including end play and backlash.
4.2.3. Oil filter
Replacement of the oil filter cartridge at specified intervals.
4.2.4. Diagnostics and troubleshooting
Troubleshooting common lubricating system problems like oil consumption, pressure, and deterioration.
4.3. Fuel Injection Pump
Information on the fuel system, injection pump, and nozzle, including specifications and troubleshooting.
4.3.1. General information of fuel system
Components and overview of the fuel system, including tank, pump, nozzles, and filters.
4.4.2. Injection pump
Servicing intervals and recommendations for the injection pump to ensure engine performance.
1) DE12 (A)
Specifications for DE12 engine (A) fuel injection pump, governor, and nozzle.
2) DE12 (B)
Specifications for DE12 engine (B) fuel injection pump, governor, and nozzle.
3) DE12T
Specifications for DE12T engine fuel injection pump, governor, timer, and nozzle.
4) DE12TI (280PS)
Specifications for DE12TI (280PS) engine fuel injection pump and related components.
5) DE12TI (310PS)
Specifications for DE12TI (310PS) engine fuel injection pump and related components.
6) DE12TI (340PS)
Specifications for DE12TI (340PS) engine fuel injection pump and related components.
7) DE12TIS (290PS)
Specifications for DE12TIS (290PS) engine fuel injection pump and related components.
8) DE12TIS (310PS)
Specifications for DE12TIS (310PS) engine fuel injection pump and related components.
9) DE12TIS (320PS)
Specifications for DE12TIS (320PS) engine fuel injection pump and related components.
10) DE12TIS (340PS)
Specifications for DE12TIS (340PS) engine fuel injection pump and related components.
4.3.3. Fuel feed pump
General descriptions and construction of the fuel feed pump, including disassembly and testing.
4.3.4. injection nozzle
General descriptions of the injection nozzle and its role in combustion.
2) 1 - spring type (DE12, DE12T)
Disassembly, reassembly, and adjustment of 1-spring type injection nozzles.
3) 2-spring type (DE12TI, DE12TIS)
Inspection and adjustment of 2-spring type injection nozzles, including pressure settings.
4.4. Turbocharger
Details on turbocharger specifications, functions, precautions, and troubleshooting.
4.4.1. Main data and specifications
Key data and specifications for turbocharger models DE12T, DE12TI, and DE12TIS.
4.4.2. General descriptions
General description of turbocharger operation, including turbine, compressor, and bearings.
4.4.3. Functions
Explanation of the functions of turbocharger components like turbine, compressor, and bearings.
4.4.4. Precautions for operation
Precautions for operating the engine and turbocharger, including starting, running, and stopping.
4.4.5. Walk-around check and servicing
Procedures for walk-around checks and servicing of the intake, exhaust, fuel, and lubricating systems.
4.4.6. Periodical checking and servicing
Periodic checks and servicing for the turbocharger, including rotor condition and play.
4.4.7. Diagnostics and troubleshooting
Troubleshooting common turbocharger issues like black smoke, white smoke, low output, and noise.
Appendix
Tightening Torque for Major Parts
Torque specifications for primary engine components and their tightening sequences.
Tightening Torque for Fuel Injection System
Torque specifications for fuel injection system components.
Standard Bolt Tightening Torque Table
General table for bolt tightening torques based on size, grade, and material.
Tightening Torque for Hollow Screw (4-hole)
Specific torque values for hollow screws used in the engine.
Maintenance Specification Table
Table detailing inspection values and corrections for engine part maintenance.
Crankshaft and Connecting Rod Specifications
Inspection and tightening torque specifications for crankshaft and connecting rod bearings.
Camshaft and Timing Gear Specifications
Inspection specifications for camshaft and timing gears.
Valve System Specifications
Inspection specifications for valves, guides, springs, and related components.
Tappet and Rocker Arm Specifications
Inspection specifications for tappets and rocker arms.
Lubricating System Specifications
Specification values for oil pressure, oil pump, and valve components.
Cooling System Specifications
Specification values for radiator, water pump, and thermostat.
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