Daewoo Doosan 844J Operation and Maintenance Manual 022-00029JE – PDF DOWNLOAD
DESCRIPTION:
Daewoo Doosan 844J Operation and Maintenance Manual 022-00029JE – PDF DOWNLOAD
- JOHN DEERE reserves the right to improve our products in a continuing process to provide the best possible product to the market place. These improvements can be implemented at any time with no obligation to change materials on previously sold products.
- It is recommended that consumers periodically contact their distributors for recent documentation on purchased equipment. This documentation may include attachments and optional equipment that is not available in your machine’s package.
- Please call your distributor for additional items that you may require. Illustrations used throughout this manual are used only as a representation of the actual piece of equipment, and may vary from the actual item.
TO THE OPERATOR OF A JOHN DEERE WHEEL LOADER
Unsafe use of the wheel loader could lead to serious injury or death. Operating procedures, maintenance and equipment practices or traveling or shipping methods that do not follow the safety guidelines on the following pages could cause serious, potentially fatal injuries or extensive damage to the machine or nearby property.
Please respect the importance of taking responsibility for your own safety, and that other people who may be affected by your actions
Safety information on the following pages is organized into the following topics.
1. “General Safety Essentials” on page 1-4
2. “Location of Safety Labels” on page 1-4
3. “Unauthorized Modifications” on page 1-13
4. “General Hazard Information” on page 1-13
5. “Before Starting Engine” on page 1-21
6. “Machine Operation” on page 1-24
7. “Maintenance” on page 1-31
8. “Battery” on page 1-39
9. “Towing” on page 1-41
10. “Shipping and Transportation” on page 1-42
- Improper operation and maintenance of this machine can be hazardous and could result in serious injury or death. Operator and maintenance personnel should read this manual thoroughly before beginning operation or maintenance. Keep this manual in the storage compartment to the rear of the operator’s seat, and have all personnel involved in working on the machine read the manual periodically.
- Some actions involved in operation and maintenance of the machine can cause a serious accident, if they are not done in a manner described in this manual.
- The procedures and precautions given in this manual apply only to intended uses of the machine. If you use your machine for any unintended uses that are not specifically prohibited, you must be sure that it is safe for any others.
- In no event should you or others engage in prohibited uses or actions as described in this manual. John Deere delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped.
- If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult John Deere or your John Deere distributor before operating the machine
LEARN SIGNAL WORDS USED WITH SAFETY ALERT SYMBOL
The words “CAUTION,” “WARNING,” and “DANGER” used throughout this manual and on decals on the machine indicate degree of risk of hazards or unsafe practices. All three degrees of risk indicate that safety is involved. Observe precautions indicated whenever you see the Safety Alert “Triangle,” no matter which signal word appears next to the “Exclamation Point” symbol
Safety precautions are described in SAFETY from page 1-4 on.
John Deere cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety messages in this manual and on the machine may not include all possible safety precautions. If any procedures or actions not specifically recommended or allowed in this manual are used, you must be sure that you and others can do such procedures and actions safely and without damaging the machine. If you are unsure about the safety of some procedures, contact a John Deere distributor
GENERAL SAFETY ESSENTIALS
ACCESSORY APPLICATIONS
This wheel loader has been designed primarily for moving earth with a bucket. For use as a grapple or for other object handling, contact John Deere. Lifting-work applications are permitted in approved lift configuration, to rated capacity only, with no side-loading (unless prohibited by local regulation). Do not use machine for activities for which it was not intended. Do not use bucket for lifting work, unless lift slings are used in approved configuration.
LOCATION OF SAFETY LABELS
There are several specific warning signs on this machine. The exact location of hazards and the description of the hazards are reviewed in this section. Please become familiarized with all warning signs. Make sure that all of the warning signs are legible. Clean the warning signs or replace the warning signs if you cannot read the words. Replace the illustrations if the illustrations are not visible. When you clean the warning signs, use a cloth, water and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the safety signs. Solvents, gasoline, or other harsh chemicals could loosen the adhesive that secures the warning sign. Loose adhesive will allow the warning sign to fall off. Replace any safety sign that is damaged, or missing. If a safety sign is attached to a part that is replaced, install a safety sign on the replacement part.
