Doosan DE12 Series Manual

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

Preface
This Operation&Maintenance manual provides information on engine management and maintenance tech-
niques to customers and maintenance technicians who use 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.
Exact operation and proper maintenance is essential for operating engines with the optimum conditions and
best performance. This Operation&Maintenance manual provides detailed description of specifications, speci-
fied values, fault diagnosis, component diagrams, and drawings for easier and more precise understanding of
the product and proper maintenance and troubleshooting.
With our recommended working methods and procedures, high-level maintenance techniques and safety of
workers can be ensured. Please read and understand this manual before working with out engines.
We, Doosan Infracore, continue development and investment for best performance, improved quality, and
enhanced maintenance techniques. The design of our product may be changed without prior notice and without
any liability and this manual may not contain all of changes in design made to improve the product.
We do ou
r best to provide more convenient and safe maintenance techniques and meet the requirements of cus-
tomers.
If you have any question or find any error in this Operation&Maintenance manual, please contact us.
Thank you for purchasing our engine and we hope this Operation&Maintenance manual be helpful for you.
Doosan Infracore Co., Ltd.
2020.06.
950106-029004EN
* Items ex
empted from warranty coverage
 Malfunctions resulting from failing to comply with the proper handling instructions, regular inspections, and
machine storage techniques specified in the user manual
 Malfunctions resulting from failing to have the machine repaired at a designated dealer or center, or
resulting from the use of non-genuine parts
 Malfunctions resulting from unauthorized modifications, changes, or external hardware
 Malfunctions resulting from incorrect operation by the user, delayed repairs, accidents, and natural disas-
ters
* The contents of this operation and maintenance manual are the exclusive property of Doosan Infracore. Any unau-
thorized reproduction, printing and distribution thereof are strictly prohibited.

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. DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS
3.1. Disassembly ......................................................................................................................................... 37
3.2. Inspection and Measurement ............................................................................................................... 51
3.3. Reassembly ......................................................................................................................................... 66
3.4. Breaking-In ........................................................................................................................................... 88
4. MAINTENANCE OF MAJOR COMPONENTS
4.1. Cooling System .................................................................................................................................... 90
4.2. Lubricating System .............................................................................................................................. 95
4.3. Fuel Injection Pump ............................................................................................................................. 99
4.4. Turbocharger ..................................................................................................................................... 131
 Appendix
 Parts & After Service Center
 Worldwide Network

GENERAL INFORMATION - 1 -
1. GENERAL INFORMATION
1.1. General Repair Instructions
1. Before performing service operation, disconnect the grounding cable from the battery for reducing the
chance of cable damage and burning due to short-circuiting.
2. Use covers for preventing the components from damage or pollution.
3. Engine oil and anti-freeze solution must be handled with reasonable care as they cause paint damage.
4. The use of proper tools and special tools where specified is important to efficient and reliable service
operation.
5. Use genuine 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.
7. To facilitate proper and smooth reassemble operation, keep disassembled parts neatly in groups. Keeping
fixing bolts and nut separate is very important as they vary in hardness and design depending on position of
installation.
8. Clean the parts before inspection or reassembly. Also clean oil ports, etc. using compressed air to make
certain they are free from restrictions.
9. Lubricate rotating and sliding faces of parts with oil or grease before installation.
10. When necessary, use a sealer on gaskets to prevent leakage.
11. Carefully observe all specifications for bolts and nuts torques.
12. When service operation is completed, make a final check to be sure service has been done property.

GENERAL INFORMATION - 2 -
1.2. Engine Characteristics
1.2.1. OMEGA combustion bowl
The OMEGA combustion bowl is a unit designed to
perform high efficiency, low emission combustion.
As the rim around the combustion bowl port of the
upper of the piston has been machined in a smaller
size than the interior of the combustion bowl, strong
swirl is produced in the combustion bowl and strong
squish flow makes the fuel be mixed more sufficiently
with air.
Due to the application of OMEGA combustion
system and optimal utilization of intake and exhaust
port configuration within the cylinder head, the
DE12 series diesel engines discharge very low
level of hazardous exhaust gases such as smoke,
nitrogen oxide, hydrocarbon, or carbon monoxide
and thus ensure high performance and low fuel
consumption.
EA8M1001

