Part of the Doosan Repair Manuals.
Wrenching on a Doosan DX480LCA or DX500LCA hydraulic excavator? This 758-page Doosan DX480LCA, DX500LCA shop manual PDF (OEM #950106-00411E) covers both machines from swing bearing to track assembly. You get complete electrical schematics for the starting, charging, and monitoring circuits, full hydraulic schematics, and a dedicated troubleshooting, testing, and adjustment section covering pilot pressure and pump regulator setup. Teardown and reassembly procedures walk through the main pump, main control valve, swing device, travel motor, center joint, and every cylinder on the boom, arm, and bucket. Set the dash-size 8 ORFS swivel nuts at 5.1 to 5.7 kg-m, and confirm the 10 micron return line filter before you fire it back up. A dead travel motor doesn't care about your schedule. Bookmarked with a full text layer; search any spec, pull it up on your phone, and get back to digging.
What's Inside This Doosan DX480LCA, DX500LCA Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 5-48 | Track Excavator Safety |
| Specifications | 49-82 | Specification for DX480LCA / DX500LCA |
| Upper Structure | 83-178 | Cabin, Counterweight, Fuel Tank, Fuel Transfer Pump, Swing Bearing |
| Lower Structure and Chassis | 179-212 | Track Assembly |
| Engine and Drive Train | 213-222 | Drive Coupling |
| Hydraulic System Troubleshooting, Testing and Adjustment | 223-304 | Troubleshooting, Pilot Pressure, Power Mode Valve, Pressure Up Valve, Pump Regulator |
| Accumulator | 305-312 | Gas-Charged Storage, Precharge Pressure, Diaphragm, Valve Assembly |
| Center Joint (Swivel) | 313-332 | Hydraulic Oil Flow, Disassembly, Inspection, Reassembly, Slipper Seals |
| Cylinders | 333-346 | Arm Cylinder, Boom Cylinder, Bucket Cylinder, Disassembly, Reassembly |
| Swing Device | 347-402 | Hydraulic Motor, Reduction Gear, Brake Part, Disassembly, Reassembly |
| Travel Device | 403-460 | Travel Motor, Reduction Gear, Brake Valve, Disassembly, Reassembly |
| Main Control Valve | 461-518 | Main Spool, Anti Drift Valve, Relief Valve, Load Check Valve, Reassembly |
| Remote Control Valve (Work Lever / Joystick) and Breaker EPPR Valve | 519-604 | Joystick, Pressure Reducing Valve, Breaker EPPR Valve, Solenoid Valve, Troubleshooting |
| Electrical System | 605-728 | Electrical Supply System, Engine Starting Circuit, Charging System, Monitoring System, Engine Control System, Air Conditioner System |
| Attachments | 729-758 | Boom and Arm, Bucket |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Orfs Swivel Nut Recommended Torque (Dash Size 4) | 2.4 - 2.6 kg•m | p. 114 |
| Orfs Swivel Nut Recommended Torque (Dash Size 6) | 3.3 - 3.9 kg•m | p. 114 |
| Weight of Counterweight | 8,500 kg (18,740 lb) | p. 140 |
| Weight of Counterweight (Optional) | 9,000 kg (19,840 lb) | p. 140 |
| Hydraulic reservoir return line filter rating | 10 micron | p. 233 |
| Pilot circuit filter rating | 10 micron | p. 233 |
| Main Relief Pressure (Normal) | 320 kg/cm2 | p. 76 |
| Main Relief Pressure (Pressure Up) | 350 kg/cm2 | p. 76 |
| Fuel Tank Capacity | 620 liters | p. 68 |
| Hydraulic Reservoir Capacity | 265 liters | p. 68 |
| Engine Power (DIN 6270) | 323 ps | p. 73 |
| Max Torque | 139 kg•m | p. 73 |
Doosan DX480LCA, DX500LCA Common Problems This Manual Covers
Doosan DX480LCA hydraulic oil overheats and machine loses power under load after long digging cycles
Check hydraulic oil level and condition first; the reservoir holds 265 liters and low or milky oil causes cavitation and heat. Replace the 10 micron return line filter if clogged, then test main relief pressure against the 320 kg/cm2 normal setting using the procedure starting on page 223.
Manual Section: Hydraulic System Troubleshooting, Testing and Adjustment p. 223Swing is slow and jerky with grinding noise from the swing motor area
Drain a sample of case drain oil from the swing motor and check for metal particles. Inspect the reduction gear oil level and condition. Follow the swing device troubleshooting on page 347 for slow rotation and brake torque checks; confirm system pressure reaches the 320 kg/cm2 main relief setting before condemning the motor.
Manual Section: Swing Device p. 347Hydraulic oil leaking at hose fittings and split flange connections on the pump lines
Clean the fitting and retorque before replacing anything. Tighten ORFS swivel nuts to spec for their dash size, 5.1 to 5.7 kg•m for dash 8, using the chart on page 114. Torque split flange bolts evenly in a cross pattern, 3.7 to 4.8 kg•m for 1 inch flanges (page 115). Replace any hose with a cracked cover or wet braid.
Manual Section: Upper Structure p. 114Boom or arm cylinder weeping oil past the rod seal and drifting down overnight
Wipe the rod dry and cycle the boom; a fresh oil ring means the U-packing is done. Check for rod scoring before ordering seals. If the cylinder drifts with clean rods, test the boom overload relief valve at its 360 kg/cm2 (5,112 psi) setting (page 234), then reseal the cylinder following the disassembly procedure on page 333.
Manual Section: Cylinders p. 333Machine pulls to one side when traveling and one final drive runs hot
Check reduction gear oil in the slow-side final drive first; a hot case plus low oil means bearing damage. Swap travel lines at the center joint to isolate the motor from the control valve, then work through the sideways travel diagnostics on page 403. Replace the 10 micron return filter (page 233) after any motor failure to catch debris.
Manual Section: Travel Device p. 403Frequently Asked Questions
How do I reset the failure log on the Doosan DX480LCA / DX500LCA?
To delete the memorized record of past failures, navigate to the 'Delete Fail Log' screen in the special menu. Press the Enter button (3 on Figure 23) when 'YES' is selected. The deletion signal will be displayed, and the screen will return to the previous menu after 3 seconds. p. 646
What is the fuel tank capacity for the DX480LCA and DX500LCA?
The fuel tank capacity for both the DX480LCA and DX500LCA models is 620 liters (164 U.S. gal). p. 68
What is the tightening torque for the counterweight mounting bolts on the DX480LCA and DX500LCA?
The mounting bolts for the counterweight on the DX480LCA and DX500LCA must be torqued to 250 kg•m (1,807 ft lb). p. 143
What is the standard tightening torque for the M20 x 1.5 metric fastener, grade 10.9?
The standard tightening torque for an M20 x 1.5 metric fastener, grade 10.9, is 22.5 kg•m (162.74 ft lb). p. 110
What is the procedure for priming the fuel system if the engine does not start?
If the engine does not start, loosen the plug on top of the fuel filter head. Pump the hand-operated primer pump located by the fuel injection pump until fuel is present at the plug hole, then tighten the plug and continue pumping until strong resistance is felt. p. 159
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