Daewoo DE12T Series Diesel Engine Shop Manual PDF (EN)

FOREWORD This manual is designed to serve as a reference for DAEWOO Heavy Industries & Machinery Ltd's (here after DAEWOO’s) customers and distributors who wish to gain basic product knowledge on DAEWOO's DE12T, DE12TI, DE12TIA and DE12TIS diesel engines. These economical and high-performance diesel engines (6 cylinders, 4 strokes, in-line type) have been so designed and manufactured to be used for the industrial application. They meet all the requirements such as low noise, fuel economy, high engine speed and durability. To maintain the engine in optimum condition and retain maximum performance for a long time, CORRECT OPERATION and PROPER MAINTENANCE are essential.

In this manual, the following symbols are used to indicate the type of service operations to be performed. Removal Adjustment Installation Cleaning Disassembly Pay close attention-Important Reassembly Tighten to specified torque Align the marks Use special tools of manufacturer's Directional Indication Lubricate with oil Inspection Lubricate with grease Measurement During engine maintenance, please observe following instructions to prevent environmental damage; Take old oil to an old oil disposal point only. Ensure without fail that oil will not get into the sea or rivers and canals or the ground.

Treat undiluted anti-corrosion agents, antifreeze agents, filter element and cartridges as special waste. The regulations of the relevant local authorities are to be observed for the disposal of spent coolants and special waste. If you have any question or recommendation in connection with this manual, please do not hesitate to contact our head office, dealers or authorized service shops near by your location for any services. For the last, the content of this maintenance instruction may be changed without notice for some quality improvement. Thank you. DAEWOO Heavy Industries & Machinery LTD. Feb. 2005

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CONTENTS 1. SAFETY REGULATIONS & ENGINE SPECIFICATIONS ......................................................... 1 1.1. General Notes 1.5. Notes on Safety in Handling Used Engine Oil 1.2. Regulations Designed to Prevent Accidents 1.6. General Repair instructions 1.3. Regulations Designed to prevent Damage 1.7. Engine Specification to Engine and Premature Wear 1.8. Engine Assembly 1.4. Regulations Designed to Prevent Pollution 2. TECHNICAL INFORMATION ................................................................................................... 16 2.1. Engine Model and Serial Number 2.12. Cylinder Compression Pressure 2.2. Engine Type 2.13. Injection Nozzle 2.3. Engine Timing 2.14.

Fuel Injection Nozzle 2.4. Valves 2.15. Battery 2.5. Lubrication System 2.16. Air Removal of Fuel System 2.6. Fuel System 2.17. Fuel Supply Pump 2.7. Cooling System 2.18. Turbocharger 2.8. Fan Belt 2.19. Starting Motor 2.9. Air Cleaner 2.20. Electrical Equipment 2.10. Intercooler 2.21. Diagnosis and Remedy 2.11. Valve Clearance Adjust Procedure 2.22. Engine Inspection 3. DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS ....................................... 48 3.1. Disassembly 3.3. Reassembly 3.2. Inspection and Measurement 4. COMMISSIONING AND OPERATION ..................................................................................... 99 4.1. Preparation 4.4. Operation in Winter Time 4.2.

Breaking-In 4.5. Tuning the Engine 4.3. Inspections After Starting 5. MAINTENANCE AND CARE ................................................................................................. 103 5.1. Periodical Inspection and Maintenance 5.4. Replacement of Fuel Filter 5.2. Lubrication System 5.5. Fuel System Checks 5.3. Adjustment of Valve Clearance 5.6. Injection Nozzle Maintenance

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6. MAINTENANCE OF MAJOR COMPONENTS ...................................................................... 111 6.1. Fuel Injection Pump 6.4. Turbocharger 6.2. Cooling System 6.5. Air Intake System 6.3. Lubricating System 6.6. V-belts 7. SPECIAL TOOL LIST ............................................................................................................. 174 Appendix Part & After service center Applications for Daewoo Engine Worldwide Network

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1. SAFETY REGULATIONS & ENGINE SPECIFICATIONS 1.1. General Notes Day-to-day use of power engines and the service products necessary for running them presents no problems if the persons occupied with their operation, maintenance and care are given suitable training and think as they work This summary is a compilation of the most important regulations. These are broken down into main sections which contain the information necessary for preventing injury to persons, damage to property and pollution. In addition to these regulations those dictated by the type of engine and its site are to be observed also. Important :

If, despite all precautions, an accident occurs, in particular through contact with caustic acids, fuel penetrating the skin, scalding from oil, antifreeze being splashed in the eyes etc., consult a doctor immediately. 1.2. Regulations Designed to Prevent Accidents 1.2.1. During commissioning, starting and operation Before putting the engine into operation for the first time, read the operating instructions carefully and familiarize yourself with the “critical” points, If you are unsure, ask your DAEWOO representative.

For reasons of safety we recommend you attach a notice to the door of the engine room prohibiting the access of unauthorized persons and that you draw the attention of the operating personal to the fact that they are responsible for the safety of persons who enter the engine room. The engine must be started and operated only by authorized personnel. Ensure that the engine cannot be started by unauthorized persons. When the engine is running, do not get too close to the rotating parts. Wear close-fitting clothing. Do not touch the engine with bare hands when it is warm from operation risk of burns. Exhaust gases are toxic.

Comply with the installation instructions for the installation of DAEWOO diesel engines which are to be operated in enclosed spaces. Ensure that there is adequate ventilation and air extraction. Keep vicinity of engine, ladders and stairways free of oil and grease. Accidents caused by slipping can have serious consequences. - 1 - SAFETY REGULATIONS & ENGINE SPECIFICATIONS

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