Doosan 440 Plus Shop Manual

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For use in service manual

form SB4031E01
SB4032E01
Nov. 2004

SERVICE MANUAL CONTENTS

NOTICE
This form lists the contents of the complete Service Manual for this product.
The items listed with form numbers are available and included in the manual.
If form numbers listed with mark(*) are, they are not available for the initial release of the
manual. When items are updated, or supplements added, they will be announced in
preview and should be ordered as they become available.

TITLE FORM NUMBER

Service Manual Contents SB4032E01

FOREWORD

Safety & Foreword SB4033E00

ENGINE

A2000 Diesel Engine (430 Series), A2300 Diesel Engine (440 Plus) SB4102E00
B3.3 Diesel Engine (450 Series & 460 Series) SB4135E00

VEHICLE

Vehicle Systems SB4036E00

Skid Steer Loader SB4015E00

HYDRAULIC & HYDROSTATIC

Hydraulic & Hydrostatic Systems SB4149E00

ELECTRIC

Electric Systems SB4038E00

Electric System (440 Plus) SB4103E00

OPERATION & MAINTENANCE

430 Series & 450 Series SB2333E01

440 Plus & 460 Series SB2334E02

Models ; 430 Series, 440 Plus, 450 Series, 460 Series

This is the cut pages sample. Download all 1136 page(s) at: ManualPlace.com
 SB4033E00
Jul. 2000

Satety & Foreword

For Skid Steer Loaders
1550XL(DSL702)
1760XL(DSL802)
2060XL(DSL902)
 Important Safety Information

Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary
training, skills and tools to perform these functions properly.

Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.

Basic safety precautions are listed in the “Safety” section of the Service or Technical Manual. Additional safety
precautions are listed in the “Safety” section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific hazards.
If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in
this publication and on the product labels are identified by the following symbol.

WARNING

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintenance and repair information.

Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.

DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication,
maintenance or repair procedures you choose.

The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product. Obtain the complete
and most current information before starting any job. DAEWOO dealers have the most current information
available.
 SB2003E00
A p r. 1 9 9 9
WARNING

SAFETY
machine. If this cannot be done, make sure the
WARNING forks or other im plements are blocked correctly to
prevent them from dropping unexpectedly.
The proper and safe lubrication and malntenance
for this machine, recommended by DAEWOO, are 5. Use steps and grab handles (if applicable)when
outilined in the OPERATION & MAINTENANCE mounting or dismounting a machine. Clean any
GUIDE of this machine. mud or debris from steps, walkways or work
plaftorms before using. Always face machine when
Improper performance of lubrication or maintenance using steps, ladders and walkways. When it is not
procedures is dangerous and could result in injury possible to use the designed access system,
or death. Read and understand the OPERATION & provide ladders, scaffolds, or work platforms to
MAINTENANCE GUIDE before performing any perfom safe repair operations.
lubrication or maintenance.
6. To avoid back injury, use a hoist when lifting
components which weigh 23 kg (50 lb.) or more.
The serviceman or mechanic may be unfamitiar with Make sure all chains, hooks, slings, etc., are in
many of the systems on this machine. This makes it good condition and are of the correct capacity. Be
important to use caution when performing service sure hooks are positioned correctly. Lifting eyes
work A knowledge of the system an/ or components are not to be side loaded during a lifting operation.
is important before the removal or disassembly of
any component. 7. To avoid bums, be alert for hot parts on machines
which have just been stopped and hot fluids in
Because of the size of some of the machine lines, tubes and compartments.
components, the serviceman or mechanic should
check the weights noted in this Manual, Use proper 8. Be careful when removing cover plates. Gradually
lifting procedures when removing any components. back off the last two bolts or nuts located at
opposite ends of the cover or device and pry cover
Following is a list of basic precautions that should loose to relieve any spring or other pressure,
always be observed. before removing the last two bolts or nuts
completely.
1. Read and understand all Waming plates and
decals on the machine before operating, 9. Be careful when removing filler caps, breathers
lubricating or repairing the product. and plugs on the machine. Hold a rage over the
cap or plug to prevent being sprayed or splashed
2. Always wear protective glasses and protective by liquids under pressure. The danger is even
shoes when working around machines. In greater if the machine has just been stopped
particular, wear protective glasses when pounding because fluids can be hot.
on any part of the machine or its attachments with
a hmmer or sledge. Use welders gloves, 10. Always use tools that are in good condition and
hood/goggles, apron and other protective clothing be sure you understand how to use them before
appropriate to the welding job being performed. Do performing any service work.
not wear loose-fitting or tom clothing. Remove all
rings from fingers when working on machinery. 11. Reinstall all fasteners with same part number. Do
not use a lesser quality fastener if replacements
3. Do not work on any machine that is supported only are necessary. Do not mix metric fasteners with
by lift jacks or a hoist. Always use blocks or jack standard nuts and bolts.
stands to support the machine before performing
any disassembly. 12. If possible, make all repairs with the machine
parked on a level, hard surface. Block machine
4. Lower the bucket or other implements to the so it does not roll while working on or under
ground before performing any work on the machine.
 WARNING

