Doosan DX480LC, DX520LC. Operation and Maintenance Manual (2009)

15. Tightening bolt for bottom roller

•

Tool: 32 mm (

)

•

Torque: 75 kg•m (735 Nm, 542 ft lb)

FG001599

Figure 125

16. Tightening bolt for track guard

•

Tool: 32 mm (

)

•

Torque: 75 kg•m (735 Nm, 542 ft lb)

FG001600

Figure 126

17. Bolt for track shoes

Tighten the bolts in the order as shown in the Figure 127 (1

→ 4)

•

Tool: 32 mm (

)

•

Torque: 105 kg•m (1029 Nm, 759 ft lb)

FG014337

Figure 127

Inspection, Maintenance and Adjustment

OP000812

4-66

19. Fixing bolt for track frame and side frame

•

Tool: 50 mm (

)

•

Torque: 175 kg•m (1715 Nm, 1265 ft lb)

FG001605

Figure 131

20. Fixing bolt for fan motor

•

Tool: 19 mm (

)

•

Torque: 11 kg•m (108 Nm, 80 ft lb)

FG001606

Figure 132

21. Fixing bolt for auxiliary pump

•

Tool: 10 mm (

)

•

Torque: 11 kg•m (108 Nm, 80 ft lb)

FG001607

Figure 133

22. Fixing breaker filter (Optional)

•

Tool: 30 mm (

)

•

Torque: 27 kg•m (265 Nm, 195 ft lb)

FG001970

Figure 134

Inspection, Maintenance and Adjustment

OP000812

4-68

23. Fixing bolt for main frame and RCW support (Optional)

•

Tool: 36 mm (

)

•

Torque: 95 kg•m (931 Nm, 687 ft lb)

FG012316

Figure 135

24. Fixing bolt for RCW cylinder pin (a) (Optional)

•

Tool: 19 mm (

)

•

Torque: 11 kg•m (108 Nm, 80 ft lb)

FG012317

Figure 136

- Fixing bolt for RCW cylinder pin (b) (Optional)

•

Tool: 19 mm (

)

•

Torque: 11 kg•m (108 Nm, 80 ft lb)

FG012320

Figure 137

OP000812

Inspection, Maintenance and Adjustment

4-69

BUCKET

Bucket Tooth Replacement

WARNING

Due to the possibility of flying metal objects, always wear

safety helmet, protective gloves and eye protection when

changing bucket teeth.

Curl the bucket upwards and place the round rear surface

of the bucket firmly on the ground. Shut the engine off and

lock out the hydraulic controls before working on the

bucket.

NOTE:

These instructions are only for DOOSAN OEM

buckets. If you are using other manufacturers

buckets, refer to their specific instructions.

HAOC680L

Figure 140

On a routine basis, inspect bucket teeth to make sure that

tooth wear or breakage has not developed. Do not allow

replaceable bucket teeth to wear down to a point that

bucket adapter is exposed. See Figure 140.

To replace a tooth (1, Figure 141), use a hammer and

punch to drive locking pin (2) and lock washer (3) out of

tooth adapter (4).

Once worn tooth has been removed, use a putty knife to

scrape adapter as clean as possible.

Slide new tooth into position and insert lock washer.

FG000346

Figure 141

Insert locking pin into tooth and with a hammer, drive pin in

until lock washer seats in locking groove.

OP000812

Inspection, Maintenance and Adjustment

4-71

Bucket O-ring Replacement

WARNING

Due to possibility of flying metal objects, always wear

safety helmet, protective gloves and eye protection when

changing pins.

Inspect bucket O-rings on a routine basis. If worn or

FG000502

damaged, replacement is necessary.

Figure 142

Roll old O-ring (1, Figure 143) onto boss (2) around bucket

pin (3). Remove bucket pin and move arm or bucket link

(4) out of way.

ARO1390L

Figure 143

Remove old O-ring and temporarily install new O-ring (1,

Figure 144) onto bucket boss (2). Make sure that O-ring

groove on both bucket link (4) and boss have been

cleaned.

Realign arm or link with bucket pin hole and insert bucket

pin (3, Figure 143).

ARO1391L

Figure 144

Roll new O-ring (1, Figure 145) into O-ring groove.

ARO1392L

Figure 145

Inspection, Maintenance and Adjustment

OP000812

4-72

BUCKET SHIMMING

PROCEDURES

New Bucket Installation

If a new bucket is being installed on the excavator,

measure the inside dimension between the bucket ears

and the outside dimension across the arm mounting boss.

Subtract the clearance on both sides from the difference of

the two and shim accordingly, before assembly.

WARNING

To check end play (side-to-side) clearance at bucket

attachment point, the bucket must be free to move but at all

other times lower it to the ground or use support blocks to

immobilize this assembly. Shut off engine and tag and lock

out controls to prevent movement during this procedure.

Shimming Procedures for Installed Bucket

With bucket attached, curl bucket and arm outward and

"Y"

lower boom so that bucket teeth are pointing away from

"X"

excavator, just a few inches off ground. This position

provides easy accessibility for dimensional measurements.

Force bucket to one side and check for end play (side to

side) clearance under O-rings at attachment point. Total

clearance should be 1 mm (0.04 in) between side face of

boss and inside edge of ear bushing (Y, Figure 146). Too

tight a fit (less than 1 mm (0.04 in)) can cause excessive

wear while too much clearance may produce excessive

noise and potentially hazardous slack control.

Recheck end play by forcing bucket towards opposite side

and repeating clearance measurements.

If an adjustment is required, remove two jam nuts

(1,

HAAH0010

Figure 146) and bolt (2) from pin (3). Add or remove shims

(4) as required. Use an equal amount of shims on each

Figure 146

side. Install bolt (2) and two jam nuts (1). Jam nuts must

clear boss by 1 - 2 mm (0.04 - 0.08 in) at point (X).

OP000812

Inspection, Maintenance and Adjustment

4-73

ELECTRICAL SYSTEM

NOTE:

Never disassemble electrical or electronic parts.

Consult with a DOOSAN distributor or sales agency

before servicing.

Battery

WARNING

Battery electrolyte contains sulfuric acid and can quickly

burn the skin and eat holes in clothing. If you spill acid on

yourself, immediately flush the area with water.

Battery acid could cause blindness if splashed into the

eyes. If acid gets into the eyes, flush them immediately with

large quantities of water and see a doctor at once.

If you accidentally drink acid, drink a large quantity of water

or milk, beaten egg or vegetable oil. Call a doctor or poison

prevention center immediately.

When working with batteries, always wear safety glasses or

goggles.

Battery generates hydrogen gas, so there is danger of an

explosion. Do not bring lighted cigarettes near the battery,

or do anything that will cause sparks.

Before working with batteries, shut down engine and turn

the starter switch to the "O" (OFF) position.

Avoid short circuiting the battery terminals through

accidental contact with metallic objects, such as tool.

When removing or installing, check which is the positive (+)

terminal and negative (-) terminal.

When removing the battery, first disconnect the negative (-)

terminal. When installing the battery, first connect the

positive (+) terminal.

If the terminals are loose, there is danger that the defective

contact may generate sparks that will cause an explosion.

When installing the terminals, install them tightly.

Batteries in Cold Weather

In colder weather a greater drain is placed on the batteries when

they are used for the preheat cycle and when starting a cold

engine. Battery performance decreases as the temperature gets

lower.

In extremely cold weather, remove the batteries at night and

move them to a warm location. This will help to keep them at a

higher power level.

Inspection, Maintenance and Adjustment

OP000812

4-74

Inspection of Battery Electrolyte Level

This machine has two maintenance free batteries. They never

require the addition to water.

When the charge indicator becomes transparency, it means low

electrolyte state because of the leakage or charging system

error. Determine the cause of problem and replace the batteries

immediately.

FG000347

Figure 147

Check Charging State

Check charging state through the charging indicator.

•

GREEN: Sufficiently charged.

•

BLACK: Insufficient charged.

•

TRANSPARENT: Replace battery.

Check the Battery Terminals

Be certain that the battery is held securely in its compartment.

Clean the battery terminals and the battery cable connectors. A

solution of baking soda and water will neutralize acid on the battery

surface, terminals, and cable connectors. Petroleum jelly or grease

can be applied to the connectors to help prevent corrosion.

Battery Replacement

When the charging indicator indicates transparency state, replace

the battery. The batteries should always be replaced in pairs.

HAOU790L

Figure 148

Using an old battery with a new one will shorten the life span of

the new battery.

OP000812

Inspection, Maintenance and Adjustment

4-75

Fuses

The fuses in the fuse box are used to protect the various

electrical circuits and their components from being

damaged. See Figure 149. The fuses used are standard

automotive type fuses.

