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.

OP000522
1-5
Safety
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 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.
CANOPY TYPE
10
11
89
7
12
4
3
6
5
12
6
5
FG007474
1
2
Figure 1

OP000522Safety
1-6
1. Warnings for Operation, Inspection
and Maintenance (190-00688, 190-00092)
2. Warnings for High Voltage
(190-00689, 190-00096)
AVOID DEATH OR SERIOUS INJURY. - READ AND UNDERSTAND
OPERATION MANUAL AND SAFETY LABELS prior to operating
this machine.
190-00688
190-00092
Never get in under the machine while it is being jacked up
with boom and arm.
Sound the horn to alert the people nearby before operating,
and make sure that all persons are clear of area.
Controls may be changed for attachments or operator
preference. Try control pattern before operating.
ARO1080L
ARO1090L
DANGER
SERIOUS INJURY OR DEATH BY
ELECTROCTION can occur if
machine or attachments are
not a safe distance from electrical
power lines.
Line voltage Safe Distance
6.6 kv
66.6 kv
275.0 kv
At least 3m(10ft)
At least 5m(16ft)
At least 10m(33ft)
190-00689
190-00096

OP000522
1-7
Safety
3. Warnings When Opening a Front
Window (2190-3388, 190-00093)
4. Warnings for a High-pressure
Cylinder (190-00122)
FG000665
2190-3388
190-00093
190-00122
ARO1110L

OP000522Safety
1-8
5. Warnings When Adjusting Track
Tension (2190-3386A, 190-00521)
6. Warnings for Leaving Operator's
Seat (190-00693, 190-00094)
190-00521
2190-3386A
ARO1120L
ARO1140L
190-00094
190-00693

OP000522
1-9
Safety
7. Warnings for Batteries Maintenance
(2190-2533A, 190-00100)
8. Warnings for High Temperature
Hydraulic Oil (190-00691, 190-00097)
ARO1150L
190-00100
2190-2533A
ARO1160L
190-00691
190-00097

OP000522Safety
1-10
9. Warnings for Hot Coolant (190-00692,
190-00097)
10. Warnings for Rotating Parts
(190-00694, 190-00095, 190-00557)
ARO1170L
190-00097
ARO1190L
190-00095
190-00557

OP000522
1-11
Safety
11. Warning Tag - Used When Inspection
and Maintenance (190-00695, 190-00098)
12. Keep Out of the Swing Area
(2190-3380A, 190-00163)
190-00098
ARO1200L
WARNING
DO NOT OPERATE
when performing inspection
or maintenance
190-00695
FG008064
2190-3380A
190-00163

OP000522Safety
1-12
SUMMARY OF SAFETY
PRECAUTIONS FOR LIFTING IN
DIGGING MODE
To lift safely while in Digging Mode, the following items must
be evaluated by the operator and the work site crew.
• Condition of ground support.
• Excavator configuration and attachments.
• Weight, lifting height and lifting radius.
• Safe rigging of the load.
• Proper handling of the suspended load.
Tag lines on opposite sides of the load can be very helpful
in keeping a suspended load secure, if they are anchored
safely to control points on the ground.
Always engage the "Digging Mode" control on the Instrument
Panel before using the excavator for lifting work.
DANGER!
Unsafe use of the excavator while making rated lifts
could cause serious, potentially fatal injuries or
extensive damage to the machine or nearby property.
Do not let anyone operate the machine unless they've
been properly trained and understand the information in
the Operation and Maintenance Manual.
WARNING!
NEVER wrap a tag line around your hands or body.
NEVER rely on tag lines or make rated lifts when wind
gusts are more than 48.3 km/h (30 MPH). Be prepared
for any type of wind gust when working with loads that
have a large surface area.
WARNING!
If you need more information or have any questions or
concerns about safe operating procedures or working
the excavator correctly in a particular application or in
the specific conditions of your individual operating
environment, please consult your local DOOSAN
representative.

OP000522
1-13
Safety
UNAUTHORIZED
MODIFICATIONS
Any modification made without authorization or written
approval from DOOSAN can create a safety hazard, for
which the machine owner will be held responsible.
For safety's sake, replace all OEM parts with the correct
authorized or genuine DOOSAN part. For example, not
taking the time to replace fasteners, bolts or nuts with the
correct replacement parts could lead to a condition where
the safety of critical assemblies are dangerously compromised.
GENERAL HAZARD
INFORMATION
Safety Rules
Only trained and authorized personnel can operate and
maintain the machine.
Follow all safety rules, precautions and instructions when
operating or performing maintenance on the machine.
Do not operate the machine if you are not feeling well, if
you are taking medication that makes you feel sleepy, if you
have been drinking, or if you are suffering from emotional
problems. These problems will interfere with your sense of
judgment in emergencies and may cause accidents.
When working with another operator or with a person on
work site traffic duty, be sure that all personnel know the
nature of the work and understand all hand signals that are
to be used.
Always observe strictly any other rules related to safety.
Safety Features
Be sure that all guards and covers are installed in their
proper position. Have guards and covers repaired
immediately if damaged.
Be sure that you understand the method of use of safety
features such as safety lock lever and the seat belt, and
use them properly.
Never remove any safety features. Always keep them in
good operating condition.
Failure to use safety features according to the instructions in
the Operation and Maintenance Manual could result in
serious bodily injury.

OP000522Safety
1-14
Inside Operator's Cabin
When entering the operator's cabin, always remove all mud
and oil from the soles of your shoes. If you operate the
travel pedal with mud or oil stuck to your shoes, your foot
may slip and this may cause a serious accident.
After using the ashtray, make sure that any matches or
cigarettes are properly extinguished, and be sure to close the
ashtray. If the ashtray is left open, there is danger of fire.
Do not stick suction pads to the window glass. Suction pads
act as a lens and may cause fire.
Do not leave lighters laying around the operator's cabin. If
the temperature inside the operator's cabin becomes high,
there is danger that the lighter may explode.
Do not use cellular telephones inside the operator's cabin
when driving or operating the machine. There is
danger that this may lead to an unexpected accident.
Never bring any dangerous objects such as flammable or
explosive items into the operator's cabin.
To ensure safety, do not use the radio or music
headphones when operating the machine. There is danger
that this may lead to a serious accident.
When operating the machine, do not put your hands or
head out of the window.
When standing up from the operator's seat, always place
safety lock lever securely in the "LOCK" position. If you
accidentally touch the work equipment levers when they are
not locked, the machine may suddenly move and cause
serious injury or damage.
When leaving the machine, lower the work equipment
completely to the ground, set safety lock lever to the "LOCK"
position and shut down engine. Use the key to lock all the
equipment. Always remove the key and take it with you.
Clothing and Personal Protective Items
Secure long hair, and avoid loose clothing and jewelry.
These items have the tendency to catch on controls or
protrude into parts and cause serious injury or death.
Do not wear oily clothes. They are highly flammable.
Full eye protection, a hard hat, safety shoes and gloves
may be required at the work site.
While working on the machine, never use inadequate tools.
They could break or slip, causing injury, or they may not
adequately perform intended functions.
HAOA020L
Figure 2