13. Disconnect battery before starting to work on 20. Do not operate a machine if any rotating part is
machine. Hang “Do Not Operate” tag in the damaged or contacts any other part during
Operator’s Compartment. operation. Any high speed rotating component
that has been damaged or altered should be
14. Repairs, which require welding, should be checked for balance before reusing.
performed only with the benefit of the appropriate
reference information and by personnel
adequately trained and knowledgeable in welding
procedures. Determine type of metal being
welded and select correct welding procedure and
electrodes, rods or wire to provide a weld metal
strength equivalent at least to that of parent
metal.

15. Do not damage wiring during removal operations.

Reinstall the wiring so it is not damaged nor will it
be damaged in operation by contacting sharp
corners, or by rubbing against some object or hot
surface. Do not connect wiring to a line
containing fluid.

16. Be sure all protective devices including guards

and shields are properly installed and functioning
correctly before starting a repair. If a guard or
shield must be removed to perform the repair
work, use extra caution.

17. Loose or damaged fuel, lubricant and hydraulic

lines, tubes and hoses can cause fires. Do not
bend or strike high pressure lines or install ones
which have been bent or damaged. Inspect lines,
tubes and hoses carefully. Do not check for leaks
with your hands. Pin hole (very small) leaks can
result in a high velocity oil stream that will be
invisible close to the hose. This oil can penetrate
the skin and cause personal injury. Use
cardboard or paper to locate pin hole leaks.

18. Tighten connections to the correct torque. Make

sure that all heat shields, clamps and guards are
installed correctly to avoid excessive heat,
vibration or rubbing against other parts during
operation. Shields that protect against oil spray
onto hot exhaust components in event of a line,
tube or seal failure must be installed correctly.

19. Relieve all pressure in air, oil or water systems

before any lines, fittings or related items are
disconnected or removed. Always make sure all
raised components are blocked correctly and be
alert for possible pressure when disconnecting
any device from a system that utilizes pressure.
Foreword •Amount of dirt in air cleaner elements and air
leakage.
How to Use This Manual •Oil levels in the engine oil pan and status of oil
(viscosity, color and mixed impurities).
This manual provides information for servicing the •Water mixed in the oil and oil leakage.
1760XL(DSL802) skid steer loader. All service •Clogging of the oil filter element.
procedures are broken down into detailed steps, •Deviations from designated adjusting points.
listed in their recommended sequence. The manual •Damaged parts and loosening of tightening fittings.
uses both photographs and drawings to help locate •Maintenance conditions of the machine in service, if
and itemize components. possible.

The table of Contents on the preceding pages is your 3) Preparation for disassembly
best tool for finding the service procedure you need.
To save unnecessary work, reserve the necessary
Be certain to observe all Safety information included facilities, tools, and parts racks as well as adequate
in these pages. floor space considering the extent of disassembly.
Keep the area and facilities clean.