The section on “Fuse Identification” on page 4-77, lists the

circuits and the fuse amperage required for each circuit. If

a fuse blows, determine the cause and repair any faults or

failures.

Do not insert a higher amperage fuse into a lower

amperage slot. Serious damage to the electrical

components or fire can result.

HAOC670L

Figure 149

CAUTION

Before replacing a fuse, be sure to turn starter switch to "O"

(OFF) position.

Fuse Boxes

There are two fuse boxes (Figure 150) on the left side of the

heater box. The fuses prevent electrical devices from

overloading or shorting.

A decal attached to the inside of the fuse box's cover indicates

the function and amperage of each fuse.

Spare fuses are mounted on the inside of fuse box's cover. (One

each of a 10A, 15A, 20A and 30A.)

Change a fuse if the element separates. If the element of a new

FG000110

fuse separates, check the circuit and repair the circuit.

Figure 150

CAUTION

Always replace fuses with the same type and capacity fuse

that was removed. Otherwise, electrical damage could result.

Inspection, Maintenance and Adjustment

OP000812

4-76

Fuse Identification

Fuse Box (1)

Fuse Box (2)

FG000542

Figure 151

Fuse Box One

Fuse Box Two

No.

Name

Capacity

Name

Capacity

Warning Light (Optional)

10A

Horn

10A

2-pump (Optional)

10A

Quick Clamp (Optional)

10A

Cigar Lighter

10A

Travel Alarm (Optional)

10A

12V Power

10A

Auxiliary Mode

10A

Wiper, Washer

10A

Check Connector

10A

Lower Wiper (Optional)

10A

Pilot Cutoff

10A

Stereo

10A

Memory Backup

10A

Starter Switch, Hour Meter

10A

Room Light

10A

Spare

30A

Cabin Light (Optional)

30A

Air Conditioner, Heater

20A

Work Light

20A

Shear, Breaker (Optional)

15A

Fuel Heater

20A

Seat Heater (Optional)

15A

Instrument Panel, Pressure Sensor

15A

e-EPOS, Booster, Travel speed

15A

Headlight

15A

changer, Booster

ECU

15A

Fuel Pump (Optional), Wiper

15A

OP000812

Inspection, Maintenance and Adjustment

4-77

ENGINE COOLING SYSTEM

General

Keeping an engine's cooling system in peak operating condition,

can have many benefits to keeping a machine in good operating

condition. A properly functioning cooling system will; improve

fuel efficiency, reduce engine wear, and extend component life.

Always use distilled water in the radiator. Contaminants in tap

water neutralize the corrosion inhibitor components. If tap water

must be used, it should not exceed 300 ppm hardness, or

contain more than 100 ppm of either chloride or sulfate. Water

that has been treated with a water softener also contains salt

that will cause corrosion of components. Water from creeks and

stagnant pools usually contains dirt, minerals and/or organic

material that are deposited in the cooling system and impair

cooling efficiency. Distilled water is the best.

Make at least a minimum mixture of 40% antifreeze with 60%

distilled water for adding additional fluid to the system during

normal maintenance. This level will help maintain the additive

concentration of the system. Check the coolant every 500 hours.

Engine overheating is often caused by bent or clogged radiator

fins. The spaces between the fins can be cleaned by use of air

or water under pressure. When straightening bent fins, use care

not to damage the tubes or break the bond between the fins and

the tubes.

CAUTION

Maintaining the proper anticorrosive additive levels in

antifreeze will help protect the engine and other

components from becoming corroded.

If anticorrosive additive levels are not properly maintained

and monitored, server damage to the cooling pump and

cylinder liners may result. This corrosion can also result in

the radiator tubes becoming clogged and loosing their heat

transfer efficiency. The engine (Model: DV11) uses a

wet-type cylinder liner design, which requires, a high

efficiency cooling system flow, to maintain proper engine

temperatures.

The coolant and its additives can be checked by using

coolant test paper (No: 60.99901-0038).

WARNING

Pressure at air nozzle must not exceed 2.1 kg/cm² (30

psi). Always wear goggles when using compressed air.

Do not pour cold water into radiator when engine is very

hot and water level is below the top of the tubes. Such

action could result in damage to engine cylinder heads.

Inspection, Maintenance and Adjustment

OP000812

4-78

Heavy duty diesel engines require a balanced mixture of water

and antifreeze. Drain and replace the mixture every year or

2,000 hours of operation, which ever comes first. This will

eliminate buildup of harmful chemicals.

Antifreeze is essential in any climate. It broadens the operating

temperature range by lowering the coolant's freezing point and

by raising its boiling point. Do not use more than 50% antifreeze

in the mixture unless additional freeze protection is required.

Never use more than 68% antifreeze under any condition.

Measuring the Concentration of Coolant

The coolant and its additives can be checked by using coolant

test strips (No: 60.99901-0038). Use the following procedure to

conduct the test:

With a coolant temperature of 10° - 55°C (50° - 131°F),

drain 1 liter (1 U.S. quart) it from the radiator into a clean

plastic container.

NOTE:

Do not take the sample from the coolant

recovery tank. Recovery tank coolant

concentration can differ from the concentration

level of coolant in the radiator.

Dip test strip, into coolant sample for 3 - 5 seconds.

Remove strip and excessive coolant by giving the strip one

shack.

Wait for 45 seconds, for the test strip to change color.

NOTE:

Measuring time should not be more than 75

seconds. If it is over this time limit, the color will

be changed and an inaccurate reading will

result.

Compare the color of the test strip with the color table on

the outside of test strip container bottle, and determine

what numeric value corresponds to the color in the table.

Check antifreeze concentration levels by comparing

the color change at the end of test paper, with the

green spectrum range, with the green symbol on the

upper portion of the container bottle.

NOTE:

A suitable concentration indicator should

be between 33% and 50%).

Check the anticorrosive additives, by comparing

brown color in the middle range of the test strip and

pink color on the lower part of the test strip, with the

brown and pink spectrum range. Where the brown

(vertical) color and pink (horizontal) color intersects

represents the anticorrosive additive level.

NOTE:

A reading between 0.3 and 0.8, represents

an adequate additive level.

Correct the antifreeze concentration and additive levels.

OP000812

Inspection, Maintenance and Adjustment

4-79

If anticorrosive additive level is below 0.3, add 100%

pure antifreeze to the radiator.

If anticorrosive additive level is greater 0.8, add a

50% distilled water and antifreeze mixture to lower

the additive reading.

NOTE:

In either case keep the antifreeze concentration

level between 33% and 50%.

Run the engine to recirculate the coolant mixture. Be sure

that engine reaches operating temperature to ensure a

thorough mix. Shut down engine and retest antifreeze.

NOTE:

When making adjustment, drain 1 liter (1 U.S.

quart) of coolant from the radiator. Add 30 cc (1

fl oz) at a time to the drained fluid. Keep track of

how many cc's (fl oz's) were added to the 1 liter

(1 U.S. quart) to obtain a proper reading. Then

multiply that number times the total system

capacity of liters (U.S. quarts). Add that amount

to the radiator.

Example: If 1 liter needs 90 cc to obtain proper

reading. Then system capacity of

liters x 90 cc = 3,600 cc (3.6 liters) of

correction fluid.

Inspection, Maintenance and Adjustment

OP000812

4-80

Types of Antifreeze

There are two main classifications of antifreeze available on the

market today.

Ethylene Glycol - Doosan Genuine Antifreeze Solution

(for all seasons)

Propylene Glycol - Doosan Genuine Antifreeze Solution

(for all seasons)

Ethylene glycol has been on the market for many years. Its

chemical properties do not provide the improved corrosion

resistance that propylene glycol does. Ethylene glycol is also

very hazardous to the environment, people and animals.

DOOSAN recommends that ethylene glycol be replaced with

propylene glycol.

The newer propylene glycol antifreeze comes in many different

colors. Some of the colors are pink, red, orange and yellow.

There are even some that come in a blue-green color. The

blue-green color makes it very difficult to tell the difference of

what type of antifreeze is in a cooling system. The colors are

only a dye added to the clear antifreeze. Do not rely on color.

Keep careful machine records of what brand and type of

antifreeze is used in the unit. If you are unsure of what type of

antifreeze is in the system, drain and flush the system.

CAUTION

Do not mix the ethylene glycol and propylene glycol

solutions. If these two chemicals are mixed, undesirable

chemicals may be formed, which damages the equipment.

Do not mix up the solutions from different manufacturers.

Otherwise, the performance may be deteriorated. It is

recommended to use the Doosan Genuine Product.

In the regions under extreme weather, the user should

determine the performance of the coolant suitable for the

weather condition and decide the replacement cycle.