TABLE OF CONTENTS:
Daewoo Doosan 844J Operation and Maintenance Manual 022-00029JE – PDF DOWNLOAD
Safety.......................................................................................................... 7 To the Operator of a John Deere Wheel Loader................................................................ 7 Learn Signal Words Used with Safety Alert Symbol........................................................ 9 General Safety Essentials................................................................................... 10 Accessory Applications.................................................................................. 10 Location of Safety Labels................................................................................... 10 1. Warning for Operation, Inspection and Maintenance (190-00971A)....................................... 12 2. Warning for Crush Hazard (190- 00948)................................................................ 12 3. Warnings When Opening Engine Hood (190-00095)........................................................ 13 4. Warning for Handling Accumulator (190-00953A)........................................................ 13 5. Keep Out of Steering Turn Area (4190-1992A).......................................................... 14 6. Warning for High Temperature Hydraulic Oil (190-00691)............................................... 14 7. Warning for High Temperature Coolant (190-01098)..................................................... 14 8. Warning for Battery Maintenance (2190-2533A, 190-00938).............................................. 15 9. Warning for Block Wheel (190-00940).................................................................. 15 10. Warning for Performing Maintenance on Front Attachment (190-00937).................................. 16 11. Warning for Fan (2190-3315)......................................................................... 16 12. Warning Tag (190-00695)............................................................................. 16 13. Warning for Pressure Oil (190-00943)................................................................ 17 14. Warning for ROPS (190-00755)........................................................................ 17 Unauthorized Modifications.................................................................................. 18 General Hazard Information.................................................................................. 18 Safety Rules............................................................................................ 18 Safety Features......................................................................................... 18 Inside Operator's Compartment........................................................................... 19 Clothing and Personal Protective Items.................................................................. 19 Breathing Masks, Ear Protection May Be Required......................................................... 20 Asbestos Dust Hazard Prevention......................................................................... 20 Mounting and Dismounting................................................................................ 21 Fuel, Oil and Hydraulic Fluid Fire Hazards.............................................................. 21 Precautions When Handling Fluids at High Temperature.................................................... 22 Injury from Work Equipment.............................................................................. 22 Fire Extinguisher and First Aid Kit..................................................................... 23 Protection from Falling or Flying Objects............................................................... 23 Install Additional Safety Equipment If Conditions Require............................................... 24 Maintain Standard Safety Equipment in Good Condition.................................................... 24 Attachment Precautions.................................................................................. 25 Accumulator............................................................................................. 25 Engine Ventilation...................................................................................... 25 Emergency Exit.......................................................................................... 26 Before Starting Engine...................................................................................... 27 Work Site Precautions................................................................................... 27 Checks Before Starting Engine........................................................................... 28 Engine Starting......................................................................................... 28 Before Operating Machine................................................................................ 29 Machine Operation........................................................................................... 30 Operate While Seated at Operator's Station ONLY......................................................... 30 Seat Belts Must Be Used at All Times.................................................................... 30 Movement Alarms......................................................................................... 30 Travel Precautions...................................................................................... 31 Sloping Terrain Requires Caution........................................................................ 31 Avoid High-voltage Cables............................................................................... 32 Before Starting to Dig, Contact Authorities............................................................. 32 Be Aware of Height Obstacles............................................................................ 32 Use Care on Loose Support............................................................................... 32 Use Solid Support Blocking.............................................................................. 33 Digging Beneath Overhangs............................................................................... 33 Digging Beneath Wheel Loader............................................................................ 33 Stay Alert for People Moving Through Work Area.......................................................... 33 Be Aware of and Conform to Local Regulations............................................................ 33 Never Use Ether Starting Aids........................................................................... 34 Observe General Safety Rules............................................................................ 34 Take Time to Provide Good Visibility.................................................................... 34 Keep "Pinch Point" Areas Clear - Use Caution in Reverse................................................. 35 Operate Carefully on Snow and Ice and in Very Cold Temperatures......................................... 35 Parking Machine......................................................................................... 35 Shutdown Control Functions.............................................................................. 36 Never Let Anyone Ride on Attachment..................................................................... 36 Maintenance................................................................................................. 37 Use Warning Tag During Service.......................................................................... 37 clean Before Inspection or Maintenance.................................................................. 37 Proper Tools............................................................................................ 38 Use of Lighting......................................................................................... 