Precautions For Disassembly

General Precautions For Disassembly
1) Removal of parts
Preparations before disassembly
•Proceed with the disassembly by confirming the
1) Wash the machine before moving it to into the
fitting conditions of the relative parts, their positions
repair shop.
fore-and aft, left-and-right, upper-and-lower, and the
sequence of their removal.
Prior to moving the machine into the repair shop
remove dust and dirt thoroughly by washing the
•Confirm match marks for mating joints before
machine. Dirt brought into the shop will degrade the
separating parts and where necessary, punch match
cleanliness of the parts handled in the shop, will
marks to clearly identify their relative position to
produce scratches, and can contaminate the inside of
prevent confusion during reassembly.
reassembled units.
•For disassembly of certain designated parts, use
specified special tools.
2) Checking and inspection before disassembly.
•When a part, after removal of fastening nuts and
bolts, is still found to be unremovable, never force
Before attempting to disassemble, check thoroughly
the part. Carefully check for the cause of the
to determine the cause of the problem, and record it.
tightness and remove the cause.
This will not only prevent needless disassembly and
•Keep the disassembled parts in an orderly condition.
losses from needless replacement parts and
Take special care to identify similar parts by
manhour costs, but will also prevent repetition of the
attaching tags or markings.
same problem.
•See that standard parts such as bolts and nuts are
stored in good order with reference to quantity and
It is important to keep records of problems and
where they are to be used.
replacements in order to advise serviceman how to
prevent trouble. Items to be checked and recorded
2) Checking and inspecting during disassembly.
are as follows:
•The cause of the actual trouble is often discovered
•Model, machine serial number and service meter
in the course of disassembly. Thus careful checking
readings.
of sliding surfaces for any signs of seizing or
•Reason for disassembly.
interference, and their mating conditions, is
•Components replaced.
important.
•Measure and record during disassembly the various
Check for symptom, location and cause of problem. If
end clearances, backflashes and protrusions that
necessary, try repeating the same problem.
are necessary to determine the trouble.

Foreword 5 How to Use This Manual

3) Maintaining clearance adjustmnets Procesures after disassembly

Keep each set of shims or washers stored in an 1) Cleaning

orderly manner so that its original arrangement with
the same clearances can be obtained at reassembly. •Wash disassembled parts clean, neatly arrange the
parts according to each assembly, and keep in
4) Maintaining linkage adjustments storage, free from dust and dirt.
Special care should be taken to remove sludge and
Be careful to maintain the original adjustment of the dust thoroughly from oil holes in the parts and from
rods unless some readjustment is necessary. When it the interior of the tubes.
is necessary to remove the rod end for disassembly, •More effective cleaning can be achieved by use of
measure and record the length of the rod before two vessels filled with detergent, one for washing
disassembly. dirty parts and the other for rinsing.
When washing special parts, increase the number of
5) disassembly of taper-fitted or force-fitted parts vessels and keep the dirty detergent away from
these parts.
•Remove any scars or dents, clean well and •Kerosene or neutral-anhydride light oil is a suitable
reassemble. detergent for cleaning viscous bearing oils.
•When looseness of fit exists in taper-fitted or force- •When washing a large casting, immerse it in a
fitted parts, carefully check for the cause of the vessel filled with detergent (alkalinity pH10 to 12,
faulty fit, remove the cause and reassemble. temperature 50 to 70 ûC) (122û to 158 ûF) for up 10
minutes. Then, rinse it thoroughly with water.
6) Disassembly of bearings •If harmful chemical agents are used as the
detergent, take care to protect the skin and eyes. Do
•Do not attempt to remove a bearing by force, but not attempt to drain waste fluid into the sewage
remove it with a suitable puller such as shown in the system.
figure below.
2) Dust-proofing

•Cover washed parts in storage to keep them free

from dust and dirt. Cap all pipes.
•Apply suitable rust-preventive treatment to the parts
if they are to be kept an extended period of time in
storage before reassembly.