OP000812

Inspection, Maintenance and Adjustment

4-81

Antifreeze Concentration Tables

Ethylene Glycol - Doosan Genuine Antifreeze Solution (for all seasons)

(2,000 Hour / Yearly)

Ambient Temperature

Cooling Water

Antifreeze

-10°C (14°F)

80%

20%

-15°C (5°F)

73%

27%

-20°C (-4°F)

67%

33%

-25°C (-13°F)

60%

40%

-30°C (-22°F)

56%

44%

-40°C (-40°F)

50%

Propylene Glycol - Doosan Genuine Antifreeze Solution (for all seasons)

(2,000 Hour / Yearly)

Ambient Temperature

Cooling Water

Antifreeze

-10°C (14°F)

78%

22%

-15°C (5°F)

71%

29%

-20°C (-4°F)

65%

35%

-25°C (-13°F)

59%

41%

-30°C (-22°F)

55%

45%

-40°C (-40°F)

48%

52%

NOTE:

Mixing ratio is for reference purpose only, and is not

an absolute standard.

NOTE:

Replacement cycle of the Doosan Genuine Product is

2,000 hours or one year.

Inspection, Maintenance and Adjustment

OP000812

4-82

FUEL TRANSFER PUMP

(OPTIONAL)

WARNING

Do not dry operate fuel pump for more than fifteen seconds.

•

Cooling and lubrication of pump is achieved by

fuel passing through pump. If pump is dry

operated, heat generated by moving parts will

cause damage to pump rotors, vanes and seals.

To prevent unnecessary wear and/or damage to

pump do not dry operate fuel pump for more than

fifteen seconds.

Do not operate pump for more than fifteen minutes at a time.

•

Continuous usage of pump over recommended

time interval will cause overheating of motor and

will result in causing motor damage.

Do not use refueling pump for other types of fuel or fluids.

(Use only for diesel fuel.)

•

Do not use refueling pump for other types of fuel

which have a low flash point.

•

Do not use refueling pump for fuel contaminated

with water or high humidity. Moisture in pump

mechanism can cause rust and can create pump

failure.

Always operate pump using strainer installed on inlet hose.

This will prevent any foreign materials from being

introduced into pump. Always maintain pump and all of its

components in a clean condition.

•

If dirt or other foreign materials enter pump, it can

become lodged between the rotor and/or vanes and

generate heat which can cause pump damage.

•

Do not remove strainer or use a strainer with

larger mesh to increase flow of fuel.

Be careful not to overfill or spill fuel.

Make sure direction of check valve is in line with flow

direction of fuel.

If any pump parts or components become lost, damaged or

inoperable, immediately replace it with a new ones.

IMPORTANT

If there are any sign of leakage while operating transfer

pump, inspect the following components to prevent any

fires or hazardous fuel spills.

•

Check all hoses leading to and from the transfer

pump.

•

Check all hose clamps.

•

Check transfer pump inlet port.

OP000812

Inspection, Maintenance and Adjustment

4-83

The transfer pump is used to transfer fuel from a refueling

source to the fuel tank. A check valve is installed in the inlet

hose to prevent fuel from flowing back from fuel tank to source.

A strainer is installed in inlet hose to prevent any foreign material

from being introduced into transfer pump or fuel tank.

A thermal limiter, built into the motor, will automatically shut off

power if motor is overheating to protect it from being damaged.

FUEL

FUEL TANK

OUT

FG000161

Figure 152

Reference

Description

Number

Body

Strainer Cap

Check Valve

Inlet Hose

Strainer

Remove strainer cap (4, Figure 152) from strainer (3) on

end of inlet hose (5).

NOTE:

Keep strainer cap (4, Figure 152) in a safe

location to reseal strainer (3) after refueling is

complete.

Insert inlet hose (5, Figure 152) into refueling tank.

Turn fuel pump switch (Figure 153) inside of battery box on

front side to "I" (ON) position.

NOTE:

Transfer pump rate of flow is approximately 35

liters/minute (9.24 U.S. gpm). Use extra care

FG001580

not to overfill fuel tank so that fuel does not over

Figure 153

flow.

Once fuel transfer is completed, immediately turn switch to

"O" (OFF) position to stop pump.

Lift inlet hose (5, Figure 152) from fueling source and turn

switch to "I" (ON) position for two - three seconds to drain

remaining fuel from hose to fuel tank.

Install strainer cap (4, Figure 152) on inlet strainer (3) and

return hose (5) to storage position.

Inspection, Maintenance and Adjustment

OP000812

4-84

HANDLING OF ACCUMULATOR

WARNING

Even though the engine is stopped, the hydraulic

accumulators for the pilot system are still charged. Do not

disconnect any pilot system hoses until accumulator

pressure has been released from the circuit. To release

pressure, turn the starter switch to the "I" (ON) position and

operate all hydraulic control levers and forward/reverse

travel levers. Even though the engine is shutdown hydraulic

actuated components may move while releasing pilot

pressure. Keep all personnel away from excavator while

performing this operation.

•

Set safety lever on "LOCK" position after

stopping engine.

•

DO NOT mishandle accumulator(s). They are very

dangerous because they contain high-pressure

nitrogen gas.

•

DO NOT punch a hole or apply heat or fire to an

accumulator.

•

DO NOT weld on accumulator, or try attaching

anything to it.

•

When replacing an accumulator, contact a

DOOSAN distributor or sales agency so the gas

can be properly released.

•

Wear safety goggles and protective gloves when

working on an accumulator. Hydraulic oil under

pressure can penetrate the skin and cause

serious injuries.

Release pilot accumulator pressure using the following

procedure;

Position the machine on firm, level ground. Lower the front

attachment to the ground and shut down engine.

Set safety lever on "RELEASED" position.

Turn starter switch to the "I" (ON) position.

Fully stroke work and travel levers in all directions.

Set safety lever on "LOCK" position.

Turn key to "O" (OFF) position and remove from starter

switch.

Remove accumulator by unscrewing it slowly.

FG013208

Figure 154

OP000812

Inspection, Maintenance and Adjustment

4-85

TRACK TENSION

WARNING

Safely measuring track tension requires two people. One

person must be in the operator's seat, running the controls

to keep one side frame in the air, while the other person

makes dimensional checks. Take all necessary precautions

to make sure the machine won't move or shift position

during service. Warm up the engine to prevent stalls, travel

the excavator to an area that provides level, uniform ground

support and/or use support blocks when necessary.

The track adjusting mechanism is under very

high-pressure. NEVER release pressure too suddenly. The

grease cylinder valve should never be backed off more than

one complete turn from the fully snugged down position.

Bleed off pressure slowly and keep your body away from

the valve at all times.

Track shoe link pins and bushings wear with normal usage,

reducing track tension. Periodic adjustment is necessary to

compensate for wear and it may also be required by working

conditions.

Track tension is checked by jacking up one side of the

excavator. See Figure 155. Place blocking under frame

while taking measurement.

90 ~ 110

FG000345

Figure 155

Measuring the distance (A, Figure

156) between the

bottom of the side frame and the top of the lowest crawler

shoe. Recommended tension for operation over most

types of terrain is 380 - 430 mm (14.96 - 16.93 in)

NOTE:

This measurement can be thrown off if there is

too much mud or dirt or other material in the

track assembly. Clean off the tracks before

checking clearance.

Too little sag in the crawler track (less than 380 mm

(14.96 in) clearance) can cause excessive component

FG000162

wear. The recommended adjustment can also be too tight

Figure 156

causing accelerated stress and wear if ground conditions

are wet, marshy or muddy, or if the ground is hard and full

of rocks or gravel.

Inspection, Maintenance and Adjustment

OP000812

4-86

The increased clearance recommended for muddy ground

conditions is between 430 - 460 mm (16.93 - 18.11 in). The

clearance should be approximately 460 mm (18.11 in) for

operation over gravel, rocky terrain, or over sand or snow.

WARNING

The track adjusting mechanism is under very

high-pressure. NEVER release pressure too suddenly.

The grease cylinder valve should never be backed off

more than 1 complete turn from the fully snugged

down position. Bleed off pressure slowly and keep

your body away from the valve at all times. If there is

problem in the fitting thread, the valve or fitting might

be ejected at high speed to cause fatal wound.

Track tension adjustments are made through the grease

fitting (1, Figure 157) in the middle of each side frame.

Adding grease increases the length of an adjustment

cylinder

(2). The longer the adjustment cylinder, the

greater the pressure on the tension spring pushing the

track idler wheel outward.

If there is not enough slack or clearance in the tracks and

the adjustment is too tight, the idler wheel and adjusting

cylinder can be retracted by bleeding off grease through

hole in valve (3, Figure 157) by loosening valve slowly.

