Part of the Doosan Repair Manuals.
This is the factory shop manual Doosan issued for the DX480LC and DX520LC crawler excavators, publication K1008703CE, 2010 edition, covering the DV11-powered K-series machines. Inside you get cab removal and installation for both NON-ROPS and ROPS versions, track assembly wear limits and tension procedure, main pump drive coupling install, and full teardown coverage of the hydraulics: main pump (A8VO200), main control valve, swing motor, travel motor with gearbox, center joint, all three cylinder types, fan drive gear pump, vane fan motor, joystick remote control valves, and the solenoid valve block. The complete hydraulic schematic sits on page 729, and separate NON-ROPS and ROPS electrical schematics are printed at pages 970 and 977. Testing and adjustment specs included.
Other editions of this manual
What's Inside This Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 7-52 | Track Excavator Safety, Safety Precautions, To the Operator of a DOOSAN Excavator, Learn Signal Words Used with Safety Alert Symbol, General Safety Essentials, Accessory Applications |
| Specifications | 53-88 | Specification for DX480LC/520LC, Safety Precautions, General Description, Component Locations, General Dimensions (DX480LC), General Dimensions (DX520LC) |
| General Maintenance | 89-126 | General Maintenance Procedures, Safety Precautions, Welding Precautions and Guidelines, Hydraulic System - General Precautions, Maintenance Service and Repair Procedure, General Precautions |
| Upper Structure | 127-258 | Cabin (Non-ROPS), Safety Precautions, Cab Identification, Removal, Installation, Cabin (ROPS) |
| Lower Structure and Chassis | 259-298 | Track Assembly, Safety Precautions, General Description, Track Tension, Cleaning and Inspection (Wear Limits and Tolerances), Track Shoe |
| Engine and Drive Train | 299-308 | Drive Coupling (Main Pump), Safety Precautions, Drive Coupling, Installation of Drive Coupling, Installation Procedure |
| Hydraulics - Hydraulic System Troubleshooting, Testing and Adjustment | 309-344 | Hydraulic System Troubleshooting, Testing and Adjustment, Safety Precautions, Hydraulic System - General Notes, Hydraulic Schematic, General Notes, Operation of Working Components |
| Hydraulics - Accumulator to Cylinders | 345-382 | Accumulator, Safety Precautions, General Description, Specifications, Center Joint (Swivel), Center Joint Disassembly Diagram |
| Hydraulics - Swing Motor | 383-418 | Swing Motor, Safety Precautions, Operation Manual, Information on Marking, Specifications, Structure and Operational Principles |
| Hydraulics - Travel Motor (with Gearbox) | 419-482 | Travel Motor (with Gearbox), Safety Precautions, General Description, Theory of Operation, Hydraulic Motor Operation, Reduction Gearbox Operation |
| Hydraulics - Main Pump | 483-540 | Main Pump, Safety Precautions, Ectional View, A8VO200LA1KH1/63, General Repair Guidelines, Seal Kits and Sub- Assemblies |
| Hydraulics - Gear Pump (Fan Cooling Drive) | 541-558 | Gear Pump (Fan Cooling Drive), Safety Precautions, Disassembling Single Gear Pump, Reassembling Single Gear Pump, Disassembling Double Gear Pump(Opt), Reassembling Double Gear Pump(Opt) |
| Hydraulics - Main Control Valve | 559-616 | Main Control Valve, Safety Precautions, General Description, When All Spools Are in Neutral, Single Operation, Combined Operation |
| Hydraulics - Remote Control Valve (Work Lever / Joystick) | 617-638 | Remote Control Valve (Work Lever / Joystick), Safety Precautions, General Description, Structure, Function, Parts List |
| Hydraulics - Travel Control Valve (with Damper) | 639-664 | Travel Control Valve (with Damper), Safety Precautions, General Description, Theory of Operation, Pressure Reducing Valve, Operating Theory of Damper Mechanism |
| Hydraulics - Fan Motor (Vane Type) | 665-686 | Fan Motor (Vane Type), Safety Precautions, Parts List, Introduction and Description, Description, Applications |
| Hydraulics - Fan Cooling Flow In-Out Change Valve and Solenoid Valve Assembly | 687-710 | Fan Cooling Flow In-Out Change Valve, Safety Precautions, Cooling Fan a Change of Direction Valve, Solenoid Valve Assembly, 5-Solenoid Valve, Parts List |
| Hydraulics - Breaker EPPR Valve (Opt) and Hydraulic Schematic DX480LC/520LC | 711-729 | Breaker EPPR Valve (Opt), Safety Precautions, Structure, Numbers and Names of Parts, Functions and Operation, Cautions for Operation |
| Electrical System - Electrical System (Non-ROPS) | 730-847 | Electrical System (Non-ROPS), Safety Precautions, Electrical Supply System, Engine Starting Circuit, Start Operation, After Start |
| Electrical System - Electrical System (ROPS) | 848-963 | Electrical System (ROPS), Safety Precautions, Electrical Supply System, Engine Starting Circuit, Start Operation, After Start |
| Electrical System - Electrical Schematic (Non-ROPS) and Electrical Schematic (ROPS) | 964-977 | Electrical Schematic (Non-ROPS), Safety Precautions, DX300LL/DX300/340/350/380/420/480/520LC, Electrical Schematic (ROPS) |
| Attachments | 978-1007 | Boom and Arm, Safety Precautions, Front Attachment Pin Specifications, DX300LC, DX340LC / DX350LC, DX420LC |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine model | DV11, performance rated to DIN 6270 | p. 77 |
| Alternator | 24V x 50A | p. 77 |
| Main relief pressure | 320 kg/cm² (4,641 psi); 350 kg/cm² (4,970 psi) with Pressure Up | p. 80 |
| Shipping weight, DX480LC | 47,000 kg (103,617 lb) | p. 72 |
| Shipping weight, DX520LC | 47,110 kg (103,860 lb) | p. 74 |
| Bucket digging force | 267 kN or 27,200 kg (60,000 lb) | p. 72 |
| Arm digging force | 216 kN or 22,000 kg (48,500 lb) with 3,350 mm (11' 0") arm | p. 72 |
| Fuel tank capacity | 620 liters (164 U.S. gal) | p. 72 |
| Hydraulic system capacity | 500 liters (132 U.S. gal) | p. 72 |
| Hydraulic reservoir capacity | 265 liters (70 U.S. gal) | p. 72 |
| Counterweight | 8,500 kg (18,700 lb) | p. 72 |
| Upper turntable weight | 9,915 kg (21,900 lb) | p. 72 |
| Lower structure weight, below swing bearing | 18,800 kg (41,400 lb) | p. 72 |
| Standard boom weight | 3,490 kg (7,700 lb) | p. 72 |
| Arm weight, 3,350 mm | 1,620 kg (3,570 lb) | p. 72 |
| Ground pressure, 600 mm (23.6") shoe | 0.81 kg/cm² (11.5 psi) | p. 72 |
| Ground pressure, 750 mm (29.5") shoe | 0.67 kg/cm² (9.5 psi) | p. 72 |
| Optional shoe weight penalty | add 700 kg (1,540 lb) for 750 mm; 1,500 kg (3,310 lb) for 900 mm | p. 72 |
| Main control valve subspool plug torque | 9.48 - 11.01 kg·m (69 - 80 ft lb) | p. 613 |
| Main control valve cap bolt torque | 10.50 - 11.52 kg·m (76 - 83 ft lb) | p. 613 |