7) Safety

•Keep the area where the machine is to be

disassembled clean and orderly.
•When loosening a bolt or nut, use a correct size
wrench and always pull the wrench toward you. Use
of a mis-matched wrench because of confusion
between the inch and metric system, or pushing the
wrench away from your body may cause accidents
through slipping of the wrench or the hand.
•For jobs involving two or more persons, keep close
contact by mutual checking and exchange of
necessary signals.

Foreword 6 General Precautions For Disassembly

General Precautions for Assembly •Remove remnants of loctite or any thread bonding
agent from the removed bolts with appropriate
Preparations before disassembly solvent. Apply 2 or 3 drops of fresh loctite before
retightening bolts.
1) Installation of parts
(3) Check in the course of assembly
•Thoroughly clean all parts before assembly. Check
for scratches and nicks on the surfaces of the parts, During assembly, check and record end clearances,
and repair if necessary. end plays, protrusions, steps and backflashes at
Special care should be paid to the sliding surfaces each stage of assembly.
of parts which, if left soiled, will cause reduced
machine life. (4) Reinsertion of shims
•Use detergent to remove any rust preventive before
assembly. •Insert stored sets of shims or washers in their
•Make sure to align match marks of those parts that positions in the same order as disassembly.
are marked before attempting to assemble. •After inserting, check for correct values of
•Use the correct or a press-fitting tool or driver when clearances.
assembling bearings, bushings and oil seals. Also,
use the prescribed “special tool” for assembly of (5) Assembly of control linkage
certain designated parts.
•Coat the surface parts to be press-fitted with moly Assemble each control link to the same length as
bdenum disulfide grease. disassembly, unless adjustments are necessary.
Reassemble and properly adjust.
(2) Tightening bolts and nuts
(6) Assembly of taper-fitted or force-fitted parts
•Tighten the bolts and nuts fastening parts together
by alternately (left-and-right and upper-and-lower) •Repair scratches and nicks, and thoroughly clean
turning symmetrically opposite nuts and bolts, to the parts before fitting.
apply even tightening force. •If proper fit cannot be obtained between the taper-
fitted parts, carefully check for the cause.
•Check and see that there is no dust, rust or
scratches found on the surface of the shaft on which
an oil seal is to be fitted and coat the shaft with
grease or lubricating oil so that the oil seal can be
installed smoothly.
•When installing an oil seal, use a suitable guide and
jig as shown in the figure below to prevent oil seal
damages.

Seal
Seal
•When tightening bolts on certain designated parts,
tighten them in the prescribed sequence as shown
in the figure, in order to exert even torque on every
bolt. In this method called the “template methods”.
the bolts are tightened stepwise and sometimes
loosened, so that the bolts and nuts are well seated Guide Jig
or the bearing comes into close and even contact.
•Apply engine oil to the screw threads of certain
designated bolts so that smooth and even tightening
of the bolts may be obtained.
•With wires, cotter pins or lock washers, securely •After press-fitting an oil seal, check for alignment.
lock those bolts and nuts which cannot be checked Allowable limit of misalignment :
from the outside or are used for important parts that 0.2 mm per 100 mm dia. (1/64” per 3 15/16” dia.).
require locking. •When applying bonding agent on the circumference

Foreword 7 General Precautions For Assembly

of an oil seal, avoid contact of the lip surface with
the onding agent.
Remove excess bonding agent on the guide and jig Jig
before using them to install another oil seal.