FG000163

NOTE:

After track tension is adjusted by loosening

Figure 157

valve, be sure to tighten valve (3, Figure 157)

with 14 kg•m (137 Nm, 101 ft lb).

WARNING

Do not loosen or remove the grease fitting (1, Figure

157) until the pressure is entirely bleed off by slowly

loosening valve (3, Figure 157).

OP000812

Inspection, Maintenance and Adjustment

4-87

VENTING AND PRIMING

HYDRAULIC SYSTEM

Main System Pump

NOTE:

If pump is run without sufficient oil in the main

hydraulic pump, damage can occur. Always vent

pump of air after draining hydraulic system.

Shut down engine.

Remove flushing hose (1) from the adapter (2).

Remove adapter (2) and O-ring from the pump housing.

Fill pump housing with hydraulic oil.

Install new O-ring onto adapter (2) and assemble the

adapter on pump housing.

Connect flushing hose (1) to adapter (2).

FG001573

Start engine, and run at "LOW IDLE". Raise boom to its

Figure 158

maximum height.

Very slowly loosen negative control hose connector (3)

until hydraulic oil start to leak from the connection.

When hydraulic oil begins to leak, tighten hose connector.

10. Shut down engine, turn starter switch "ON", and slowly

lower the boom until the bucket pin touches the ground.

(This will increase the air pressure in the hydraulic tank)

11. Slowly loosen air bleeding plug (4) until hydraulic oil leaks

out.

12. When hydraulic oil begins to leak, then tighten plug (4).

Hydraulic Cylinders

IMPORTANT

If cylinders are operated in high idle after the hydraulic

system has been drained or the cylinder has been rebuilt,

damage to piston packing and seals may occur. Always

vent air from cylinders at low idle and at a slow speed.

Run engine at low idle. Extend and retract each cylinder to

within 100 mm (4 in) of fully stroking it 4 - 5 times.

Operate fully extend and retract each cylinder 3- 4 times.

Repeat procedure until cylinders extend and retract

smoothly.

Inspection, Maintenance and Adjustment

OP000812

4-88

Swing Motor

IMPORTANT

If the air is not vented from the system, it will cause damage

to the swing motor and bearings.

NOTE:

Perform this only when oil has been drained from

swing motor.

FG000159

Shut down engine.

Figure 159

Disconnect drain hose and fill swing motor case with

hydraulic oil.

Connect the drain hose.

Start engine and set throttle at "LOW IDLE" and swing

upper structure slowly two full revolutions to the left and

right.

Travel Motor

NOTE:

Perform this only when oil is drained from travel

motor

Shut down engine

Disconnect drain hose (Figure 160) and fill motor case with

hydraulic oil.

Connect drain hose.

Start engine and set engine speed control dial to "LOW

FG000160

IDLE." Run the engine for one minute and slowly drive

Figure 160

excavator forwards and backwards.

General Venting

After venting air from all components, shut the engine

down and check the hydraulic oil level. Fill hydraulic oil

tank to "H" mark on sight gauge.

Start engine and operate all controls again, run engine for

five minutes to ensure all systems have been vent and

purged of air. Set engine speed to "LOW IDLE," and check

hydraulic oil level again. Add oil as necessary.

Check for oil leaks and clean all fill and venting locations.

OP000812

Inspection, Maintenance and Adjustment

4-89

LONG TERM STORAGE

When a machine is taken out of service and stored for a time

exceeding 30 days, steps must be taken to protect the machine.

Leaving equipment outdoors exposed to the elements will

shorten its life.

An enclosure will protect the machine from rapid temperature

changes and lessen the amount of condensation that forms in

hydraulic components, engine, fuel tank, etc. If it is not possible

to put the machine in an enclosure, cover it with a tarpaulin.

FG014341

Check that the storage site is not subject to flooding or other

Figure 161

natural disasters.

After the machine has been positioned for storage and the

engine shut down, perform the following operations:

Before Storage

Keep the excavator in the position shown in Figure 92 to prevent

rust of the hydraulic piston rods.

•

Inspect for damaged, loose or missing parts.

•

Repaint necessary area to prevent oxidation.

•

Wash and clean all parts of machine.

•

Store the machine indoor, stable place. If stored

outside, cover with a waterproof tarpaulin.

•

Perform lubrication procedures on all grease points.

•

Apply a coating of light oil to the exposed plated

metal surfaces (such as hydraulic cylinder rods, etc.)

and to all the control linkage and control cylinders.

(Control valve spools, etc.)

•

Remove the battery from the excavator to be fully

charged and stored.

•

Inspect the coolant recovery tank and radiator to

make sure the antifreeze level in the system is

correct. Make sure that antifreeze concentration is

enough for the lowest temperature anticipated during

storage.

•

Seal all external openings (i.e. engine exhaust outlet,

crankcase and hydraulic breather, fuel vent line, etc.)

with tape wide enough to cover the opening,

regardless of size.

NOTE:

When sealing with tape, be sure to extend

tape approximately one inch

(25 mm)

beyond opening to insure a good seal.

Inspection, Maintenance and Adjustment

OP000812

4-90

During Storage

•

Once a month, start the engine and follow the

"Hydraulic Oil Warm-up" procedures listed in this

manual.

NOTE:

Remove all seals from the machine (i.e.

crankcase and hydraulic breathers, engine

air intake, fuel tank vent lines, etc.).

Operate hydraulic functions for traveling, swing and

digging two or three times for lubrication after

"Hydraulic Oil Warm-up." Coat all the moving parts

and surfaces of the components with a new oil film

after operating. At the same time, charge the battery.

Rotate track to prevent track seizing. "

•

Every 90 days, use a hydrometer to measure the

protection of the coolant. Refer to the antifreeze/

coolant protection chart to determine protection of the

cooling system. Add coolant as required.

After Storage

•

When operating the work equipment, remove all

grease from the hydraulic cylinder rods.

•

Add grease and oil at all lubrication points.

•

Adjust fan and alternator belt tension.

•

Connect the charged battery.

•

Check condition of all hoses and connections.

•

Check the levels of engine oil, fuel, coolant and

hydraulic circuit oil. If there is water in the oil, change

all the oil.

•

Change all filter elements.

•

When starting the engine after long-term storage,

follow the "Hydraulic Oil Warm-up" procedures listed

in this manual.

OP000812

Inspection, Maintenance and Adjustment

4-91

MAINTENANCE IN SPECIAL

CONDITIONS

NOTE:

See “Operation Under Unusual Conditions” on

page 3-42 for other recommendations.

Conditions

Maintenance Required

Operating in mud, water or rain.

Perform a walk around inspection to check for any loose

fittings, obvious damage to the machine or any fluid leakage.

After completing operations, clean mud, rocks or debris from

the machine. Inspect for damage, cracked welds or loosened

parts.

Perform all daily lubrication and service.

If the operations were in salt water or other corrosive materials,

make sure to flush the affected equipment with fresh water.

Operating in an extremely dusty or hot

Clean the air intake filters on a more frequent basis.

environment.

Clean the radiator and oil cooler fins to remove embedded dirt

and dust.

Clean the fuel system intake strainer and fuel filter more

frequently.

Inspect and clean as required the starter and alternator.

Operating in rocky terrain.

Check the undercarriage and track assemblies for damage or

excessive wear.

Inspect for loose or damaged fittings or bolts.

Relax track tension.

On a more frequent basis, inspect the front end attachments for

damage or excessive wear.

Install a top guard and front guard as required for protection

against falling rock.

Operating in extreme cold.

Use the proper fuel for the temperature conditions.

Using a hydrometer, check the antifreeze to make sure that it is

providing the proper cold weather freeze protection.

Verify the condition of the batteries. In extremely cold weather

remove the batteries at night and store them in a warmer area.

Remove mud buildup as soon as possible to prevent it from

freezing to the undercarriage and causing damage.

Inspection, Maintenance and Adjustment

OP000812

4-92

OP000813

5Transportation

Obey all local, state or federal regulations for transportation of

excavator. If unsure of regulations check with local authorities.

Check intended route for road width, overhead clearances,

weight restrictions, and traffic control regulations. Special

approval or permits may be required.

DISASSEMBLY AND ASSEMBLY

BEFORE AND AFTER

TRANSPORTATION

When necessary, machine should have counterweight and front

attachment removed for transport between locations. The tracks

should be retracted before removing counterweight and front

attachment.

If equipped, removable counterweight may also have to be

removed.

NOTE:

Obey all local, state or federal regulations for

transportation of excavator. If unsure of regulations

check with local authorities.

Check intended route for road width, overhead

clearances, weight restrictions, and traffic control

regulations. Special approval or permits may be

required.

