DRESSTA 515C, 520C Operator's Manual

OM515C520C99/1E

OPERATOR`S MANUAL

515C - 520C

SERIAL NUMBER 7001

AND UP

9001 AND UP FOR 515CH

SERIAL NUMBER 11001

AND UP

13001 AND UP FOR 520CH

DRESSTA Co. Ltd.

A JOINT VENTURE OF KOMATSU AMERICA INTERNATIONAL CO. AND HUTA STALOWA WOLA S.A.

FOREWORD

Welcome to the growing group of value-conscious people who operate DRESSTA machines

This manual covers the instructions for safe operation, lubrications, adjustments and maintenance
for normal daily care. These instructions are divided into six sections to simplify your reference to
the information most important to you. Refer to the contents page at the beginning of the section for
a complete list of the subjects covered except for Section 2, which should be read entirely.

This manual has been prepared to help you operate and maintain your machine with utmost
efficiency and safety. Read this manual thoroughly and learn your machine before you attempt to
operate it.

It is our policy to improve our products whenever it is possible and practical to do so. We reserve
the right to make changes or add improvements at any time without incurring any obligation to
install such changes on products sold previously.

Due to this continuous program of research and development, periodic revisions may be made to
this publication. It is recommended that customers contact their distributor for information on the
latest revision.

We hope you will be able to use our machines safety and to the best advantage.

DRESSTA Co. Ltd.

This material is proprietary to DRESSTA Co. Ltd. and is not to be reproduced, used or disclosed
except in accordance with written authorization from DRESSTA Co. Ltd.

DRESSTA OM515C520C99/1E

OM515C520C99/1E DRESSTA

SECTION INDEX

Section 1 Introduction.......................................................................................................................1.1

Section 2 Safety Precautions...........................................................................................................2.1

Section 3 Storage and Shipping.......................................................................................................3.1

Section 4 Operating..........................................................................................................................4.1

Section 5 Maintenance.....................................................................................................................5.1

Section 6 Specifications...................................................................................................................6.1

DRESSTA OM515C520C99/1E

SECTION CONTENTS

SECTION 1 - INTRODUCTION

This section discusses the use of this manual and serial number locations.

SECTION 2 - SAFETY PRECAUTIONS

This section lists safety rules concerning personal safety. Read this section carefully and observe
safety precautions specified herein.

SECTION 3 - STORAGE AND SHIPPING

This section discusses how to ship or store this machine.

SECTION 4 - OPERATING

The front portion of this section provides you with instructions for trouble free operation of the
machine. A universal symbol chart for instruments and controls designation is provided. The
instruments and controls area is designed to tell you "where it is, what it does and how to use it".
Read this area carefully. The remaining portion of this section outlines and illustrates the step-by­step procedures for starting, operating and stopping the machine and discusses a few operating
suggestions and techniques and simple ideas to help ease the work and lengthen the useful life of
your machine.

SECTION 5 - MAINTENANCE

The beginning of this section outlines a complete scheduled maintenance program, which helps to
reduce down-time and expense, and increase the profit and work from your machine. Read and
use this area. Following the maintenance program are the lubrication recommendations and
requirements for the machine. The remainder of the section is devoted to clearly explaining the
"how to" of the many maintenance and adjustment procedures listed in the maintenance program.

SECTION 6 - SPECIFICATIONS

This section covers the general dimensions schematics, forces and weights, refill capacities,
ground speeds and the standard and special torque values.

DRESSTA OM515C520C99/1E

SECTION CONTENTS

1. INTRODUCTION

1.1. Introduction ............................................................................................................................. 3

1.2. Serial Numbers ....................................................................................................................... 5

2. SAFETY PRECAUTIONS

2.1. General ................................................................................................................................... 3

2.2. Before Starting the Engine ...................................................................................................... 4

2.3. Operating the Machine ............................................................................................................ 4

2.4. General Maintenance Precautions ......................................................................................... 6

2.5. When Parking ....................................................................................................................... 10

2.6. Safety Graphics Location ..................................................................................................... 11

3. MACHINE TRANSPORT AND STORAGE

3.1. Machine Transport ...................................................................................................................3

3.2. Lifting on Slings ........................................................................................................................5

3.3. Moving a Disabled Machine .....................................................................................................6

3.4. Machine Storage ......................................................................................................................7

4. OPERATING

4.1. General ................................................................................................................................... 3

4.2. Universal Symbols for Instruments and Controls ................................................................... 4

4.3. Instruments and Controls ....................................................................................................... 8

4.4. Cab Door and Windows ....................................................................................................... 20

4.5. Operator’s Seat .................................................................................................................... 21

4.6. Seat Belt ............................................................................................................................... 24

4.7. Cab Heating and Ventilation .................................................................................................. 25