(7) Handling of bearings

Pressure
Pay special attention to the following
instructions so as not to damage bearing
assemblies :

a. Leave the bearings in their original package until

just before installation.
Keep bearings free from dust and dirt. Dust affects
bearing life significantly.
b. Avoid impact loads and do not apply shocks to the (8) Handling of snap rings
bearings. Absolutely avoid such unreasonable
handling like rotating a bearing excessively by •When removing or installing snap rings, use a
blowing compressed air to remove detergent from suitable ring plier, taking care not to over expand the
the bearing. snap ring.
•Make sure the snap ring is properly seated in its
Observe the following precautions when groove.
installing the bearings :
(9) Assembly of keys and keyways
a. Do not attempt to hammer the bearing assembly
or damage may occur.
Check for looseness of the key in its keyway and for
b. When installing a bearing assembly, use a suitable
the contact of the keyhead.
jig as shown in the figure below to apply pressure
If the keyhead contacts with keyway, remove the
to the inner race.
excess keyhead.
Apply the shrink fit method to the bearings
requiring large interference. Do not heat any
(10) Safety
bearings requiring large interference. Do not heat
any bearing assemblies to over 120ûC(248ûF).
•Keep the working area, tools, worker’s hands, etc.
Excessively high temperature will deteorate the
clean and orderly during assembly work.
hardness of the heat treated bearing surface.
•Use the correct size wrench when tightening a bolt
or nut to reduce the risk of injury and equipment
damage.
•For jobs involving two or more persons, keep close
Outer Race Jig contact by mutual checking and the exchange of
necessary signs.

Pressure Handling of Common Parts

(1) Handling of packings and O-ring

Inner Race •Replace all packings, gaskets O-rings, and copper

packings.
•Coat certain gaskets designated in this manual with
recommended sealant.
c. When installing a non-split type bearing with
(2) Handling of O-rings
necesary interferences of the inner and outer
races, use a suitable jig as shown in the figure
•Use only the O-rings prescribed in the Service Parts
below to apply the necessary pressure to both the
Manual. Special care should be paid to the O-rings
inner and outer races.
subjected to engine lubrication oil, since they are
made of thermal resistant, aging-free special
materials such as silicon rubber and cannot be

Foreword 8 General Precautions For Assembly

 replaced by any other ordinary O-rings.
•Coat the O-rings with oil to protect them from
scratching during installation. Be careful not to
expand the silicon rubber O-rings excessively, or
they will be easily cracked.

(3) Handling of oil seals

•Be careful to see that the oil seal lips face the
proper directions.

Oil Pressure

Main Lip Main LipDust Sealing Lip

¥Keep the oil seals free from dust, and see that there
is no rust or scratches on their surfaces (especially
on the lips).
•Before installation, coat the oil seal with grease as
outlined below, to prevent dry friction which may
occur during the break-in operation of the machine.

a. In case of a single-lip type oil seal:

Uniformly and lightly coat grease around the lip on
the opposite side of the sealing surface of the lip.

b. In case of a double-lip type oil seal :

Uniformly coat grease over the surface between
the two lips so that about half of the space of the
hollow found between the lips is filled with grease.

Foreword 9 General Precautions For Assembly

 SB4102E00
Sep.2003

Engine
For Skid Steer Loaders
• A2000 Diesel Engine
430/430Plus
• A2300 Diesel Engine
440Plus
 Important Safety Information

Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary training,
skills and tools to perform these functions properly.

Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.

Basic safety precautions are listed in the “Safety” section or the Service or Technical Manual. Additional safety
precautions are listed in the “Safety” section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards exist.
WARNING labels have also been put on the product to provide instructions and to identify specific hazards. If
these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in this
publication and on the product labels are identified by the following symbol.

WARNING

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintenance and repair information.

Operations that may cause product damage are identified by NOTICE labels on the product and in this publication.

DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication,
maintenance or repair procedures you choose.

The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product.
Obtain the complete and most current information before starting any job. DAEWOO dealers have the most
current information available.