When doing this operation, make sure that it is done on solid

level ground, with adequate room for maneuvering all equipment

and keeping personnel at a safe distance when required.

WARNING

If engine must be run while performing maintenance, use

extreme care. Always have one person in cabin at all times.

Never leave cabin with engine running.

Personnel and Equipment

Disassembly and Reassembly: 2 persons

Crane Operator: 1 person

Crane Equipment: 1 machine

OP000813

Transportation

5-1

Time Required

Work

Procedures

Time Required

Equipment to be Used

Counterweight Disassembly

20 min

Crane

RCW Counterweight

20 min

No, RCW Device

Disassembly and

Disassembly (Optional)

Loading on

Track Side Frame Disassembly

40 min

Crane

Carrier

Front Disassembly

1 h 20 min

Crane

Sub Total

2 h 20 min

Front Assembly

1 h 40 min

Crane

Track Side Frame Assembly

50 min

Crane

Counterweight Assembly

30 min

Crane

Reassembly

RCW Counterweight Assembly

30 min

No, RCW Device

(Optional)

Sub Total

3 h

Total Sum

5 h 20 min

Removable Counterweight Removal and

installation (Optional)

WARNING

Park machine on firm, level ground. Set safety lever on

"LOCK" position. See “Safety Lever” on page 3-13. Attach a

warning tag (do not operate) to operating lever.

Personal injury or death can occur from a counterweight

falling during removal and installation.

FG012326

Do not allow unnecessary personal under or around

Figure 1

counterweight during removal and installation.

Improper lifting can allow load to shift and cause injury or

death.

WARNING

If engine must be run while performing maintenance, use

extreme care. Always have one person in cabin at all times.

Never leave cabin with engine running.

Transportation

OP000813

5-2

Control Levers and Switches

The operating controls for removing and installing counterweight

are found in pump compartment.

Removal control valve lever (1, Figure 2)

Stop valve (2, Figure 2)

Solenoid valve switch (3, Figure 2)

FG012328

Figure 2

Counterweight Removal

Park machine on firm, level ground, free from any

obstructions or interference. See Figure 3. Make sure there

is enough room for a truck trailer to maneuver behind the

unit.

Make sure all operating controls are in "NEUTRAL."

Shut down engine and inspect counterweight removal

device for defects, bent or damaged links, or any other

damage to device and its operating system components.

FG012329

Figure 3

Make sure to connect counterweight (1, Figure 4), to lifting

arms (2), with pins (3), hair pins (4).

Inspect all hoses and fittings for removal device hydraulic

system. Correct if necessary.

FG012331

Figure 4

OP000813

Transportation

5-3

Open side door of pump compartment.

FG012338

Figure 5

Be sure solenoid valve switch (1, Figure 6) is in the "O"

(OFF) position.

O. In this position, the solenoid valve switch is turned

"OFF."

In this position, the solenoid valve switch is turned

"ON."

CAUTION

FG012332

Avoid personal injury from unexpected counterweight

Figure 6

movement. Do not go directly under machine

counterweight. To remove or install counterweight

hardware, go under machine entering from area on

either side of counterweight. The counterweight

weighs approximately 8,700 kg (19,180 lb, DX480LC),

10,350 kg (22,820 lb, DX520LC). Clear everyone from

area before removing or installing counterweight.

Be sure removal control valve lever (1, Figure 7) is in "O"

(NEUTRAL) position.

O. In this position, the removal control valve lever is in

"NEUTRAL."

In this position, the removal control valve lever moves

counterweight "DOWNWARD."

II.

In this position, the removal control valve lever moves

counterweight "UPWARD."

FG012333

Figure 7

Transportation

OP000813

5-4

Remove counterweight mounting bolts (1, Figure 8).

NOTE:

Make sure engine is shut down before removing

mounting bolts.

FG012334

Figure 8

10. Remove bolts

(1, Figure

9), lock washers

(2), plain

washers (3) and rear under cover (4).

FG012335

Figure 9

11. Remove bolts (1, Figure 10), lock washers (2), plain

washers (3) and open undercover (4).

FG012336

Figure 10

12. Position a trailer or support pallet behind machine.

NOTE:

Proper support pallet height: minimum 450 mm.

(17.7 in)

CAUTION

The support pallet must be 450 mm (17.7 in) - 600 mm

(23.6 in) in height. Never use a pallet that is less than

450 mm

450 mm (17.7 in) in height.

Ground

FG012337

Figure 11

OP000813

Transportation

5-5

13. Start engine and set speed to 1,200 rpm.

14. "OPEN" handle nut on stop valve.

In this position, the stop valve is "CLOSED."

II.

In this position, the stop valve is "OPENED."

FG012339

Figure 12

15. Push solenoid valve switch to "I" (ON) position.

O. In this position, the solenoid valve switch is turned

"OFF."

In this position, the solenoid valve switch is turned

"ON."

FG012340

Figure 13

16. Move removal control valve lever to "I" (DOWNWARD)

position, slowly and smoothly, to lower counterweight to

ground.

O. In this position, the removal control valve lever is in

"NEUTRAL."

In this position, the removal control valve lever moves

counterweight "DOWNWARD."

II.

In this position, the removal control valve lever moves

counterweight "UPWARD."

FG012341

Figure 14

WARNING

Be sure all personal and equipment are clear of area

where counterweight is being placed. Have an

assistant observe and be sure that area of operation

remains clear during removal.

Transportation

OP000813

5-6

17. The counterweight cannot be placed directly on ground.

Set counterweight on adequately sized and structurally

sound pallet or trailer. (See “Position a trailer or support

pallet behind machine.” on page 5-5.)

NOTE:

Proper support pallet height: minimum 450 mm.

(17.7 in)

18. Lower counterweight to pallet or trailer.

FG012342

Figure 15

19. Without operating solenoid valve switch, push or pull

removal control valve lever and then look for position

where lifting arms

(5, Figure

17) are loose on

counterweight.

FG012341

Figure 16

20. Remove hair pin (1, Figure 17) pins (2), from lifting arm (3)

connected to counterweight.

FG012343

Figure 17

21. Move removal control valve lever to "II" (UPWARD)

position, to raise lift arms above counterweight.

22. Install pins (2, Figure 17), hair pins (1) on lifting arms (3).

FG012344

Figure 18

OP000813

Transportation

5-7

Counterweight Installation

Park machine on firm, level ground, free from any

obstructions or interference. Make sure there is enough

room for a truck trailer to maneuver behind the unit.

Lower front end attachment to ground and make sure all

operating controls are in "NEUTRAL."

Shut down engine and inspect counterweight removal

device for defects, bent or damaged links, or any other

damage to device and its operating system components.

Inspect all hoses and fittings for removal device hydraulic

system. Correct if necessary.

Remove bolts (1, Figure 22), lock washers (2), plain

washers (3) and rear under cover (4).

FG012335

Figure 22

Remove bolts (1, Figure 23), lock washers (2), plain

washers (3) and open undercover (4).

FG012336

Figure 23

Open side door of pump compartment.

FG012338

Figure 24

OP000813

Transportation

5-9

Be sure solenoid valve switch (1, Figure 25) is in the "O"

(OFF) position.

O. In this position, the solenoid valve switch is turned

"OFF."

In this position, the solenoid valve switch is turned

"ON."

CAUTION

FG012332

Avoid personal injury from unexpected counterweight

Figure 25

movement. Do not go directly under machine

counterweight. To remove or install counterweight

hardware, go under machine entering from area on

either side of counterweight. The counterweight

weighs approximately 8,700 kg (19,180 lb, DX480LC),

10,350 kg (22,820 lb, DX520LC). Clear everyone from

area before removing or installing counterweight.

Be sure removal control valve lever (1, Figure 26) is in "O"

(NEUTRAL) position.

O. In this position, the removal control valve lever is in

"NEUTRAL."

In this position, the removal control valve lever moves

counterweight "DOWNWARD."

II.

In this position, the removal control valve lever moves

counterweight "UPWARD."

FG012333

Figure 26

10. "OPEN" handle nut on stop valve.

In this position, the stop valve is "CLOSED."

II.

In this position, the stop valve is "OPENED."

FG012339

Figure 27

Transportation

OP000813

5-10

11. Start engine and set speed to 1,200 rpm.

12. Push solenoid valve switch to "I" (ON) position.

O. In this position, the solenoid valve switch is turned

"OFF."

In this position, the solenoid valve switch is turned

"ON."

FG012340

Figure 28

13.

Move removal control valve lever to "I" (DOWNWARD)

position, slowly and smoothly, to lower lifting arms. While

lowering device, be sure to line up lifting arms with lifting

slots on counterweight.

