Part of the Doosan Repair Manuals.
This is the factory shop manual Doosan printed in May 2014 (publication 950106-01005E) for the DX490LC-5 and DX530LC-5 crawler excavators, the Tier 4 Final machines running the Scania-built Doosan DC 13 rated 283 kW (380 HP) at 1,800 rpm. It covers the engine down to crankshaft, liners and the SCR/reductant plumbing, then the whole hydraulic side: main pump, main control valve, swing device, fan pump, joysticks and EPPR valves, with theory of operation and parts lists for each. Undercarriage, swing bearing, track assembly, boom/arm/bucket removal, electrical troubleshooting with the E-code table, and full foldout hydraulic (page 1579) and electrical (page 1580) schematics round it out. 1,580 pages of what the dealer techs actually use.
What's Inside This Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 7-74 | Track Excavator Maintenance Safety, Safety Messages, Safe Operation Is Operator's Responsibility, Know Your Machine, Proper Work Tools and Attachments, Pressurized Fluids |
| Specifications | 75-112 | General Description, Component Locations, General Dimensions, Variable Track |
| General Maintenance and Standard Torques | 113-150 | General Maintenance Instructions, Welding Precautions and Instructions, Hydraulic System - General Precautions, Maintenance Service and Repair Procedure, General Precautions, Hydraulic System Cleanliness and Oil Leaks |
| Engine - Identification, Specifications and Tightening Torques | 151-206 | Engine, Overview, Inspection, Cleaning the Engine, Special Tools, Mounting the Engine in a Universal Stand |
| Engine - Cylinder Head and Block | 207-261 | Cylinder, Cylinder Head, Valve Mechanism, Cylinder Block, Cylinder Liner, Flywheel Housing |
| Engine - Actuating and Lubrication Systems | 262-331 | Actuating System, Camshaft, Connecting Rod, Crankshaft, Flywheel, Piston |
| Engine - Exhaust and Cooling Systems | 332-436 | Exhaust System, General Information, T113, Exhaust Temperature Sensor Before Catalytic Converter, T115, NOx Sensor, T131 NOx Sensor, T116, Reductant Pick-Up Unit |
| Engine - Fuel System | 437-485 | Fuel System, General Information, Accumulator, Fuel Manifold, Overflow Valve, Feed Pump |
| Engine - Electrical System | 486-554 | Electrical System, E44, Control Unit EMS, Control Unit EEC, Engine Speed Sensor, T110 Oil Level Sensor, T111, Fuel Pressure Sensor |
| Engine Coolant Heater | 555-570 | Engine Coolant Heater (Option), Disassembly and Assembly, Changing the Circulating Pump, Changing the Temperature Limiter, Changing the Temperature Sensor, Changing the Combustion Air Fan |
| Upper Structure - Cabin, Counterweight and Tanks | 571-638 | Cabin, Cabin Identification, Roll-Over Protective Structure (ROPS), Removal, Installation, Dimensions of Cabin Glass |
| Main Pump and Drive Coupling | 639-736 | Main Pump, Specifications, Overview, Hydraulic Circuit, Parts List, Theory of Operation |
| Main Control Valve | 737-824 | Specification, Overview, Hydraulic Circuit, Parts List, Theory of Operation |
| Swing Device | 825-882 | Specification, Overview, Hydraulics Circuit, Parts List, Theory of Operation |
| Fan Pump, Fan Motor and Gear Pump | 883-948 | Fan Pump for Oil Cooler, Specification, Overview, Parts List, Theory of Operation, Maintenance Guidelines |
| Joystick, Travel Control, Solenoid and EPPR Valves | 949-1026 | Joystick Valve (Work Lever), Specifications, Overview, Parts List, Theory of Operation, Tools and Torques |
| Accumulator | 1027-1034 | Specifications |
| Lower Structure - Swing Bearing, Center Joint, Travel Device | 1035-1136 | Swing Bearing, General Description, Parts List, Maintenance Guidelines, Disassembly, Reassembly |
| Track Assembly | 1137-1170 | Track Tension, Track Shoes and Links, Parts List, Track Removal, Track Installation |
| Front - Boom, Arm, Bucket and Cylinders | 1171-1228 | Boom and Arm, Specifications, Removal, Arm Removal, Boom Removal, Installation |
| Hydraulic System - Operation, Testing, Adjustment and Troubleshooting | 1229-1318 | Hydraulic System, General Description, Hydraulic Schematic, Hydraulic Component and Oil Flow, Hydraulic Component, Main Circuit |
| Electrical System and Troubleshooting | 1319-1490 | Electrical System, Electrical Supply System, Engine Starting Circuit, Start Operation, After Start, Engine Stop |
| Options - One Way, Two Way, Rotating and Quick Coupler | 1491-1574 | One Way, General Description, Theory of Operation, Hydraulic Circuit, Caution for Installation, Installation Procedure |
| Hydraulic and Electrical Schematics | 1575-1580 | Hydraulic Schematic / Electrical Schematic |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine model | Doosan DC 13 (Scania), 4-cycle water cooled, turbocharged | p. 173 |
| Emission level | US EPA Tier 4 Final (EU Stage IV) | p. 173 |
| Rated net power | 283 kW (380 HP) @ 1,800 rpm (SAE J1995) | p. 173 |
| Shipping weight, DX490LC-5 | 48,915 kg (107,839 lb) variable track wide; 47,655 kg (105,061 lb) fixed track | p. 94 |
| Shipping weight, DX530LC-5 | 51,484 kg (113,503 lb) variable track wide | p. 96 |
| Bucket digging force | 302 kN or 30,800 kg (68,000 lb), standard front with GP bucket | p. 94 |
| Arm digging force | 223 kN or 22,700 kg (50,050 lb) with 3,350 mm (11' 0") arm | p. 94 |
| Fuel tank capacity | 685 L (181 U.S. gal) | p. 94 |
| Hydraulic system capacity | 500 L (132 U.S. gal) | p. 94 |
| Hydraulic reservoir capacity | 392 L (103.5 U.S. gal) | p. 94 |
| Counterweight | 8,500 kg (18,700 lb) or 9,200 kg (20,283 lb) | p. 94 |
| Upper turntable weight | 10,930 kg (24,097 lb) | p. 94 |
| Lower structure weight, below swing bearing | 19,335 kg (42,626 lb) | p. 94 |
| Tail swing radius | 3,800 mm (12' 6") | p. 86 |
| Undercarriage width, variable track | 3,900 mm (12' 10") extended, 3,340 mm (10' 11") retracted | p. 86 |
| Bucket heaped capacity range | SAE 1.71 ~ 3.6 m³ (2.24 ~ 4.71 yd³) | p. 94 |
| Track tension, recommended distance "A" | 380 - 410 mm (14.96 - 16.14 in) normal; 410 - 460 mm (16.14 - 18.11 in) muddy, sandy or snowy | p. 1143 |
| Flywheel screw torque | M18 flange screw: 180 Nm + 120° | p. 186 |
| Cylinder head screw torque | Torx screw: 50 Nm + 90°, check torque 170 Nm (screws reusable 3 times) | p. 183 |
| Boom and arm weights | 7,100 mm boom 3,845 kg (8,477 lb); 3,350 mm arm 1,760 kg (3,880 lb) | p. 94 |