1
Index

Introduction Air System

About the Manual...................................................... 5 Air System Flow .......................................................98
How to Use the Manual .............................................5 Diagnosing Air System Malfunctions........................99
Generic Symbols....................................................... 6 Air Flow Restriction ..................................................99
Definition of Terms .....................................................7 Damage from Non-Filtered Air ...............................100
Illustrations ................................................................ 8 Pressure Side Air Leaks.........................................100
Exhaust Leaks........................................................101
Malfunctioning Turbocharger..................................101
Oil Consumption and Leaks...................................102
General Engine Information Turbocharger Noise ...............................................103
Rotor Assembly Clearance Measure .....................104
External Engine Components ....................................9
Engine Specifications ...............................................11
Lubricating System
Troubleshooting Logic Lubricating System Flow ........................................113
Lubricating Oil Pump ..............................................113
Engine Diagrams .................................................... 12 Pressure Regulating Valve .....................................113
Problem Isolation and Correction ........................... 12 Oil Coolers..............................................................114
Troubleshooting Logic(List of Symptoms)............... 13 Oil Filters ................................................................114
Oil Filters Bypass Valve..........................................114
Low Oil Pressure ....................................................116
Oil Level .................................................................116
Coolant System Oil Filter ..................................................................117
Oil Gauge ...............................................................117
Cooling System Components and Flow...................53 Oil Suction Tube .....................................................117
Pressure Caps .........................................................56 Bearings and Oil Pump ..........................................117
Water(Coolant) Pump...............................................57 Incorrect Oil Pump..................................................118
Thermostat ...............................................................60 Oil Dilution ..............................................................118
Gauges, Overfueling and Laoding ...........................61 Coolant Diluted Oil .................................................118
Cooling System Replacement Procedures ..............62 Fuel Diluted Oil.......................................................119
Belt Tensioner Replacement ................................... 62 Oil Leaks ................................................................123
Fan Pulley Replacement......................................... 62
Fan Hub Replacement ............................................ 63
Water Pump Replacement .......................................64
Cup Plug Replacement ............................................67 Electrical System
Electrical System Description/Operation................134
Electrical System Spec. .........................................136
Fuel System Starting Motor.........................................................137
Engine Cranking Speed Too Slow .........................139
Fuel System Components and Flow ........................68 Alternator................................................................140
Fuel System Malfunction Diagnosis.........................69 Fuel Shut Off Valve Check.....................................143
Air in the Fuel System..............................................70 Oil Pressure Switch................................................143
Fuel Water Separator/Filter Unit ..............................71
Injection Pump .........................................................72
Governor Malfunctions .............................................72
Fuel Control Lever TRavel and Adjustment .............73
VE Pump Adjustment Screws ..................................73
Manual Shut Down Levers.......................................74
Advance Timing Mechanism ....................................74
Electrical Shut off Valves .........................................75
Injection Pump Timing..............................................77
High Pressure Fuel Line ..........................................78
Injectors....................................................................79
Fuel Drain Manifold ..................................................81
Air Fuel Control Tube