38 Fire Prevention and Explosion Prevention................................................................ 38 Burn Prevention......................................................................................... 39 Welding Repairs......................................................................................... 40 Precautions for Removal, Installation, and Storage of Attachments....................................... 40 Precautions When Working on Machine..................................................................... 41 Lock Inspection Covers.................................................................................. 41 Crushing Prevention and Cutting Prevention.............................................................. 41 Do Not Run Engine If Repairs or Work Are Being Performed Alone.......................................... 41 Always Use Adequate Equipment Supports and Blocking..................................................... 42 Do Not Work on Hot Engines or Hot Cooling or Hydraulic Systems.......................................... 42 Hydraulic Cylinder Seals Require Periodic Replacement................................................... 42 High-pressure Hydraulic Lines Can Store a Great Deal of Energy.......................................... 42 Precautions with High-pressure Line, Tubes and Hoses.................................................... 43 Obtain Immediate Medical Attention if Pressurized Oil Pierces Skin...................................... 43 Use Correct Replacement Fasteners Tightened to Proper Torque............................................ 44 Safety Critical Parts Must Be Replaced Periodically..................................................... 44 Dispose of All Petroleum Based Oils and Fluids Properly................................................. 44 Check Tire Pressure and Condition....................................................................... 44 Battery..................................................................................................... 45 Battery Hazard Prevention............................................................................... 45 Disconnect Batteries Before Electrical Service or Electrical Welding.................................... 45 Use Low Heat Portable Lighting.......................................................................... 46 Boost Starting or Charging Engine Batteries............................................................. 46 Towing...................................................................................................... 47 Precautions When Towing................................................................................. 47 Shipping and Transportation................................................................................. 48 Obey State and Local Over-the-Road Regulations.......................................................... 48 Operating Controls.............................................................................................. 49 Component Locations......................................................................................... 50 Control Identification...................................................................................... 52 Steering Console and Pedals................................................................................. 53 1. Starter Switch....................................................................................... 54 2. Horn Button.......................................................................................... 54 3. Combination Switch Lever............................................................................. 55 4. Accelerator Pedal.................................................................................... 56 5. Steering Tilt Lever.................................................................................. 56 6. Brake Pedal (Right and Left Pedals).................................................................. 57 7. Steering Wheel....................................................................................... 58 8. Kick-down Switch (two Places)........................................................................ 58 9. Transmission Lever................................................................................... 59 10. Front Instrument Panel.............................................................................. 60 11. Transmission Display................................................................................ 60 Front Instrument panel...................................................................................... 62 Gauges.................................................................................................. 63 Warning Lights.......................................................................................... 63 Switches................................................................................................ 63 1. Fuel Gauge........................................................................................... 63 2. Speedometer.......................................................................................... 64 3. Hour Meter........................................................................................... 64 4. Tachometer........................................................................................... 64 5. Engine Coolant Temperature Gauge..................................................................... 65 6. Transmission Oil Temperature Gauge................................................................... 65 7. Preheat Indicator Light.............................................................................. 65 8. Air Cleaner Clogged Warning Light.................................................................... 66 9. Engine Warning Light (Yellow Color).................................................................. 66 10. Engine Stop Indicator Light (Red Color)............................................................. 66 11. Battery Warning Light............................................................................... 67 12. Left Turn and Hazard Warning Light.................................................................. 67 13. High Beam Indicator Light........................................................................... 67 14. Right Turn and Hazard Warning Light................................................................. 67 15. Work Light Indicator Light.......................................................................... 68 16. Brake Oil Pressure Warning Light.................................................................... 68 17. Unused Light........................................................................................ 68 18. Parking Brake Indicator Light....................................................................... 68 19. Unused Light........................................................................................ 69 20. Hazard Warning Light Switch......................................................................... 69 21. Blank (Empty Switch Socket)......................................................................... 69 22. Blank (Empty Switch Socket)......................................................................... 69 Transmission Display........................................................................................ 70 Right Side Switch Panel..................................................................................... 72 1. Murphy Gauge......................................................................................... 73 2. Power Socket for 12 Volt............................................................................. 73 3. LIS (Load Isolation System) Switch................................................................... 