4.8. Air Cleaner Service Indicator .................................................................................................27

4.9. Electrical Master Switch ....................................................................................................... 27

4.10. Dome Lights with Switches .................................................................................................. 28

4.11. Starting and Stopping the Engine ......................................................................................... 28

4.12. Driving the Machine .............................................................................................................. 30

4.13. Shifting Gears ....................................................................................................................... 32

4.14. Steering ................................................................................................................................. 32

4.15. Stopping the Machine ........................................................................................................... 33

4.16. Parking the Machine ............................................................................................................. 34

4.17. Loader Operations ................................................................................................................ 34

4.18. Loader Techniques ............................................................................................................... 41

4.19. Economical Operation of the Machine ................................................................................. 54

4.20. Quickcoupling ........................................................................................................................54

4.21. Ride Stabilizing Mechanism ..................................................................................................56

4.22. High-Dump Bucket ............................................................................................................... 57

DRESSTA OM515C520C99/1E

5. MAINTENANCE

5.1. General Precautions ............................................................................................................... 3

5.2. Scheduled Maintenance Guide ............................................................................................... 4

5.3. Maintenance and Service Chart .............................................................................................. 6

5.4. Lubrication ............................................................................................................................... 9

5.5. Seasonal Preparations .......................................................................................................... 14

5.6. Air Cleaning System .............................................................................................................. 15

5.7. Brakes ................................................................................................................................... 19

5.8. Cooling System ..................................................................................................................... 22

5.9. Drive Axles ............................................................................................................................ 27

5.10. Electrical System .................................................................................................................. 29

5.11. Engine ................................................................................................................................... 31

5.12. Ether Injector ......................................................................................................................... 37

5.13. Fuel System .......................................................................................................................... 38

5.14. Hydraulic System .................................................................................................................. 42

5.15. Seat Belt ................................................................................................................................ 47

5.16. Steering Gear ........................................................................................................................ 47

5.17. Tires and Rims ...................................................................................................................... 47

5.18. Transmission System ........................................................................................................... 48

5.19. ROPS Cab and ROPS Canopy .............................................................................................53

5.20. Hood Assembly and Radiator Grill ........................................................................................ 54

5.21. Loader Equipment ................................................................................................................. 55

5.22. Air Conditioner or Heater ....................................................................................................... 56

6. SPECIFICATIONS

6.1. Application ............................................................................................................................... 3

6.2. Technical Description ............................................................................................................. 3

6.3. Schematic of 515C and 520C Wheel Loader Drive Train ...................................................... 4

6.4. Schematic of Transmission Hydraulic System ...................................................................... 5

6.5. Loader Equipment and Steering Hydraulic System Schematic ............................................. 6

6.6. Wiring Diagram...................................................................................................................... 14

6.7. Brake Hydraulic System Schematic...................................................................................... 25

6.8. Specifications ........................................................................................................................ 26

6.9. 515C and 520C Loader Equipment ...................................................................................... 32

6.10. Torque Values for Standard Metric Fasteners ...................................................................... 35

6.11. Torque Values for Standard English Fasteners .................................................................... 35

6.12. Torque Values for Split Flange Connections ........................................................................ 36

6.13. Torque Values for Hydraulic Tubes and Fittings ................................................................... 37

6.14. Torque Values for Hose Clamps ........................................................................................... 37

6.15. Torque Values for Air Conditioning Tubes and Fittings ......................................................... 38

6.16. Torque Values for Air Conditioning O-Ring Connections ..................................................... 38

6.17. Special Torques .................................................................................................................... 39

6.18. Service Tools ........................................................................................................................ 40

OM515C520C99/1E DRESSTA

SECTION 1

INTRODUCTION

INTRODUCTION SECTION 1

SECTION CONTENTS

1.1. Introduction ............................................................................................................................. 3

1.2. Serial Numbers ....................................................................................................................... 5

DRESSTA OM515C520C99/1E

INTRODUCTION SECTION 1

Page 3

1.1. INTRODUCTION

Fig. 1.1. 515 Series C Wheel Loader

a - Right Hand Side of the Machine
b - Left Hand Side of the Machine

c - Front of the Machine
d - Rear of the Machine

Fig. 1.2. 520 Series C Wheel Loader

a - Right Hand Side of the Machine
b - Left Hand Side of the Machine

DRESSTA OM515C520C99/1E

c - Front of the Machine
d - Rear of the Machine

SECTION 1 INTRODUCTION

Page 4

INTRODUCTION

GENERAL

Throughout this manual there will be two types of cross references. One type - numerical - refers to
a heading within the same section. The other type - numerical followed by the section
title - refers to a heading in another section. Refer to the section contents page at the beginning of
the individual sections for specific page numbers.