O. In this position, the removal control valve lever is in

"NEUTRAL."

In this position, the removal control valve lever moves

counterweight "DOWNWARD."

II.

In this position, the removal control valve lever moves

counterweight "UPWARD."

FG012341

Figure 29

WARNING

Be sure all personal and equipment are clear of area

where counterweight is being placed. Have an

assistant observe and be sure that area of operation

remains clear during removal.

14.

Install pins (2, Figure 30) and hair pins (1), to connect

lifting arm (3) to counterweight.

15.

Apply grease to designated locations. See “Removable

Counterweight Linkage lubrication (Optional)” on

page 4-59.

16.

Move removal control valve very slowly to "II" (UPWARD)

position, to raise counterweight.

FG012343

Figure 30

OP000813

Transportation

5-11

17. When counterweight is properly installed on upper frame,

temporarily install mounting bolts (1, Figure 31).

NOTE:

Make sure engine is shut down before installing

mounting bolts.

FG012334

Figure 31

18.

Without operating solenoid valve switch, push or pull

removal control valve lever and look for position that lifting

arms are loose on counterweight. Remove remaining

stress.

O. In this position, the removal control valve lever is in

"NEUTRAL."

In this position, the removal control valve lever moves

counterweight "DOWNWARD."

II.

In this position, the removal control valve lever moves

counterweight "UPWARD."

FG012341

Figure 32

19.

Install counterweight mounting bolts (1, Figure 31).

NOTE:

Tighten bolts to 250 kg•m torque (1,810 ft lb)

NOTE:

Make sure engine is shut down before installing

mounting bolts.

20.

"CLOSE" stop valve.

In this position, the stop valve is "CLOSED."

II.

In this position, the stop valve is "OPENED."

WARNING

To avoid injury, from unexpected counterweight

movement do not enter directly under machine

counterweight during removal or installation.

FG012339

Figure 33

Verify and confirm that solenoid valve control switch

has been turned "OFF" after removal or installation of

counterweight.

Transportation

OP000813

5-12

Track Frame Extension and Retraction

CAUTION

Be sure to clean all off all dirt and mud from tread surface of

center frame, and on side frames; otherwise, it may cause

bolts to loosen.

Operate machine with side frames retracted only when

loading and unloading machine, or during driving for

loading and unloading.

Do not retract side frames for excavating or during normal

driving and operation. If machine is operated with either

side frame retracted, or even one side frame retracted,

during operation, cabin/machine will become unstable. This

can cause damage to, center frame, side frames, bolts, etc.

There are only six bolts holding side frame at each location

instead of nine.

Operation with side frame retracted could even result in a

tip over, serious injury and death.

Track Width Adjustment

The DX480LC has a variable track width device that allows

tracks to be retracted 280 mm on each side of machine.

The retraction device should only be used during transportation.

During machine operation at a work site, track width device

should be adjusted to have widest track width. If not, stability of

machine will be greatly reduced, which could result in fatal

accidents and damage.

Frame Retraction

Remove nine bolts, harden washers and spacers

(1,

Figure 36) from side frame (2) to be retracted.

NOTE:

Do not loosen two bolts (3, Figure 36) on guide

(4).

NOTE:

Repeat procedure at other center frame support

(5, Figure 36).

Reference

Description

Number

Bolt

FG005496

Side Frame

Figure 36

Bolt

Guide

Center Frame Support

Transportation

OP000813

5-14

Turn superstructure so it is perpendicular to side frame to

be retracted. Raise side frame to approximately a 15°

angle from ground using a jack. Side frame should slide by

its own weight and hit against stop.

NOTE:

If side frame does not slide in this condition,

90 ~ 110

allow side frame that is not contacting ground to

move back and forth slowly. See Figure 37.

CAUTION

FG005497

Figure 37

The arm must be set at a 90 - 110° angle. Never set it

at an angle less than 90°

After side frame (1, Figure 38) has slid into place, lower

superstructure to ground. Install six spacers, harden

washers and bolts (2).

NOTE:

Tighten bolts to 175 kg•m (1,270 ft lb).

NOTE:

Repeat procedure at other center frame

support.

After bolts for one side frame are fastened, repeat Steps 1

thru 3 for other side frame.

Store remaining bolts, spacers and washers with machine.

FG005498

Figure 38

Frame Extension

Remove six bolts, harden washers and spacers (1, Figure

39) from side frame (2) to be extended.

NOTE:

Do not loosen two bolts (3, Figure 39) on guide

(4).

NOTE:

Repeat procedure at other center frame support

(5, Figure 39).

Reference

Description

Number

Bolt

FG005499

Side Frame

Figure 39

Bolt

Guide

Center Frame Support

OP000813

Transportation

5-15

Turn superstructure so it is perpendicular to side frame to

be extended.

NOTE:

Do not attach cable on side frame step.

Attach one end of cable (1, Figure 40) (6 x 19 normal Z to

ø14 - ø16 A type) on arm (2) and other end on side frame

(3). Connect it with an appropriate holding device on both

ends.

Raise side frame (3, Figure 40) slightly with jack and block

(4). Extend arm (2) gradually to slide side frame out until it

hits stop.

FG005501

Figure 40

After side frame (1, Figure 41) has slid into place, lower

superstructure to ground. Remove cable.

Install nine spacers, harden washers and bolts (2, Figure

41).

NOTE:

Tighten bolts to 175 kg•m (1,270 ft lb).

NOTE:

Repeat procedure at other track frame support.

After bolts for one side frame are fastened, repeat Steps

thru 6 for other side frame.

FG005500

Figure 41

Transportation

OP000813

5-16

LOADING AND UNLOADING

Warning for Counterweight and Front

Attachment Removal

DANGER

DOOSAN warns any user, that removal of counterweight

from machine, front attachment or any other part, may

affect stability of machine. This could cause unexpected

movement, resulting in death or serious injuries. DOOSAN

is not liable for any misuse.

Never remove counterweight or front attachment unless

upper structure is in-line with lower structure.

FG000371

Never rotate upper structure once counterweight or front

Figure 42

attachment has been removed.

WARNING

When transporting machine, know width, height, length and

weight.

Loading or unloading machine can be a dangerous

operation. Make sure to run engine at lowest speed setting,

and travel at slowest speed possible.

Make sure that ramp being used can handle weight of

machine. If required, add blocking under ramp for additional

support.

Make sure that ramp surface is free of grease or mud that

could cause machine to slip or slide.

Make sure that trailer is parked on firm, level ground before

attempting to load/unload excavator.

If it is required to turn machine while it is on trailer, make

sure to do this at slowest engine and travel speeds

possible.

Make sure to secure excavator onto trailer as required by

local transportation laws.

OP000813

Transportation

5-17

Boom and

Model

Arm

Total Height

Total Width

Total Length

Weight

Shoes

3.35 m

7.1 m (23.3 ft)

3,730 mm

3,340 mm

12,130 mm

47.5 metric tons

DX480

(11.0 ft)

boom

(12' 3")

(10' 11")

(477.56 in)

(52.35 tons)

arm

600 g shoe

2.9 m

6.3 m (20.7 ft)

4,200 mm

3,340 mm

11,430 mm

50.7 metric tons

(9.51 ft)

boom

(13' 9")

(11' 0")

(37' 6")

(55.9 tons)

arm

600 g shoe

DX520

2.4 m

6.3 m (20.7 ft)

4,100 mm

3,340 mm

11,620 mm

50.7 metric tons

(7.87 ft)

boom

(13' 5")

(11' 0")

(38' 1")

(55.9 tons)

arm

600 g shoe

Make sure that trailer is parked on firm, level ground. See

Figure 43.

Make sure that ramps that are being used are designed to

handle weight of excavator. If required, add blocking under

90 ~ 110

ramp to provide additional support.

The ramp angle should be less than or not exceeding a 15°

angle. Ramps steeper than this may cause a problem

when loading or unloading.

FG000325

Figure 43

Set travel speed selector switch to "O" (OFF) position. See

Figure 44.

FG000023

Figure 44

Turn "OFF" auto idle selector button (1, Figure 45). The

indicator symbol will be disappeared.

Set engine speed to "LOW IDLE."

FG013833

Figure 45

Transportation

OP000813

5-18

If machine is equipped with work equipment, set work

equipment at front, and travel forward to load it.

90 ~ 110

FG000325

Figure 46

The unit does not require disassembly for normal

over-the-road transportation. If boom and arm need to be

removed, counterweight will place more weight on rear of

machine. Make sure to back excavator onto trailer so

counterweight end of excavator is positioned on ramp first.

See Figure 47.

FG000326

Figure 47

Extend bucket and arm cylinders to maximum length and

then lower boom slowly.

