Doosan DX480LCA and DX500LCA Excavator Service Manual

Table of Contents

Safety
Track Excavator Safety………………………………………………………………. SP002025
Specifications
Specification for DX480LCA / DX500LCA …………………………………….. SP002887
General Maintenance
General Maintenance Instructions……………………………………………….. SP002454
Standard Torques……………………………………………………………………… SP002404
Upper Structure
Cabin ………………………………………………………………………………………. SP002904
Counterweight…………………………………………………………………………… SP002902
Fuel Tank…………………………………………………………………………………. SP002905
Fuel Transfer Pump (Opt)…………………………………………………………… SP000021
Swing Bearing…………………………………………………………………………… SP001856
Lower Structure and Chassis
Track Assembly ………………………………………………………………………… SP002561
Engine and Drive Train
Drive Coupling (Main Pump)……………………………………………………….. SP000026
Hydraulics
Hydraulic System Troubleshooting, Testing and Adjustment …………… SP002973
Accumulator……………………………………………………………………………… SP000028
Center Joint (Swivel)………………………………………………………………….. SP002545
Cylinders………………………………………………………………………………….. SP000193
Swing Device……………………………………………………………………………. SP002565

Travel Device……………………………………………………………………………. SP002566
Main Pump……………………………………………………………………………….. SP000186
Main Control Valve ……………………………………………………………………. SP000187
Remote Control Valve (Work Lever / Joystick) ………………………………. SP002974
Travel Control Valve (with Damper)……………………………………………… SP002906
Solenoid Valve Assembly …………………………………………………………… SP001622
Breaker EPPR Valve (Opt) …………………………………………………………. SP000192
Hydraulic Schematic………………………………………………………………….. SP002957
Electrical System
Electrical System ………………………………………………………………………. SP002453
Electrical Schematic ………………………………………………………………….. SP002031
Attachments
Boom and Arm………………………………………………………………………….. SP001851
Bucket……………………………………………………………………………………… SP002958

How to Use Guide Manual

This manual provides information for servicing the Excavator. All service procedures are broken down into detailed steps, listed in their recommended sequence. The manual uses both photographs and drawings to help locate and itemize components. The table of Contents on the preceding pages is your best tool for finding the service procedure you need. Be certain to observe all Safety information included in these pages.

A schematic of each of the major engine systems is provided at the beginning of the section of the manual devoted to troubleshooting and repairing that particular system.

Basic safety precautions are list in the Safety section of the Service Manual. Additional safety precautions are list in the Safety section of the owner/operation/maintenance publication. Specific safety warnings for all these publications are provided in the description of operations where hazards exist. WARNING labels have also been put on the product to provide instructions and to identify specific hazards.

CAUSES OF FAULTS AND MEASURES

At times it may be difficult to pinpoint the source of the problem.
The following table lists some of the possible problems, possible causes and remedies. Refer to this table for possible causes and remedies to assist in correcting the sometimes difficult problems.

The table below only lists some general problems, possible causes and their remedies. In many cases the problem is not caused by the failure of a single part but, may be the result of a combination of problems from related parts and their components. Possible problems other than the ones list are not being specified but that is not to say that these are the only possible problems that can occur. The technician must diagnose the problem, considering all possible causes and repair the source of the malfunction: