Part of the Doosan Repair Manuals.
This 836-page Doosan DX27Z, DX30Z, DX35Z shop manual PDF (OEM #K1036951E) tears into the whole track excavator lineup, from swing bearing and track assembly to the main pump and main control valve. You get hydraulic schematics with complete fluid routing for the travel motor, swing motor, and remote control valve, plus electrical schematics for chasing wiring faults back to the source. Step-by-step procedures walk you through cylinders, the center joint, the accumulator, and the working attachments, right down to the bucket. Check link pitch against the 101.6 mm standard (104 mm wear limit), and pull M24 Grade 12.9 fasteners to 103 kg-m (745 ft lb). Your excavator is down, and forum guesses won't lift it. Bookmarked with a real text layer, so you can jump to any section, search any spec, and start wrenching.
What's Inside This Doosan DX30Z, DX27Z, DX35Z Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 5-50 | Track Excavator Safety |
| Specifications | 51-76 | Specification for DX30Z |
| General Maintenance | 77-114 | General Maintenance Procedures, Standard Torques |
| Upper Structure | 115-132 | Cabin, Swing Bearing |
| Lower Structure and Chassis | 133-162 | Track Assembly |
| Engine and Drive Train | 163-452 | Engine, Drive Coupling (Main Pump) |
| Hydraulics | 453-774 | Accumulator, Center Joint, Cylinders, Swing Motor, Travel Motor, Main Pump, Main Control Valve (Remote Control Valve, Travel Control Valve, Pedal Valve, Hydraulic Schematic) |
| Electrical System | 775-810 | Electrical Schematic (DX27Z/DX30Z) |
| Attachments | 811-836 | Working Attachments, Bucket |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Standard Metric Fasteners Torque (M5 x Std, Grade 3.6) | 0.15 kg•m (1.08 ft lb) | p. 104 |
| Standard Metric Fasteners Torque (M24 x 2.0, Grade 12.9) | 103.00 kg•m (744.99 ft lb) | p. 104 |
| Track tension adjustment grease injection | 10~15mm | p. 143 |
| Link Pitch Standard | 101.6 mm | p. 144 |
| Link Pitch Limit | 104 mm | p. 144 |
| Bucket end play clearance | 0.2 - 0.7 mm (0.008 - 0.027 in) | p. 835 |
| Main Relief Pressure | 210 kg/cm2 | p. 66 |
| Fuel Tank Capacity | 35 L | p. 66 |
| Hydraulic Tank Capacity | 35 L | p. 66 |
| Swing Speed | 9.7 rpm | p. 66 |
| Operating Weight | 3.18 tons | p. 66 |
| Engine Rated Power | 18.1 kW | p. 66 |
Doosan DX30Z, DX27Z, DX35Z Common Problems This Manual Covers
Doosan DX30Z hydraulics slow and weak, bucket struggles to curl under load
Check hydraulic oil level first; the tank holds 35 L. Change the return filter and pilot filter if service is overdue, then test main relief pressure against the 210 kg/cm2 spec on page 66. If pressure will not reach spec, suspect a stuck relief valve or worn main pump before condemning cylinders.
Manual Section: Hydraulics p. 453Engine won't crank or turns over slowly, dash lights dim when keyed
Check battery terminals and both chassis ground straps; corrosion there is behind most no-start complaints on these machines. Load-test the battery, verify charging output with the engine running, and trace the crank circuit on the wiring diagram, page 809. If it cranks strong but will not fire, drain the prefilter and refill the 35 L tank with clean fuel.
Manual Section: Electrical System p. 809Engine temperature climbs into the red during steady digging on warm days
Clean the radiator and oil cooler fins with compressed air, blowing from the fan side outward. Check coolant level cold; the system only holds 1.8 L, so even a small leak shows up fast. Inspect hose condition and retighten the radiator T-bolt clamps to 0.68 to 0.72 kg•m (59 to 63 in lb), page 108.
Manual Section: Engine and Drive Train p. 208Tracks sag, derail on turns, or clank against the frame when traveling
Adjust track tension by injecting grease at the adjuster valve until sag measures 10 to 15 mm, per page 143. If tension will not hold, measure link pitch; standard is 101.6 mm with a wear limit of 104 mm on page 144. Replace pins and bushings past the limit, then torque sprocket bolts to 11 kg•m.
Manual Section: Lower Structure and Chassis p. 143Bucket knocks and shifts side to side on worn pins during digging
Measure bucket end play with a feeler gauge; spec is 0.2 to 0.7 mm (0.008 to 0.027 in). Shim as needed and torque the shimming bolt to 42 Nm (31 ft lb), both covered on page 835. Grease the pins daily; dry pins wear faster than any shim job can correct.
Manual Section: Attachments p. 835Frequently Asked Questions
How do I adjust the track tension on the Doosan DX30Z?
To adjust the track tension, inject grease into the grease nipple using a grease gun. The correct tension is achieved when the distance between the rolling surface of the track roller and the contact surface of the crawler is 10-15mm. After adjustment, tighten the cartridge valve to a torque of 6-9 kg•m. p. 143
What is the tightening torque for the cartridge valve when adjusting track tension?
The cartridge valve used for track tension adjustment should be tightened to a torque of 6-9 kg•m. p. 143
What is the engine oil capacity for the 3TNV82A engine?
The engine oil capacity for the 3TNV82A engine is 5.8 quarts (5.5 liters) for the upper limit and 3.8 quarts (3.6 liters) for the lower limit. p. 205
What is the tightening torque for the fuel injection pump plunger plug on the 3TNV82A engine?
The tightening torque for the fuel injection pump plunger plug on the 3TNV82A engine is 22-26 ft-lb (30-35 N•m; 3.1-3.6 kgf•m). p. 344
What is the standard valve clearance for the 3TNV82A engine?
The standard intake and exhaust valve clearance for the 3TNV82A engine is 0.006-0.010 inches (0.15-0.25 mm). p. 211
How will I receive this Doosan DX27Z Shop Manual?
All 836 pages arrive as one searchable PDF at checkout. Read it at the desk, then take the phone out to the machine.
Can I print a copy of this Doosan DX27Z Shop Manual for the shop?
Yes. No DRM, nothing blocks printing, so run off the pages you need on whatever printer you have.
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