FG000327

Figure 48

10. Set safety lever on "LOCK" position.

Unlock

Lock

FG001091

Figure 49

OP000813

Transportation

5-19

11. Shut down engine by turning key to "O" (OFF) position

(Figure 50).

O I

12. Remove key from starter switch.

FG000175

Figure 50

13. Make sure to secure excavator onto trailer before

transporting. Place blocking (1, Figure 51) in front of and

behind each track. Use chains or cable tie-downs (2) as

required by local transportation laws.

14. Refer to Dimensions for Transportation table and drawing

for overall machine height and width measurements. Make

sure to position excavator as shown. If not transported in

this position, height measurements may be different.

FG000334

Figure 51

LIFTING WITH SLING

WARNING

Improper lifting can allow load to shift and cause injury or

damage.

Refer to “Specification” on page 7-1 of this manual for

information on weight and dimensions.

Use properly rated cables and slings for lifting.

Position machine for a level lift.

Lifting cables should have a long enough length to prevent

contact with machine. Spreader bars may be required.

NOTE:

If spreader bars are used, be sure that cables

Figure 52

are properly secured to them and that angle of

cables is factored into lift strength.

Transportation

OP000813

5-20

OP000030

6Troubleshooting

Anytime that a malfunction occurs, take immediate corrective

action. Check for and investigate the cause of the malfunction. A

schedule maintenance program can prevent malfunctions from

occurring by doing preventative maintenance. A systematic

approach should be taken to troubleshooting, since several

overlapping malfunctions may give the appearance of a problem

that does not exist. If cause for the malfunction cannot be

determined, contact your DOOSAN distributor. Never perform

an adjustment of or disassembly of, hydraulic components,

electrical and electronic components, without first consulting a

DOOSAN distributor.

ELECTRICAL SYSTEM

Problem

Cause

Remedy

Battery will not hold a

Low battery power.

Clean and retighten.

charge.

Alternator belt loose or bad.

Tighten or replace belt.

Loose or corroded terminals.

Tighten or replace as required.

Alternator faulty.

Repair or replace as required.

Low battery power.

Internal battery short.

Replace battery.

Short circuit in wiring.

Repair as required.

Engine speed is not

Speed control dial failed.

Replace control dial.

controllable.

Throttle controller failed.

Replace controller.

Speed control motor failed.

Repair or replace as required.

Blown fuse.

Replace fuse.

Wiring harness damaged.

Repair or replace as required.

Connector failed.

Repair or replace as required.

Power mode selector does

Blown fuse.

Replace fuse.

not work.

Power mode selector switch failed.

Replace switch.

Connector failed.

Replace connector.

Wiring harness damaged.

Repair or replace as required.

e-EPOS controller failed.

Repair or replace as required.

OP000030

Troubleshooting

6-1

Problem

Cause

Remedy

Working mode selector does

Blown fuse.

Replace fuse.

not work.

Working mode selector switch.

Replace switch failed.

Connector failed.

Replace connector.

Wiring harness damaged.

Repair or replace as required.

e-EPOS controller failed.

Repair or replace as required.

ENGINE

Problem

Cause

Remedy

Starter does not operate.

Low battery power.

Charge battery.

Poor terminal contact.

Clean and tighten connections.

Starter switch failed.

Replace switch.

Starter relay failed.

Replace relay.

Starter controller failed.

Replace controller.

Wiring harness faulty.

Replace harness.

Battery relay failed.

Replace relay.

Blown fuse.

Replace fuse.

Starter engages, engine

Fuel gelled in cold weather.

Replace fuel.

does not start.

Fuel filters plugged.

Replace filters.

Water or dirt in fuel system.

Clean system and add new fuel.

Air in fuel system.

Purge air from system.

Engine stop control failed.

Contact your DOOSAN dealer.

Engine stop relay failed.

Replace relay.

Blown fuse.

Replace fuse.

Engine starts, runs only at

Engine oil viscosity incorrect.

Change oil.

low speed or shuts down.

Clogged or dirty fuel injectors.

Clean injectors.

Fuel filters plugged.

Replace filters.

Troubleshooting

OP000030

6-2

Problem

Cause

Remedy

Engine knocks, runs

Low engine oil.

Refill.

unevenly or surges.

Plugged air intake system.

Clean system and replace filter.

Injection pump out of adjustment.

Contact your DOOSAN dealer.

Plugged fuel filter.

Replace fuel filter.

Water or dirt in fuel system.

Clean system and add new fuel.

Clogged or dirty fuel injectors.

Clean injectors.

Engine has poor power.

Plugged air intake system.

Clean system and replace filter.

Clogged or dirty fuel injectors.

Clean injectors.

Fuel filters plugged.

Replace filters.

Engine speed control cable out of

Readjust.

adjustment.

Injection pump out of adjustment.

Contact your DOOSAN dealer.

Valve backlash faulty.

Adjust backlash.

Engine runs hot.

Low coolant level.

Add coolant.

Thermostat faulty.

Replace thermostat.

Radiator cap faulty.

Replace radiator cap.

Radiator core plugged.

Clean radiator.

Oil cooler core plugged.

Clean oil cooler.

Fan belt loose or damaged.

Tighten or replace as required.

Temperature sensor faulty.

Replace sensor.

HYDRAULIC SYSTEM

Problem

Cause

Remedy

None of the controls

Hydraulic pump failed.

Contact your DOOSAN dealer.

function (loud noise from

Low hydraulic oil level.

Add hydraulic oil as required.

pumps).

Suction line plugged or damaged.

Clean or replace as required.

None of the controls

Pilot pump failure.

Contact your DOOSAN dealer.

function (no noise from

Cut off solenoid valve failed.

Replace solenoid.

pumps).

Pilot cutoff switch is ON.

Adjust pilot cutoff switch clearance.

OP000030

Troubleshooting

6-3

Problem

Cause

Remedy

All actuators have low

Low hydraulic oil level.

Add hydraulic oil as required.

power.

Suction filter clogged.

Clean filter.

Hydraulic pumps faulty.

Contact your DOOSAN dealer.

Main relief pressure too low.

Contact your DOOSAN dealer.

Hydraulic pumps excavating.

Bleed air from hydraulic pumps.

Only one or two actions

Overload relief pressure too low.

Reset pressure.

have little or no power.

Makeup check valve leaking.

Clean or replace as required.

Control valve spool faulty.

Replace valve spool.

Dirt in valve spool.

Clean or replace as required.

Actuator failed.

Repair or replace as required.

Cylinder seal failed.

Repair or replace as required.

Cylinder rod damaged.

Repair or replace as required.

Remote control valve failed.

Replace control valve.

Wrong pilot line connection.

Reconnect pilot lines.

Oil temperature too high.

Oil cooler faulty.

Contact your DOOSAN dealer.

Fan belt loose.

Tighten fan belting as required.

SWING SYSTEM

Problem

Cause

Remedy

No swinging motion.

Swing brake valve faulty.

Replace brake valve.

Hydraulic timer faulty.

Replace timer.

Low brake release pressure.

Adjust pressures.

Swing motor failed.

Replace swing motor.

Remote control valve failed.

Replace control valve.

Wrong pilot line connection.

Reconnect pilot lines.

Swing motion jerky.

Swing gear worn.

Replace swing gear.

Swing bearing damaged.

Replace bearing.

Improper lubrication.

Add grease.

Troubleshooting

OP000030

6-4

TRAVEL SYSTEM

Problem

Cause

Remedy

Travel motion does not

Center joint leaking.

Repair or replace as required.

function.

Parking brake will not release.

Repair parking brake.

Travel motor failed.

Repair or replace as required.

Remote control valve failed.

Repair or replace as required.

Wrong pilot line connection.

Reconnect pilot lines.

Travel speed is too low.

Track tension too high or too low.

Adjust tension.

Damaged rollers or idlers.

Repair or replace as required.

Track frame damaged.

Repair as required.

Parking brake will not release.

Repair parking brake.

