Part of the Doosan Repair Manuals.
Wrenching on a Doosan DX480LC or DX520LC track excavator? All 866 pages of this shop manual PDF (OEM #K1008703BE) are built to put your machine back to factory spec, swing bearing to travel motor. You get full hydraulic schematics plus a dedicated troubleshooting, testing, and adjustment section covering the main pump, swing motor, travel motor, and main control valve. Inside: complete electrical schematics for both models, teardown procedures for cylinders, track assembly, center joint, and swing reduction gear, and a standard torque reference. Torque the final drive's drilled head bolts to 2,700 kg-cm (195 ft lb), and keep the return line filter at 10 micron. No more bleeding a hydraulic circuit on a guess. Bookmarked with a real text layer: search any spec, pull it up on your phone in the cab, and get back to digging.
What's Inside This Doosan DX480LC, DX520LC Manual
| System | Pages | Key Topics |
|---|---|---|
| Dx480Lc/520Lc | 1-4 | - |
| Safety | 7-50 | Track Excavator Safety |
| Specifications | 51-84 | Specification for DX480/520LC |
| General Maintenance | 85-122 | General Maintenance Procedures, Standard Torques |
| Upper Structure | 123-238 | Cabin, Counterweight, Fuel Tank, Fuel Transfer Pump (Opt), Swing Bearing, Swing Reduction Gear |
| Lower Structure and Chassis | 239-278 | Track Assembly |
| Engine and Drive Train | 279-288 | Drive Coupling (Main Pump) |
| Hydraulic System Troubleshooting, Testing and Adjustment | 291-324 | Safety Precautions, Applicable Models, Hydraulic System - General Notes, Hydraulic Schematic, Operation of Working Components, Boom Operating Circuit |
| Accumulator | 325-396 | Safety Precautions, Applicable Models, General Description |
| Travel Motor (with Gearbox) | 397-460 | Safety Precautions, Applicable Models, General Description, Theory of Operation, Hydraulic Motor Operation, Reduction Gearbox Operation |
| Main Pump | 461-518 | Safety Precautions, Applicable Models, A8VO200LA1KH1/63, General Repair Guidelines, Seal Kits and Sub-Assemblies, Sealing the Drive Shaft |
| Gear Pump (Fan Cooling Drive) | 519-594 | Safety Precautions, Applicable Models, Disassembling Single Gear Pump, Reassembling Single Gear Pump, Disassembling Double Gear Pump(Opt), Reassembling Double Gear Pump(Opt) |
| Remote Control Valve (Work Lever / Joystick) | 595-642 | Safety Precautions, Applicable Models, General Description, Function, Torques, Tools and Materials |
| Fan Motor (Vane Type) | 643-688 | Safety Precautions, Applicable Models, Introduction and Description, General, Description, Applications |
| Breaker EPPR Valve (Opt) | 689-707 | Safety Precautions, Applicable Models, Structure, Numbers and Names of Parts, Functions and Operation, Cautions for Operation |
| Electrical System | 708-836 | Electrical Schematic DX480LC/520LC |
| Attachments | 837-866 | Boom and Arm, Bucket |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Swing Reduction Gearbox Weight | 170 kg (375 lb) | p. 201 |
| bearing temperature | 90° - 100°C (194° - 212°F) | p. 212 |
| Torque for drilled head bolts on end of shaft | 2,700 kg•cm (195 ft lb) | p. 220 |
| Hydraulic reservoir return line and pilot circuit filter rating | 10 micron | p. 299 |
| Reservoir intake strainer rating | 80 mesh, 177 micron | p. 299 |
| Boom overload relief valve pressure setting | 360 kg/cm2 (5,112 psi) | p. 300 |
| Arm overload relief valve pressure setting | 360 kg/cm2 (5,112 psi) | p. 301 |
| Internal sealing PF3/4 engagement torque | 15±1.09 kg m | p. 343 |
| External sealing PT3/8 engagement torque | 4.5 ~ 9.5 kg m | p. 343 |
| Tightening Torque for M5 shaft bolts (Strength Class 12.9) | 10 Nm | p. 421 |
| DX480LC | ||
| Fuel Tank Capacity | 620 liters | p. 70 |
| DX520LC | ||
| Fuel Tank Capacity | 620 liters | p. 72 |
Doosan DX480LC, DX520LC Common Problems This Manual Covers
Doosan DX480LC final drive grinding noise during travel, gearbox oil milky and drive power dropping
Drain the travel motor gearbox and inspect the oil for metal flake or hydraulic fluid intrusion; either one means failed oil seals or worn bearings, not just old oil. Replace the gearbox oil seal and refill to the capacity given in the travel-device section. Do not borrow the figure on page 265 — that one is the TRACK ROLLER fill, 'approximately 450.0 cc (1 pint)' of clean ENGINE oil. Recheck the level after a short test run.
Manual Section: Lower Structure and Chassis p. 265Swing motor grinds and rotation jerks under load, swing speed slower than normal
Check the swing reduction gear oil first: drain it and look for metal particles or a burnt smell. Refill with 3.8 liters of gear oil, the capacity on page 234. Run the swing and feel the housing; bearing temperature above the 90 to 100°C (194 to 212°F) range on page 212 points to bearing replacement, not an oil change.
Manual Section: Upper Structure p. 234All hydraulic functions slow and weak, oil overheating after an hour of digging
Test pilot pressure at the pump; spec is 40 ±5 bar (580 ±73 psi) on page 308. If pilot checks good, gauge the main relief: low stage should hold 320 to 325 bar per page 310. Low readings across every circuit point to a worn pump or stuck relief valve. Replace the 10 micron return filter while the system is open.
Manual Section: Hydraulic System Troubleshooting p. 308Center joint weeps hydraulic oil around the swivel, travel circuit pressure dropping intermittently
Pull the center joint and replace every O-ring and seal; external leakage usually means contamination has scored the sliding surfaces, so inspect the spool bore closely. On reassembly, tighten the spacer bolts to 5 to 6 kg m per page 344 and torque the M12 cover bolts to 10 to 12.5 kg m, page 345. Badly scored surfaces call for overhaul or replacement.
Manual Section: Hydraulics p. 344Frequently Asked Questions
What does error code E12 mean on a Doosan DX480LC/DX520LC?
Error code E12 indicates a position error of the wind direction actuator in the air conditioning system. This error means the actuator failed to move to the designated position within 40 seconds. p. 808
What is the tightening torque for the main relief valve cap on the main control valve?
The tightening torque for the main relief valve cap (width across flats 41) is 9.48 - 11.01 kg•m (69 - 80 ft lb). p. 591
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. 165
What is the correct tightening torque for the counterweight mounting bolts on the DX480LC and DX520LC?
The mounting bolts for the counterweight on both the DX480LC and DX520LC should be tightened to 250 kg•m (1,807 ft lb). p. 145
What is the recommended engine oil capacity for filling the travel motor gearbox?
The travel motor gearbox should be filled with approximately 450.0 cc (1 pint) of clean engine oil. p. 265
What format is this Doosan DX480LC manual in?
Immediate download of the complete 866-page searchable Shop Manual. Access it on any device, from a laptop at your desk to a phone in the field.
Can I print just the pages I need from this Doosan DX480LC manual?
Absolutely. No DRM or copy protection. Print the whole manual or just the pages you need. Any home or office printer works.
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