Doosan DX35Z User manual

Copyright Doosan 2006K1025196E 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
K1025196E
Serial Number 5001 and Up
September 2006
DX35Z

Table of Contents
I
K1025196E
Table of Contents
Safety..........................................................................................1-1
To the Operator of a DOOSAN Daewoo Excavator ..................... 1-1
Location of Safety Labels ................................................................ 1-5
Summary of Safety Precautions for Lifting in Digging Mode ..... 1-13
Unauthorized Modifications............................................................. 1-14
General Hazard Information ........................................................... 1-14
Before Starting Engine ................................................................... 1-24
Machine Operation.......................................................................... 1-28
Maintenance .................................................................................... 1-36
Battery.............................................................................................. 1-45
Towing ............................................................................................. 1-47
Shipping and Transportation .......................................................... 1-48
Excavator Rated Lift Capacity Tables........................................... 1-49
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 and Air Conditioning System (Optional) ......................... 2-21
Seat Adjustment.............................................................................. 2-24
Seat Belt.......................................................................................... 2-24
Front Windows ................................................................................ 2-26
Door Side Latch.............................................................................. 2-28

Table of ContentsK1025196E
II
Cabin Storage Compartments........................................................ 2-28
Hanger ............................................................................................. 2-29
Cup Holder...................................................................................... 2-29
Emergency Glass Breaking Tool................................................... 2-29
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 ........................................................................... 3-27
Towing Procedure ........................................................................... 3-28
Hydraulic Breaker............................................................................ 3-29
Operating Techniques..................................................................... 3-36
Operation Under Unusual Conditions............................................ 3-38
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

Table of Contents
III
K1025196E
Air-Conditioning System.................................................................. 4-39
Bolt and Nut Inspection ................................................................. 4-40
Bucket .............................................................................................. 4-41
Electrical System............................................................................. 4-47
Engine Cooling System .................................................................. 4-50
Handling of Accumulator ................................................................ 4-54
Long Term Storage ........................................................................ 4-55
Maintenance in Special Conditions ............................................... 4-56
Track Tension ................................................................................. 4-57
Venting and Priming Hydraulic System ........................................ 4-59
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

Table of ContentsK1025196E
IV
Index ...........................................................................................8-1

OP000468
1-1
Safety
OP000468
1Safety
TO THE OPERATOR OF A
DOOSAN DAEWOO
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 1-13
3. “Unauthorized Modifications” on page 1-14
4. “General Hazard Information” on page 1-14
5. “Before Starting Engine” on page 1-24
6. “Machine Operation” on page 1-28
7. “Maintenance” on page 1-36
8. “Battery” on page 1-44
9. “Towing” on page 1-46
10. “Shipping and Transportation” on page 1-47
11. “Excavator Rated Lift Capacity Tables” on page 1-48
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.

OP000468Safety
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.

OP000468
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.

OP000468Safety
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.

OP000468
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.
CANOPY TYPE 10
11
89
7
12
4
3
2
65
1
12
6
5
FG007474
Figure 1

OP000468Safety
1-6
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.

OP000468
1-7
Safety
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

OP000468Safety
1-8
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

OP000468
1-9
Safety
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

OP000468Safety
1-10
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

OP000468
1-11
Safety
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

OP000468Safety
1-12
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

OP000468
1-13
Safety
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.

OP000468Safety
1-14
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.