OP000030

Troubleshooting

6-5

OP000814

7Specification

DX480LC

Standard Specification

SPECIFICATION

COMPONENT

METRIC

ENGLISH

Bucket

CECE

1.9 m³

2.47 yd³

capacity

PCSA

2.15 m³

2.81 yd³

Equipment weight

47.5 metric tons

52.3 tons

Engine

Model

DV11

Type

Water cooled - 6 cylinders

Rated output

333 ps @1,800 rpm

328 hp @1,800 rpm

Maximum torque

1,136 ft lb @ 1,300

157 kg•m @ 1,300 rpm

rpm

Fuel tank capacity

620 liters

164 U.S. gal.

Hydraulic

Type

Axial piston

pump

Discharging pressure

5,000 psi

350 kg/cm²

Maximum discharge quantity

2 x 355 liters/min

2 x 93.7 U.S. gpm

Hydraulic oil

Tank Level

265 liters

70 U.S. gal.

capacity

System

500 liters

132 U.S. gal.

Performance

Digging

Bucket

27.6 metric tons

30.4 tons

capability

Arm

22.0 metric tons

24.2 tons

Swing speed

8.8 rpm

Travel speed

High speed

5.0 km/h

3.11 MPH

Low speed

3.1 km/h

1.92 MPH

Traction force

High speed

17.8 metric tons

19.6 tons

Low speed

33.6 metric tons

37 tons

Gradeability

35° (70% slope)

Ground pressure

11.8 psi

0.81 kg/cm²

Ground clearance

770 mm

30.3 in

Track shoe width

600 mm

23.6 in

Upper roller qty.

3 per side

Bottom roller qty.

9 per side

OP000814

Specification

7-1

6.3 m

7.1 m (23.3 ft) BOOM

(20.7 ft)

7.1 m (23.3 ft) BOOM

BOOM

DIMENSION

3.35 m

2.9 m

3.98 m

2.9 m

3.35 m

(11.0 ft)

(9.51 ft)

(13.1 ft)

(9.51 ft)

(11.0 ft)

ARM

Remarks

Variable

RCW

Fixed

12,130 mm

12,230 mm

12,210 mm

11,430 mm

12,230 mm

12,180 mm

(39' 10")

(40' 1")

(37' 6")

(40' 1")

(39' 12")

3,800 mm

3,700 mm

3,700 mm (12' 2")

(12' 6")

(12' 2")

8,430 mm

8,530 mm

8,510 mm

7,730 mm

8,430 mm

8,480 mm

(27' 8")

(28' 0")

(27' 11")

(25' 4")

(27' 8")

(27' 10")

4,470 mm (14' 8")

5,465 mm (17' 11")

1,250 mm

1,310 mm

* 1,460 mm (4' 9") / 1,470 mm (4' 10")

(4' 1")

(4' 4")

3,730 mm

3,900 mm

3,935 mm

4,200 mm

3,730 mm

3,720 mm

(12' 3")

(12' 10")

(12' 11")

(13' 9")

(12' 3")

(12' 2")

2,990 mm (9' 10") / 3,296 mm (10' 10") CAT Walk

1,500 mm (4' 11") / 1,806 mm (5' 11") CAT Walk

1,490 mm (4' 10")

2,750 mm

K (Std)

3,300 mm (10' 10") / 2,740 mm (9' 0") (Transport position)

(9' 0")

K (Narrow)

2,920 mm (9' 7") / 2,360 mm (7' 9") (Transport position)

3,350 mm

L (Std)

3,900 mm (12' 10") / 3,340 mm (11' 0") (Transport position)

(10' 12")

L (Narrow)

3,520 mm (11' 7") / 2,990 mm (9' 10") (Transport position)

600 mm (1' 12")

570 mm

* 770 mm (2' 6") / 780 mm (2' 7")

(1' 10")

3,200 mm

* 3,350 mm (10' 12") / 3,465 mm (11' 4")

(10' 6")

* HD TYPE

OP000814

Specification

7-3

Working Range

G.L

-1

-2

-3

-4

-5

-6

-7

-8

FG004616

Figure 2

BOOM TYPE

7.1 m (23.3 ft)

6.3 m (20.7 ft)

DIM.

3.35 m

2.9 m

3.98 m

* 3.35 m

** 3.35 m

2.9 m

ARM TYPE

(11.0 ft)

(9.5 ft)

(13.1 ft)

(11.0 ft)

(9.5 ft)

Max. digging

12,120 mm

11,720 mm

12,670 mm

12,150 mm

12,120 mm

10,770 mm

radius

(39' 9")

(38' 5")

(41' 7")

(39' 10")

(39' 9")

(35' 4")

Max. digging

7,810 mm

7,360 mm

8,440 mm

7,850 mm

7,655 mm

6,810 mm

depth

(25' 7")

(24' 2")

(27' 8")

(25' 9")

(25' 1")

(22' 4")

Max. digging

11,080 mm

10,940 mm

11,230 mm

10,930 mm

10,925 mm

9,720 mm

height

(36' 4")

(35' 11")

(36' 10")

(35' 10")

(31' 11")

Max. dump

7,880 mm

7,730 mm

8,040 mm

7,850 mm

7,725 mm

6,595 mm

height

(25' 10")

(25' 4")

(26' 5")

(25' 9")

(25' 4")

(21' 8")

Min. digging

5,170 mm

5,190 mm

5,140 mm

5,170 mm

4,750 mm

radius

(16' 12")

(17' 0")

(16' 10")

(16' 12")

(15' 7")

* HD TYPE / ** FIXED TRACK

Specification

OP000814

7-4

DX520LC

Standard Specification

SPECIFICATION

COMPONENT

METRIC

ENGLISH

Bucket

CECE

2.87 m³

3.75 yd³

capacity

PCSA

3.2 m³

4.19 yd³

Equipment weight

50.7 metric tons

55.9 tons

Engine

Model

DV11

Type

Water cooled - 6 cylinders

Rated output

333 ps @1,800 rpm

328 hp @1,800 rpm

Maximum torque

1,136 ft lb @ 1,300

157 kg•m @ 1,300 rpm

rpm

Fuel tank capacity

620 liters

164 U.S. gal.

Hydraulic

Type

Axial piston

pump

Discharging pressure

350 kg/cm²

5,000 psi

Maximum discharge quantity

2 x 355 liters/min

2 x 93.7 U.S. gpm

Hydraulic oil

Tank Level

265 liters

70 U.S. gal.

capacity

System

500 liters

132 U.S. gal.

Performance

Digging

Bucket

27.6 metric tons

30.4 tons

capability

Arm

22.0 metric tons

24.2 tons

Swing speed

8.8 rpm

Travel speed

High speed

5.0 km/h

3.11 MPH

Low speed

3.1 km/h

1.92 MPH

Traction force

High speed

17.8 metric tons

19.6 tons

Low speed

33.6 metric tons

37 tons

Gradeability

35° (70% slope)

Ground pressure

0.88 kg/cm²

12.5 psi

Ground clearance

770 mm

30.3 in

Track shoe width

600 mm

23.6 in

Upper roller qty.

3 per side

Bottom roller qty.

9 per side

OP000814

Specification

7-5

6.3 m (20.7 ft)

9.0 m (29.5 ft)

11.0 m (36.1 ft)

6.3 m (20.7 ft)

BOOM

DIMENSION

2.9 m (9.51 ft)

2.4 m (7.87 ft)

6.0 m (19.7 ft)

8.0 m (26.3 ft)

2.9 m (9.51 ft)

ARM

Remarks

Variable

RCW

Fixed

11,430 mm

11,620 mm

14,050 mm

16,090 mm

11,430 mm

11,420 mm

(37' 6")

(38' 1")

(46' 1")

(52' 9")

(37' 6")

3,800 mm

3,700 mm

3,700 mm (12' 2")

(12' 6")

(12' 2")

7,730 mm

7,920 mm

10,350 mm

12,390 mm

7,630 mm

7,720 mm

(25' 4")

(25' 12")

(33' 11")

(40' 8")

(25' 0")

(25' 4")

4,470 mm (14' 8")

5,465 mm (17' 11")

1,250 mm

1,310 mm

1,460 mm (4' 9")

(4' 1")

(4' 4")

4,200 mm

4,100 mm

3,910 mm

4,070 mm

4,200 mm

4,160 mm

(13' 9")

(13' 5")

(12' 10")

(13' 4")

(13' 9")

(13' 8")

2,990 mm (9' 10") / 3,296 mm (10' 10") CAT Walk

1,500 mm (4' 11") / 1,806 mm (5' 11") CAT Walk

1,490 mm (4' 10")

2,750 mm

K (Std)

3,300 mm (10' 10") / 2,740 mm (9' 0") (Transport Position)

(9' 0")

K (Narrow)

2,920 mm (9' 7") / 2,360 mm (7' 9") (Transport Position)

3,350 mm

L (Std)

3,900 mm (12' 10") / 3,340 mm (11' 0") (Transport Position)

(10' 12")

L (Narrow)

3,520 mm (11' 7") / 2,990 mm (9' 10") (Transport Position)

600 mm (1' 12")

570 mm

770 mm (2' 6")

(1' 10")

3,200 mm

3,350 mm (10' 12")

(10' 6")

OP000814

Specification

7-7

Doosan DX480LC, DX520LC. Operation and Maintenance Manual (2009) - page 5