73 4. Boom Float Switch.................................................................................... 74 5. Headlight Switch..................................................................................... 74 6. front Work Light Switch.............................................................................. 75 7. Rear Work Light Switch............................................................................... 75 8. Rear Wiper Switch.................................................................................... 76 9. Parking Brake Switch................................................................................. 77 10. Pilot Cutoff Switch................................................................................. 77 11. Transmission Cutoff Switch.......................................................................... 78 12. Automatic Transmission Switch....................................................................... 78 13. Rotating Beacon Light Switch (Option)............................................................... 79 14. Auxiliary Switch.................................................................................... 79 15. Cup holder.......................................................................................... 79 16. Pilot Control Valve Lever (Two Lever Design)........................................................ 79 17. Kick-down switch (Two places) / Log Fork Switch (Option)............................................ 80 Various Cabin Locations..................................................................................... 81 1. Cabin Light.......................................................................................... 82 2. Stereo............................................................................................... 82 3. Heater and Air conditioner Control Panel............................................................. 82 4. Speakers............................................................................................. 82 5. Storage Box.......................................................................................... 83 6. Washer Tank.......................................................................................... 83 7. Hot/Cold Refrigerator................................................................................ 83 8. Electrical Box....................................................................................... 84 9. Fuse Box Two......................................................................................... 84 10. Fuse Box One........................................................................................ 84 Heater and Air Conditioner Operation........................................................................ 85 Location of Controls and Vents.......................................................................... 85 Operation Panel......................................................................................... 86 1. Fan and Air Conditioner Switch....................................................................... 86 2. Blower Fan Switches.................................................................................. 87 3. Temperature Control Switch........................................................................... 87 4. Selector Switch for Wind Direction................................................................... 87 5. Ventilation Selector Switch.......................................................................... 88 Memory Function of Used Mode............................................................................ 88 Additional Operating Instruction........................................................................ 89 Stereo...................................................................................................... 90 1. On-off / Volume Control Knob......................................................................... 90 2. Balance / Fader Control.............................................................................. 90 3. BASS / TREBLE Control................................................................................ 91 4. Am/Fm Band Selector.................................................................................. 91 5. Automatic Memory (Ame)............................................................................... 91 6. Tape Eject Button.................................................................................... 91 7. Cassette Slot........................................................................................ 91 8. & 9. Play Direction Button........................................................................... 91 10. Automatic Selector.................................................................................. 91 11. Dolby B Selector.................................................................................... 92 12. Metal Selector...................................................................................... 92 Care of Stereo.......................................................................................... 92 Seat Adjustment............................................................................................. 94 1. Adjusting Seat Forward/ Backward Lever............................................................... 94 2 & 3. Adjusting Seat's Angle and Height Lever.......................................................... 94 4. Weight Adjustment Knob............................................................................... 94 5. Backrest Adjustment Lever............................................................................ 94 6. Angle Adjustment of Armrest.......................................................................... 95 7. Headrest............................................................................................. 95 Seat Belt................................................................................................... 96 Seat Belt Locking and Unlocking......................................................................... 96 Door Side Latch............................................................................................. 97 Fuse Box/Relay.............................................................................................. 98 Fuse Boxes.............................................................................................. 98 Relay...................................................................................................100 Circuit Breaker.........................................................................................100 Fusible Link............................................................................................101 Window Glass Breaking Tool..................................................................................102 Operation.......................................................................................................103 Instrument Panel Control Functions..........................................................................103 Monitoring System.......................................................................................103 New Machine Break-in Procedures.............................................................................103 Engine Start and Stop.......................................................................................104 Inspection Before Starting Engine.......................................................................104 Engine Start............................................................................................104 Starting with Auxiliary Batteries.......................................................................108 Engine Shut Down........................................................................................109 Hydraulic System