Part of the Doosan Repair Manuals.
This is the factory shop manual for the Doosan DX490LC-3 and DX530LC-3 crawler excavators, 2012 edition (publication 950106-00259E, printed May 2012). It covers the whole machine: the Isuzu 6WG1 common-rail diesel with full disassembly, DTC diagnostics and wiring, the A8VO200 main pump, main control valve, swing and travel devices, cylinders, undercarriage, cab and counterweight removal, plus attachments. The complete ISO hydraulic schematic (SP002570) and full machine electrical schematic (SP002572) are bound in, so you are not chasing a separate schematic book for most work. Specs are real numbers: 394.28 ps at 1,800 rpm, 330 kg/cm2 main relief (350 with Pressure Up), 500 liter hydraulic system. If you keep one of these 49 to 52 ton machines digging, this is the book the dealer techs use.
What's Inside This Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 5-72 | Maintenance Safety, Fire and Explosion Prevention, Personal Protective Equipment, Emergency Procedures |
| Specifications | 73-104 | Model Identification, Serial Number Ranges, Operating Dimensions, ROPS Certification |
| General Maintenance | 105-142 | Maintenance Instructions, Standard Torques, Cleaning Procedures, Long-Term Storage |
| Upper Structure | 143-204 | Cabin, Counterweight, Fuel Tank, Swing Bearing |
| Lower Structure and Chassis | 205-238 | Track Assembly, Undercarriage Maintenance |
| Engine - Service Information and Maintenance | 239-341 | Engine Service Information Guide, Maintenance Information, Plastic Gauge Use, Special Tools, Abbreviations |
| Engine - Functional Inspection, Symptom and DTC Diagnostics | 342-452 | Functional Inspection, Engine Compression Pressure Inspection, Fuel System Check, Air Intake System Check, Exhaust System Check, DPD Control System Check |
| Engine - Engine Control System | 453-598 | Engine Control, DTC P-Code Diagnostics with Flash Codes, ECM Programming, Sensor and Injector Circuit Tests |
| Engine - Mechanical Disassembly and Assembly | 599-1032 | Mechanical, Cylinder Head Cover, Cylinder Head Assembly, Idle Gear, Cylinder Block, Crankshaft |
| Engine - Fuel, Cooling and Lubrication Systems | 1033-1180 | Fuel System, Fuel Supply Pump, Injector, Fuel Filter, Pressure Limiter, Fuel Pressure Sensor |
| Engine - Induction, Exhaust and Emission Control | 1181-1235 | Induction, Boost Temperature Sensor, Turbocharger Assembly, Intercooler, Air Cleaner Filter, IMT Sensor |
| Engine - Electrical and Wiring Diagram | 1236-1304 | Electrical, Glow Plug, Starter Assembly, Supplementary Information, Wiring Diagram, Using the Wiring Diagram |
| Engine Coolant Heater and Drive Coupling | 1305-1330 | Engine Coolant Heater (Option), Disassembly and Assembly, Changing the Circulating Pump, Changing the Temperature Limiter, Changing the Temperature Sensor, Changing the Combustion Air Fan |
| Hydraulic System Troubleshooting, Testing and Adjustment | 1331-1390 | Hydraulic System Troubleshooting, Testing and Adjustment, Hydraulic System - General Notes, Hydraulic Schematic, General Notes, Operation of Working Components, Boom Operating Circuit |
| Cylinders, Swing Device and Travel Device | 1391-1532 | Cylinders, General Description, Theory of Operation, Parts List, Special Tools and Materials, Piston Nut |
| Main Pump and Gear Pump | 1533-1600 | Main Pump A8VO200LA1KH1/63, Sectional View, Seal Kits, Driveshaft and Control Housing Service, Gear Pump |
| Main Control Valve | 1601-1658 | General Description, When All Spools Are in Neutral, Single Operation, Combined Operation, Antidrift Valve |
| Fan Motors and Fan Pump | 1659-1718 | Fan Motor for Oil Cooler, Disassembly, Assembly, Preassemble, Assembling, Fan Motor for Radiator |
| Remote, Travel, Solenoid and Breaker EPPR Valves | 1719-1792 | Remote Control Valve (Work Lever / Joystick), General Description, Theory of Operation, Parts List, Specifications, Torques |
| Hydraulic Schematic | 1793-1802 | DX490LC-3/DX530LC-3 |
| Electrical System | 1803-1956 | Electrical Schematic, Battery Maintenance, Boost Starting, Electrical Shock Prevention |
| Electrical Schematic | 1957-1966 | DX420LC-3/DX490LC-3/DX530LC-3 |
| Attachments | 1967-1992 | Boom and Arm, Bucket, Work Tool Compatibility |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine model | Isuzu 6WG1, diesel 4-cycle water-cooled inline 6-cylinder OHC | p. 269 |
| Engine power (rated) | 394.28 ps (389 hp) @ 1,800 rpm | p. 95 |
| Engine maximum torque | 197.82 kg·m (1,430 ft lb) @ 1,350 rpm | p. 95 |
| Main relief pressure | 330 kg/cm² (4,693 psi); 350 kg/cm² (4,978 psi) with Pressure Up | p. 98 |
| Pilot pressure that opens the control spools | 7 - 9 kg/cm² (100 - 130 psi) | p. 1343 |
| Hydraulic system capacity | 500 liters (132 U.S. gal) | p. 90 |
| Hydraulic reservoir capacity | 265 liters (70 U.S. gal) | p. 90 |
| Shipping weight, DX490LC-3 | 49,000 kg (108,027 lb) | p. 90 |
| Shipping weight, DX530LC-3 | 51,800 kg (114,200 lb) | p. 92 |
| Bucket digging force, DX490LC-3 | 302 kN or 30,800 kg (68,000 lb) | p. 90 |
| Arm digging force, DX490LC-3 | 223 kN or 22,700 kg (50,050 lb) | p. 90 |
| Bucket digging force, DX530LC-3 | 295 kN or 30,063 kg (66,280 lb) | p. 92 |
| Arm digging force, DX530LC-3 | 253 kN or 25,789 kg (56,855 lb) | p. 92 |
| Ground pressure on 600 mm (24") shoe | 0.85 kg/cm² (12.0 psi) DX490LC-3; 0.89 kg/cm² (12.7 psi) DX530LC-3 | p. 90 |
| Track shoe widths | 600 mm (24") standard; 750 mm (30"), 800 mm (32"), 900 mm (36") optional | p. 90 |
| Track tension, recommended distance "A" | 380 - 410 mm (14.96 - 16.14 in) normal ground; 410 - 460 mm (16.14 - 18.11 in) muddy, sandy or snowy | p. 214 |
| Track adjuster grease valve | never loosen more than one full turn from fully tightened; 27 mm socket | p. 214 |
| Main pump | Rexroth A8VO200LA1KH1/63 | p. 1538 |
| Alternator | 24V x 80A | p. 95 |
| Counterweight | 8,500 kg (18,700 lb) or 9,200 kg (20,283 lb) | p. 90 |