A Series Diesel Engine 3 Index

Base Engine Components Engine Replacement and Testing
Operation and Description .....................................148 Engine Replacement..............................................222
Cylinder Head and Valve Train ..............................149 Engine Removal.....................................................222
Front Gear Housing and Gear Train ......................150 Engine Installation..................................................224
Front Crankshaft Seal ............................................150 Engine Testing........................................................226
Camshaft, Tappets and Push Rods .......................150
Flywheel Housing and Flywheel ............................151
Piston and Rod Assemblies ...................................152 Specifications
Crankshaft and Main Bearings...............................154
Oil Pan ...................................................................156 General Engine ......................................................227
Base Engine Component .......................................156 Fuel System ...........................................................227
Air and Fuel System...............................................157 Lubricating Oil System ...........................................227
Compression Check...............................................158 Cooling System ......................................................228
Piston Ring Seal ....................................................158 Air Intake System ...................................................228
Valce Sealing .........................................................158 Exhaust System .....................................................228
Valve Seal Wear.....................................................160 Electrical System....................................................228
Front Gear Housing and Gear TRain.....................161 Drive Belt Tension ..................................................228
Rocker Levers ........................................................162 Capscrew Markings and Torque Values.................229
Piston and Rod Assembly ......................................163 Fraction, Decimal, Millimeter Conversions.............232
Crankshaft and Main Bearings...............................165 Newton-Meter to Foot-Pound Conversions............233
Cylinder Block ........................................................166 Pipe Plug Torque Values ........................................233
Flywheel Housing and Flywheel ............................166 Weights and Measures-Conversion Factors..........234
Base Engine Componen Specifications.................168
Gear Train ..............................................................169
Camshaft ................................................................169
Tappets...................................................................169 Special Tools
Pistons ...................................................................170
Connecting Rod .....................................................171 Special Tool List .....................................................236
Crankshaft ..............................................................171
Cylinder Block ........................................................171
Cylinder Bore .........................................................172
Base Engine Components .....................................173
Rocker Levers ........................................................174
Rocker Levers Assembly .......................................179
Valve Clearance .....................................................179
Four Cylinder Engine .............................................179
Camshaft and Tappet .............................................180
Camshaft Inspection ..............................................181
Camshaft Bushing Inspection ................................182
Tappet Inspection ...................................................183
Gear Housing or Gasket ........................................186
Flywheel Ring Gear and Rear Sel .........................187
Brass Drift Pin ........................................................187
Flywheel .................................................................188
In Chassis Overhaul...............................................189
Cylinder Head Removal .........................................190
Main Bearing Preliminary Inspection .....................191
Main Bearing ..........................................................194
Piston and Rod ......................................................196
Piston, Pin and Connecting Rod ............................197
Piston Ring Gap .....................................................202
Piston Rings ...........................................................202
Piston and Rod Assembly ......................................204
Cylinder Head and Gasket.....................................207
Cylinder Head.........................................................211
Valves.....................................................................214
Valve Seats ............................................................216
Valve Springs .........................................................219
Cylinder Head ........................................................220

A Series Diesel Engine 4 Index

Introduction

About the Manual

The procedures in this manual were developed for an in-chassis environment. The information has been grouped
by the main engine systems. The Table of Contents defines the systems. The index at the beginning of each
section subdivides the instructions for the various components of the system. Wrench sizes and special tools are
identified in the procedures as needed.

How to Use the Manual

The organization of this manual is based on the troubleshooting logic presented in Section 2. To fix a problem, find
the logic chart for the particular symptom. Follow the steps specified until the problem is corrected.

The left column of the charts indicates a probable cause. The right column provides a brief description of the
corrective action with a reference to the repair procedure or diagnostic discussion when appropriate.

The logic charts reflect three basic considerations:

1. Assumes the engine has provided satisfactory service prior to the problem.
2. Performing the easiest things first.
3. Most logical cause in descending order.

If the problem occurs with a new engine or after repair of the engine, the diagnostics discussion for each major
system will provide guidance for sorting out the cause of the problem.

A Series Diesel Engine 5 Introduction

Doosan 440 Plus Shop Manual
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Generic Symbols
The following group of symbols has been used in this manual to help communicate the intent of the instructions.
When one of the symbols appears, it conveys the meaning defined below.

Warning – Serious personal injury or extensive property damage can result if the warning
instructions are not followed.

Causion – Minor personal injury can result or a part, an assembly or the engine can be
damaged if the caution instructions are not followed.

The component weighs 23kg [50lb] or more. To avoid personal injury, use a hoist or get
assistance to lift the component.

Indicates a REMOVAL or DISASSEMBLY step.

Indicates an INSTALLATION or ASSEMBLY step.

INSPECTION is required.

CLEAN the part or assembly.

PERFORM a mechanical or time MEASUREMENT.

LUBRICATE the part or assembly.

Indicates that a WRENCH or TOOL SIZE will be given.

TIGHTEN to a specific torque

PERFORM an electrical MEASUREMENT.

Refer to another location in this manual or another publication for additional information.

A Series Diesel Engine 6 Introduction

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