Warm-up................................................................................111 Hydraulic System Warm-up - Cold Weather.................................................................111 Machine Travel..............................................................................................111 Machine Shutdown............................................................................................114 Additional Braking..........................................................................................116 Boom Raise Kick-out.........................................................................................116 Boom Lower Kick-out (Option)................................................................................117 Bucket Angle Indicator......................................................................................118 Adjustment of Bucket Position Switch........................................................................118 Towing Machine..............................................................................................119 Emergency Release of the Parking Brake..................................................................120 Adjusting regulations...................................................................................121 If Engine Stalls While Traveling............................................................................122 Allowable Water Depth.......................................................................................122 Inspection, Maintenance and Adjustment..........................................................................123 Preventive Maintenance......................................................................................123 Serial Numbers..........................................................................................123 Safety Precautions......................................................................................124 Table of Recommended Lubricants.............................................................................125 Fluid Capacities............................................................................................127 Maintenance Intervals.......................................................................................128 10 Hour / Daily Service.................................................................................128 50 Hour / Weekly Service................................................................................128 250 Hour / Monthly Service..............................................................................129 500 Hour / 3 Month Service..............................................................................129 1,000 Hour / 6 Month Service............................................................................129 1,500 Hour / 9 Month Service............................................................................129 2,000 Hour / Yearly Service.............................................................................129 12,000 Hour / Six Year Service..........................................................................129 10 Hour / Daily Service.....................................................................................131 Grease Front Attachment Pins............................................................................131 Inspect All Tires for Correct Tire Pressure and Signs of Damage or Abnormal Wear........................131 Check Engine Oil Level..................................................................................131 Check Transmission Oil Level............................................................................132 Check Hydraulic System Oil Level........................................................................132 Check for Leaks In Hydraulic System.....................................................................134 Refill Fuel.............................................................................................134 Check for Leaks In Fuel System..........................................................................134 Drain Fuel Condensation.................................................................................135 Check Coolant Level.....................................................................................135 Check Antifreeze Protection Levels......................................................................136 Check Level of Window Washer Fluid......................................................................136 Inspect the Bucket Teeth and Side Cutters for Signs of Wear.............................................136 Inspect Seat Belt for Proper Operation..................................................................136 Inspect the Structure for Cracks and Faulty Welds.......................................................136 Check the Operation of All Switches.....................................................................137 Check the Operation of All Exterior Lights, Horn and Control Console Indicator and Monitor Lights.......137 Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal Operati.......137 Check Operation of All Controls.........................................................................137 Inspect Engine Fan Blade................................................................................138 Check Air Intake System.................................................................................138 Check Crankcase Breather Tube...........................................................................139 50 Hour / Weekly Service....................................................................................140 Perform All Daily Service Checks........................................................................140 Grease Front Attachment Pins............................................................................140 Grease Steering Cylinder Rod and Base Ends..............................................................145 Grease Upper and Lower Center Pins......................................................................145 Change Engine Oil and Filter (Initial)..................................................................145 Hydraulic Full Flow Filter Replacement (Initial)........................................................146 Clean Exterior of Radiator, Oil Cooler and Air Conditioner Evaporator...................................146 250 Hour / Monthly Service..................................................................................147 Perform All Daily and 50 Hour Service Checks............................................................147 Grease Drive Shaft Center Bearing.......................................................................147 Replace Hydraulic System Pilot Filter...................................................................147 Check Engine Air Intake Precleaner......................................................................148 Hydraulic Full Flow Filter Replacement..................................................................149 Drain Water From Hydraulic Oil Tank.....................................................................150 Clean Air Cleaner.......................................................................................150 Change Engine Oil and Filter............................................................................152 Replace DCA4 Coolant Filter Cartridge...................................................................153 Replace Fuel Filter.....................................................................................155 Axle Differential and Planetaries Oil Replacement (Initial).............................................156 Check Differential Gear Oil.............................................................................156 Check Planetary Gear Oil................................................................................156 