Doosan DX27Z User manual

Copyright Doosan 2006K1028289E Operation and Maintenance Manual
DOOSAN reserves the right to improve its products continuously, delivering the best possible product to
the marketplace. These improvements can be implemented at any time with no obligation to change
materials previously sold. It is recommended that consumers periodically contact their distributors for most
recent documentation on purchased equipment.
This documentation may include attachments and optional equipment 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.
Operation and Maintenance Manual
K1028289E
Serial Number 5001 and Up
December 2006
DX27Z

K1028289E
I
Table of Contents
Table of Contents
Safety..........................................................................................1-1
To the Operator of a Excavator...................................................... 1-1
Location of Safety Labels ................................................................ 1-5
Summary of Safety Precautions for Lifting in Digging Mode ..... 1-12
Unauthorized Modifications............................................................. 1-13
General Hazard Information ........................................................... 1-13
Before Starting Engine ................................................................... 1-23
Machine Operation.......................................................................... 1-27
Maintenance .................................................................................... 1-35
Battery.............................................................................................. 1-42
Towing ............................................................................................. 1-44
Shipping and Transportation .......................................................... 1-45
Excavator Rated Lift Capacity Tables........................................... 1-46
Operating Controls ...................................................................2-1
Component Locations ....................................................................... 2-2
Operator's Area................................................................................. 2-4
Operational Controls and Panels..................................................... 2-6
instrument Panel ............................................................................. 2-13
Stereo (Optional)............................................................................. 2-18
Fuse boxes...................................................................................... 2-19
Miscellaneous Electrical Devices ................................................... 2-20
Heating System (Optional) ............................................................. 2-21
Seat Adjustment.............................................................................. 2-23
Seat Belt.......................................................................................... 2-23
Front Windows ................................................................................ 2-25
Door Side Latch.............................................................................. 2-27
Cabin Storage Compartments........................................................ 2-27

K1028289E
II
Table of Contents
Hanger ............................................................................................. 2-28
Cup Holder ...................................................................................... 2-28
Emergency Glass Breaking Tool ................................................... 2-28
Operation....................................................................................3-1
To Handle a New Excavator ........................................................... 3-1
Starting and Stopping the Engine ................................................... 3-2
Safety Lever .................................................................................... 3-13
Travel ............................................................................................... 3-14
Operating Instructions ..................................................................... 3-19
Operating Precautions .................................................................... 3-23
Parking Excavator ........................................................................... 3-28
Towing Procedure ........................................................................... 3-29
Hydraulic Breaker............................................................................ 3-30
Operating Techniques..................................................................... 3-37
Operation Under Unusual Conditions............................................ 3-39
Inspection, Maintenance and Adjustment ............................4-1
Preventive Maintenance.................................................................... 4-1
Preliminary Work Machine Setup for Maintenance........................ 4-3
Table of Recommended Lubricants................................................. 4-5
Fluid Capacities................................................................................. 4-7
Lubrication and Service Chart ......................................................... 4-7
Maintenance Intervals ..................................................................... 4-10
10 Hour / Daily Service ................................................................. 4-12
50 Hour / Weekly Service ............................................................. 4-20
250 Hour / Monthly Service .......................................................... 4-23
500 Hour / 3 Month Service ......................................................... 4-29
1,000 Hour / 6 Month Service ...................................................... 4-31
2,000 Hour / Yearly Service.......................................................... 4-33
4,000 Hour / Biennial Service ....................................................... 4-37
12,000 Hour / Six Year Service.................................................... 4-38
Bolt and Nut Inspection ................................................................. 4-39

K1028289E
III
Table of Contents
Bucket .............................................................................................. 4-40
Electrical System............................................................................. 4-46
Engine Cooling System .................................................................. 4-49
Handling of Accumulator ................................................................ 4-53
Long Term Storage ........................................................................ 4-54
Maintenance in Special Conditions ............................................... 4-55
Track Tension ................................................................................. 4-56
Venting and Priming Hydraulic System ........................................ 4-58
Transportation ...........................................................................5-1
Loading and Unloading .................................................................... 5-1
Lifting With Sling............................................................................... 5-4
Troubleshooting ........................................................................6-1
Control Valve..................................................................................... 6-1
Relief Valve ....................................................................................... 6-2
Center Joint....................................................................................... 6-2
Control Lever..................................................................................... 6-3
Attachments ....................................................................................... 6-3
Hydraulic Motor ................................................................................. 6-4
Hydraulic Cylinder ............................................................................. 6-4
Hydraulic Pump................................................................................. 6-5
Swing System ................................................................................... 6-5
Travel ................................................................................................. 6-6
Specification ..............................................................................7-1
Standard Specification ...................................................................... 7-1
Overall Dimensions ........................................................................... 7-2
Working Range ................................................................................. 7-4
Approximate Weight of Workload Materials.................................... 7-5
Index ...........................................................................................8-1

K1028289ETable of Contents
IV

OP000522
1-1
Safety
OP000522
1Safety
TO THE OPERATOR OF A
EXCAVATOR
Please respect the importance of taking responsibility for
your own safety, and that of other people who may be
affected by your actions.
The safety information on the following pages is organized
into the following sections:
1. “Location of Safety Labels” on page 1-5
2. “Summary of Safety Precautions for Lifting in Digging
Mode” on page 1-12
3. “Unauthorized Modifications” on page 1-13
4. “General Hazard Information” on page 1-13
5. “Before Starting Engine” on page 1-23
6. “Machine Operation” on page 1-27
7. “Maintenance” on page 1-35
8. “Battery” on page 1-42
9. “Towing” on page 1-44
10. “Shipping and Transportation” on page 1-45
11. “Excavator Rated Lift Capacity Tables” on page 1-46
DANGER!
Unsafe use of the excavator 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.

OP000522Safety
1-2
WARNING!
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.
DOOSAN delivers machines that comply with all
applicable regulations and standards of the country to
which it has been sent. 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 DOOSAN or your
DOOSAN distributor before operating the machine.

OP000522
1-3
Safety
Learn the Signal Words Used with the
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 ALERT SYMBOL
Be Prepared - Get to Know All Operating and Safety
Instructions.
This is the Safety Alert Symbol. Wherever it appears in
this manual or on safety signs on the machine you
should be alert to the potential for personal injury or
accidents. Always observe safety precautions and follow
recommended procedures.
CAUTION!
This word is used on safety messages and safety labels
and indicates potential threat of a hazardous situation
that, if not avoided, could result in minor or moderate
injury. It may also be used to alert against a generally
unsafe practice.
WARNING!
This word is used on safety messages and safety labels
and indicates potential threat of a hazardous situation
that, if not avoided, could result in serious injury or
death. It may also be used to alert against highly unsafe
practice.
DANGER!
This word is used on safety messages and safety labels
and indicates an imminent hazard of a situation that, if
not avoided, is very likely to cause death or extremely
serious injury. It may also be used to alert against
equipment that may detonate or explode if handled or
treated carelessly.

OP000522Safety
1-4
Safety precautions are described in SAFETY from page 1-5 on.
DOOSAN 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 any procedures, contact a DOOSAN distributor.