GENERAL INFORMATION - 3 -
1.3. Engine Specifications
1.3.1. Specification
Engine model
Items DE12 DE12T DE12TI DE12TIS
Engine type
4 cycle in-line,
Water-cooled type
Naturally aspirated
4 cycle in-line,
Water-cooled type
Turbo charged
4 cycle in-line,
Water-cooled type
Turbo charged & intercooled
Combustion chamber type Direct injection type
Cylinder liner type Replaceable dry liner
Timing gear system Gear driving type
No. of piston rings compression ring, 1 oil ring
No. of cylinders – bore
× stroke (mm) 6 – 123 × 155
Total piston displacement (cc) 11,051
Compression ratio 17.1 : 1 17.1 : 1 16.5 : 1 16.8 : 1
Engine Dimension
(length
× width × height) (mm)
1,317 X 795 X
1,029
1,317 X 847 X
1,064 1,368 X 932 X 1,151
Engine Weight(kg) 872 909 990
Rotating direction (viewed from flywheel) Counterclockwise
Firing injection order 1 – 5 – 3 – 6 – 2 – 4
Fuel Injection timing (BTDC Static) 10°or 12°
(Depend on Suffix)
8 °
(Depend on Suffix)
9° or 12 °
(Depend on Suffix)
1° or 10 °
(Depend on Suffix)
Injector pump type Mechanical Mechanical Mechanical Mechanical
Governor type RFD - C / RLD RFD - C RFD - D RLD - J
Injection nozzle type Multi-hole
(5-
ø 0.29)
Multi-hole
(5- ø 0.31)
Multi-hole
(5- ø 0.33)
Multi-hole
(5- ø 0.29)
Fuel injection pressure (kg/c
m2 ) 220 220 1st : 160
2nd : 220
1st : 160
2nd : 220
Compression pressure (kg/cm2) 28 (at 200rpm)
Intake and exhaust valve clearance
(at cold) (mm) 0.3
Intake valve Open at 18
° (B.T.D.C) 18 ° (B.T.D.C)
Close at 34
° (A.B.D.C) 32 ° (A.B.D.C)
Exhaust valve
Open at 46
° (B.B.D.C) 70 ° (B.B.D.C)
Close at 14
° (A.T.D.C) 30 ° (A.T.D.C)
Lubrication method Full forced pressure feed type
Oil pump type Gear type driven by crankshaft
Oil filter type Cartridge type
Lubricating oil capacity (Max/min) (lit) 17 / 14
Oil cooler type Water cooled
Water pump Centrifugal type driven by gear
Cooling method Fresh water forced circulation
Cooling water capacity (engine only) (lit) 19

GENERAL INFORMATION - 4 -
1.3.2. Engine Power
Production tolerance : ±5 %
* Note : All data are based on operation without cooling fan at ISO 1585(SAE J1349)
Thermostat type Wax pallet type (83 ~ 95 °C )
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
Starting motor voltage - output (V -kW) 24 – 6.0
Air heater capacity (V - A) 22 - 95 (2.1 kW)
Battery capacity (V - AH) 24 - 200
Engine model Performance
Remark
Model Suffix
Injection
timing
(BTD
C°)
Power
(PS / rpm)
Torque
(kg
• m / rpm)
Low idle
(rpm)
High idle
(rpm)
DE12
EBGBE 10 230/2,200 81/1,400 600-650 2,420
± 50
EBGBN 10 235/2,200 81.5/1,400 600-650 2,420
± 50
EBGCA 12 225/2,200 81.5/1,400 600-650 2,420
± 50
DE12T EBHBD 8 300/2,200 110/1,300 600-650 2,420
± 50
DE12TI
EBIBA 12 340/2,100 135/1,260 600-650 2,320
± 50
EURO-I
EBIBC 9 280/2,100 115/1,260 600-650 2,320
± 50
EBIBD 9 310/2,100 125/1,260 600-650 2,320
± 50
EBIBG 12 340/2,100 135/1,260 600-650 2,320
± 50
EBICH 12 340/2,100 135/1,260 600-650 2,320
± 50
EBICK 12 340/2,100 135/1,260 600-650 2,320
± 50
EBICL 12 340/2,100 135/1,260 600-650 2,320
± 50
DE12TIS
ECIBA 10 340/2,100 145/1,260 600
± 25 2,435 ± 15
EURO-II
ECIBB 1 310/2,100 125/1,260 600
± 25 2,375 ± 25
ECIBC 1 290/2,100 115/1,260 600
± 25 2,375 ± 25
ECIBD 1 360/2,100 145/1,260 600
± 25 2,375 ± 25
ECIBE 1 360/2,100 145/1,260 600
± 25 2,375 ± 25
ECIBP 10 340/2,100 145/1,260 600
± 25 2,435 ± 15
ECIBT 10 340/2,100 145/1,260 600
± 25 2,435 ± 15
ECICA 10 340/2,100 145/1,260 600
± 25 2,435 ± 15
ECICB 10 340/2,100 145/1,260 600
± 25 2,435 ± 15
ECICC 1 320/2,100 135/1,260 600
± 25 2,375 ± 25
ECICD 1 320/2,100 135/1,260 600
± 25 2,375 ± 25
ECICE 1 320/2,100 135/1,260 600
± 25 2,375 ± 25
Engine model
Items DE12 DE12T DE12TI DE12TIS