Replacing Transmission Oil and Filter (Initial).........................................................156 500 Hour / 3 Month Service..................................................................................157 Perform All Daily, 50, 150 and 250 Hour Service Checks..................................................157 Clean Exterior of Radiator, Oil Cooler and Air Conditioner Evaporator...................................157 Clean Air Conditioning Filter...........................................................................157 1,000 Hour / 6 Month Service................................................................................159 Perform All Daily, 50, 150, 250 and 500 Hour Service Checks.............................................159 Drain and Replace Transmission Oil and Filter...........................................................159 Clean Fuel Tank and Strainer............................................................................160 Check Air Condition Refrigerant.........................................................................161 Check and Adjust Engine.................................................................................161 1,500 Hour / 9 Month Service................................................................................162 Perform All 10, 50, 150, 250 and 500 Hour Service Checks................................................162 Replace Outer and Inner Air Cleaner Filters.............................................................162 Axle Differential and Planetaries Oil Replacement.......................................................162 2,000 Hour / Yearly Service.................................................................................164 Perform All Daily, 50, 150, 250, 500 and 1,000 Hour Service Checks......................................164 Replace Hoses...........................................................................................164 Bleed Brakes............................................................................................164 Change Radiator Coolant.................................................................................165 Drain and Replace Hydraulic Oil.........................................................................166 Clean Hydraulic Oil Suction Strainer....................................................................169 Check Vibration Damper..................................................................................169 Check Brake Accumulator.................................................................................170 Check Steering, Brake, Drive Shaft, Engine, and Fuel System.............................................170 12,000 Hour / Six Year Service..............................................................................171 Hose In-service Lifetime Limit (European Standard ISO8331 and EN982CEN)...............................171 Severe Conditions Maintenance...............................................................................172 Handling of Accumulator.....................................................................................173 Check Hydraulic Pressures...................................................................................174 Main Pump Pressure......................................................................................174 Transmission System Pressure............................................................................175 Brake Charge Pressure...................................................................................175 Pilot Control Valve Lever (Joystick) Activation Pressure................................................175 Steering Pump Pressure..................................................................................175 Service Brake Outlet Pressure...........................................................................176 Parking Brake Release Pressure..........................................................................176 Fan Motor Pressure......................................................................................177 Tires and Wheels............................................................................................178 Wheel Nut Torque........................................................................................178 Check Tire for Damage...................................................................................179 Electrical System...........................................................................................180 Check Battery Condition.................................................................................180 Bolt Torque Chart...........................................................................................181 Long Term Storage...........................................................................................182 Cleaning................................................................................................182 Hydraulic System........................................................................................182 Lubrication.............................................................................................182 Battery.................................................................................................182 Cooling System Care.....................................................................................182 Transportation..................................................................................................183 Loading Machine on a Trailer................................................................................183 Summary of Safety Precautions for Lifting...................................................................184 Troubleshooting.................................................................................................185 Engine......................................................................................................185 Hydraulic System............................................................................................187 Travel System...............................................................................................189 General.................................................................................................189 Transmission Error Codes................................................................................190 Steering....................................................................................................194 Braking.....................................................................................................195 Electrical System...........................................................................................195 Specifications..................................................................................................197 General Specifications......................................................................................197 Working Range...............................................................................................198 Working Capacities..........................................................................................200 Bucket Capacity.........................................................................................200 Tipping Load............................................................................................200 Material Weight.........................................................................................200 Approximate Weight of Workload Materials....................................................................200 Index...........................................................................................................203
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- This is the SAME exact manual used by your dealers to fix your vehicle.
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