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