Part of the Doosan Repair Manuals.
Wrenching on a Doosan DX420LC, DX480LC, or DX520LC hydraulic excavator? This 878-page shop manual PDF (OEM #K1008703E) takes you from swing bearing to Rexroth main pump to track assembly. Inside: complete electrical schematics for chasing e-EPOS and charging faults, hydraulic schematics with full circuit routing, and a dedicated hydraulic troubleshooting, testing, and adjustment section. You also get teardown and rebuild procedures for cylinders, swing motor, travel motor, and the Kayaba KVMG-400-DA control valve, plus standard torque tables for metric and U.S. fasteners. Set main relief pressure to 320 kg/cm2 on the DX480LC, and check swing reduction output torque against the factory figure of 1,141 kg-m (8,250 ft lb). No more chasing wiring faults with a multimeter and a prayer. Bookmarked chapters and a real text layer mean you type the spec, find the page, and get back on the sticks.
What's Inside This Doosan DX480LC, DX520LC, DX420LC Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety and General Information | 1-52 | Safety Precautions, Applicable Models, General Hazard Information, Maintenance Safety, Battery Safety, Towing, Shipping and Transportation |
| Specifications and General Maintenance | 53-106 | DX480LC/520LC Specifications, General Maintenance Procedures, Standard Torques, Bearing Inspection |
| Upper Structure | 107-216 | Cabin, Counterweight, Fuel Tank, Swing Bearing, Swing Reduction Gear |
| Lower Structure and Chassis | 217-296 | Track Assembly, Air Conditioner |
| Engine and Drive Train | 297-346 | Drive Coupling (Main Pump), Hydraulics, Hydraulic System Troubleshooting, Testing and Adjustment |
| Accumulator | 347-418 | Safety Precautions, Applicable Models, General Description |
| Travel Motor (with Gearbox) (A6V160HD) SP000185 | 419-482 | - |
| Main Pump (Rexroth) | 483-538 | Safety Precautions, Applicable Models, A8VO200LA1KH1/63, General Repair Guidelines, Seal Kits and Sub-Assemblies, Sealing the Drive Shaft |
| Control Valve (Kayaba Model Kvmg-400-Da) | 539-596 | Safety Precautions, Applicable Models, General Description, When All Spools Are in Neutral, Single Operation, Combined Operation |
| Remote Control Valve (Work Lever / Joystick) | 597-644 | Safety Precautions, Applicable Models, General Description, Function, Torques, Tools and Materials |
| Solenoid Valve Assembly | 645-692 | Safety Precautions, Applicable Models, Package, Functions of Solenoid Valve Assembly Package, Assembly Diagram and Tools Required, Solenoid Valve Diagram |
| Gear Pump (Fan Cooling Drive) | 693-726 | Safety Precautions, Applicable Models, Disassembling Single Gear Pump, Reassembling Single Gear Pump, Disassembling Double Gear Pump(Opt), Reassembling Double Gear Pump(Opt) |
| Electrical System | 727-854 | Electrical System Overview, Electrical Schematics, Monitoring System, e-EPOS Controller, Power Mode Control, Engine Control System |
| Attachments | 855-878 | Boom and Arm, Bucket, Bucket Tooth Inspection, Bucket O-Ring Replacement |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Maximum Output Speed | 67 rpm | p. 179 |
| Maximum Output Torque | 1,141 kg•m (8,250 ft lb) | p. 179 |
| Rated Torque | 81.5 kg•m | p. 443 |
| Max Rotation Rate | 3680 rpm | p. 443 |
| Engine Power (DV11) | 333 ps | p. 75 |
| Accumulator Charge Pressure | 10 kg/cm2 | p. 354 |
| DX480LC | ||
| Main Relief Pressure (Normal) | 320 kg/cm2 | p. 78 |
| Main Relief Pressure (Pressure Up) | 350 kg/cm2 | p. 78 |
| Fuel Tank Capacity | 620 liters | p. 70 |
| Hydraulic Reservoir Capacity | 265 liters | p. 70 |
| Counterweight Weight | 8,500 kg | p. 140 |
| DX520LC | ||
| Counterweight Weight | 11,100 kg | p. 140 |
Doosan DX480LC, DX520LC, DX420LC Common Problems This Manual Covers
Doosan DX480LC hydraulic power fades and oil overheat warning comes on once machine warms up
Check the hydraulic return filter first; a clogged element triggers the overheat warning and starves the pump. Replace it, then test main relief pressure against the DX480LC spec of 320 kg/cm2 normal and 350 kg/cm2 in pressure up mode, listed on page 78. Pressure that falls off when hot points to internal pump leakage.
Manual Section: Hydraulic System Troubleshooting, Testing and Adjustment p. 78Pump whines or growls at the tank, jerky boom and arm response after oil change
Verify hydraulic oil level with the machine on level ground; low oil pulls air into the suction line and cavitates the pump. Bleed air from the system, tighten suction line clamps, and check accumulator charge pressure, which should hold 10 kg/cm2 per page 354. Growling that persists after bleeding means pump internals need inspection.
Manual Section: Hydraulic System Troubleshooting, Testing and Adjustment p. 354Machine crawls or pulls to one side, travel motor case runs hot and noisy
Measure travel motor parking brake releasing pressure; the brake needs 12.5 kg/cm2 to release fully, and anything lower drags the motor and cooks the case, spec listed on page 443. Check gear oil level in the final drive, then inspect the drain line for restriction. Metal in the drained oil means internal wear, pull the motor.
Manual Section: Engine, Drive Train, and Hydraulics p. 443Swing reduction gear howls under load, case hot to touch, oil weeping from base
Drain the swing reduction gear and inspect the oil for metal flake. Refill with 3.8 liters of gear oil, the capacity listed on page 213, and check the case seals for leakage; running low from a slow leak is the usual cause of howling and heat. If noise continues with fresh oil, pull the unit and inspect gears and bearings.
Manual Section: Swing Reduction Gear Troubleshooting p. 213Frequently Asked Questions
What does error code E11 mean on a Doosan DX480LC/DX520LC?
Error code E11 indicates that the D.P.S (Differential Pressure Sensor) is in an open circuit state. This code is identified in the self-diagnosis section of the electrical system manual. p. 832
How do I enter the service menu on a Doosan DX480LC/DX520LC?
To enter the special menu, ensure the normal mode screen is displayed. Press the Enter button (3) and the Escape button (ESC, 4) simultaneously for more than 3 seconds to change the screen to the special menu. p. 766
What is the tightening torque for the main relief valve cap on the control valve?
The tightening torque for the main relief valve cap (8) is 9.48 - 11.01 kg•m (69 - 80 ft lb). p. 593
What is the fuel tank capacity for the DX480LC and DX520LC?
The fuel tank capacity for both the DX480LC and DX520LC models is 620 liters (164 U.S. gal). p. 151
What is the recommended tightening torque for the counterweight mounting bolts?
The recommended tightening torque for the counterweight mounting bolts on the DX480LC and DX520LC is 250 kg•m (1,807 ft lb). p. 144
What format is this Doosan DX420LC manual in?
This is a 878-page searchable PDF ready for immediate download. Works on any device, so pull it up on your phone while you're under the hood. No shipping, no waiting.
Can I print a copy of this Doosan DX420LC Shop Manual for the shop?
Yes. The PDF is DRM-free, so printing works from any reader and any printer.
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