GENERAL INFORMATION - 5 -
1.3.3. Performance curve
1) DE12-235PS
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. 218 g/kW.h (160 g / ps.h)
DL112001A
800
700
210
220
230
240
250
80
70
190
180
170
160
1000 1400 1800 2200
170
140
110
80
250
225
200
175
150
125
100
N m kg m
g/kW h g/ps.h
ps kW

GENERAL INFORMATION - 6 -
2) DE12T-300PS
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. 211 g/kW.h (155 g / ps.h)
110
100
90
155210
220
230
165
175
100
130
160
190
220
300
250
200
150
1000 1400 1800 2200
1100
1000
900
800
N m kg m
g/kW h g/ps.h
ps kW
DL112002A

GENERAL INFORMATION - 7 -
3) DE12T-310PS
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
145
150
155
105
115
125
1 000 1200 1400 1600 1800 2000 2200
160
200
240
280
320
DL112003A

GENERAL INFORMATION - 8 -
4) DE12TIS - 290PS
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)
145
150
155
95
105
115
11200 1400 1600 1800 2000 2200
160
200
240
280
320
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EB8O1003

GENERAL INFORMATION - 9 -
5) DE12TIS - 320PS
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
145
150
155
105
115
125
1 000 1200 1400 1600 1800 2000 2200
160
200
240
280
320
DL112003A

GENERAL INFORMATION - 10 -
6) DE12TIS - 340PS
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)
140
150
160
170
180
150
160
130
120
140
1 1200 1400 1600 1800 2000 2100
200
240
280
320
360
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EB8O1002

GENERAL INFORMATION - 11 -
7) DE12TIS- 360PS
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)
140
150
160
120
130
140
11200 1400 1600 1800 2000 2200
160
190
220
250
280
310
340
370
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EB8O1001

GENERAL INFORMATION - 12 -
1.4. Engine Assembly
1.4.1. Engine sectional view (longitudinal)
1. Cooling water pump 8. Piston pin 15. Oil pan
2. Fuel filter 9. Piston 16. Connecting rod
3. Valve 10. Chamber 17. Cam shaft
4. Valve spring 11. Crank shaft pulley 18. Flywheel housing
5. Oil filler 12. Vibration damper 19. Flywheel
6. Tappet 13. Oil pump
7. Push rod 14. Crank shaft
2
11
43 5 67 8910
12 13 14 15 16 17 18 19
1
EQM8018I

GENERAL INFORMATION - 13 -
1.4.2. Engine sectional view (cross)
1. Oil filter 8. Rocker arm
2. Cylinder block 9. Cylinder head cover
3. Fuel injection pump 10. Cylinder head
4. Alternator 11. Exhaust manifold
5. Oil cooler 12. Piston ring
6. Cooling water outlet 13. Turbocharger
7. Fuel injection nozzle 14. Oil suction pipe
14
1
2
3
4
5
6
7 8910
11
12
13
EQM8019I

GENERAL INFORMATION - 14 -
1.4.3. Engine assembly views
1) DE12 (Bus)
1. Fly wheel 11. Oil level gauge 21. Air pipe
2. Flywheel housing 12. Pilot bearing 22. Cooling water pump
3. Oil pressure unit 13. Oil filter 23. Air compressor
4. Lifting hook 14. Oil drain plug 24. Exhaust manifold
5. Oil cooler 15. Oil pan 25. Crank shaft pulley
6. Intake manifold 16. Fuel injection pump 26. Vibration damper
7. Air heater 17. Mounting bracket 27. Mounting bracket
8. Cooling warning switch 18. Power steering pump 28. Starting motor
9. Thermostat 19. Alternator 29. Fuel injection nozzle
10. Oil filler cap 20. Fuel filter 30. Cooling water pipe
1
12
13 14 15 16 17 18
2
3
45 6 7
8 20 21
9
10
19
11 22
23
25 26 27 28
24 4 29 30
EQM8007I