Throughout this manual the use of the terms "left", "right", "front", and "rear" must be understood to
avoid confusion when following the instructions. "Left" and "right" indicate the left and right sides of
the machine when facing forward in the operator's seat. The „front” is in front of the operator, the
„rear” - behind his back. See Fig. 1.1, 1.2.

Some illustrations are of general application of this model and may not show your machine
accurately in all details.

The loaders are available in 2 different versions:

1. standard version equipped with a mechanical feedback steering and a hydraulic system
controlled with either 2 or 3 levers mechanically connected with a 2 or 3-spool control valve
respectively.

2. upgraded version: equipped with a hydraulic feedback steering and a hydraulic system controlled
with 1 or 2 levers hydraulically connected with a 2 or 3-spool control valve respectively. In this
version it can be configured as CE version according to EC directives.

WARNING!: This symbol and text in bold letters is used throughout this manual
to call your attention to instructions concerning personal safety. Observe and
follow these instructions. Be certain anyone operating and servicing this
machine is aware of these rules. Failure to follow these rules may result in injury
or death.

IMPORTANT: This sign and text in italics is used throughout this manual to call your attention to
key problems for machine operation. Failure to follow such instructions may result in damage of the
machine and heavy material losses.

NOTE: This sign and text in italics is used throughout this manual to call your attention to important
function having influence on the right functioning of the machine or for informational purposes.

OM515C520C99/1E DRESSTA

INTRODUCTION SECTION 1

Page 5

1.2. SERIAL NUMBERS

Fig.1.3. Location of Machine Serial Number plates

1. The machine serial number plate is located at the bottom of the left hand side of the cab. It is

also stamped on the left rear corner of the rear frame.

Fig.1.4. Location of stamped machine serial number

Fig.1.5. Engine Serial Number Plate

DRESSTA OM515C520C99/1E

SECTION 1 INTRODUCTION

Page 6

SERIAL NUMBERS

2. The engine serial number plate is located on the left hand side of the engine in the space

designated “Engine serial number” (Fig. 1.5).

Fig.1.6. Cab Serial Number Plate

3. The cab serial number plate is located inside the cab in the right front corner near the floor board

(Fig. 1.6).

All other main components having serial numbers are each equipped with a separate serial number
plate or the number is stamped on the component body.

Use respective serial numbers when requesting information or ordering parts and proper numbers
from Parts Catalogue.

OM515C520C99/1E DRESSTA

SECTION 2

SAFETY PRECAUTIONS

SAFETY PRECAUTIONS SECTION 2

SECTION CONTENTS

2.1. General .............................................................................................................................. 3

2.2. Before Starting the Engine ................................................................................................ 4

2.3. Operating the Machine ...................................................................................................... 4

2.4. General Maintenance Precautions .................................................................................... 6

2.5. When Parking .................................................................................................................. 10

2.6. Safety Graphics Location ................................................................................................ 11

2.6.1. Safety Graphics ..................................................................................................... 12

2.6.2. Safety Graphics (Version CE) ................................................................................ 16

DRESSTA OM515C520C99/1E

SAFETY PRECAUTIONS SECTION 2

Page 3

2.1. GENERAL

WORK SAFELY - FOLLOW THESE RULES

WARNING!: This symbol and text with bold letters is used throughout this manual
to call your attention to instructions concerning personal safety. Observe and
follow these instructions. Be certain anyone operating and servicing this
machine is aware of these rules. Failure to follow these rules may result in injury
or death.

Recommendations and information given in this Section do not cover all subjects to be acquired for
safe operating of the machine. Detailed information respecting safe operating of the machine are
specified in the following Sections. Observe and follow these rules.

Operating and servicing this machine can be hazardous if performed improperly. Personnel must have
necessary skill information and use proper procedures and recommendations included in this manual.

Only trained and authorized personnel should be allowed to operate and service this machine.
Do not rush. Hurrying can lead to accidents. Haste, carelessness and lack of training are the primary

causes of equipment-related injuries.
The machine must be equipped with a fully charged fire extinguisher recharged immediately after use

and first-aid kit. The fire extinguisher is fixed on the floor at the left band side of the operator’s seat.
Operator’s seat must be equipped with safety belt. Also, the machine must be equipped with
a safety triangle.

If the machine is equipped with outside ventilation check the engine exhaust system periodically for
leaks. Exhaust gases are dangerous to the operator. On machines equipped with a cab without
outside ventilation, keep sliding windows open to outside air.

The operator must not wear loose fitting or hanging clothing, belts or jewelry and must wear shoes with
non-slipping soles as well as a hard hat insulated during cold weather.

Do not jump on or off the machine. Keep two hands and one foot, or two feet and one hand in contact
with the steps and handholds at all times. Always face the machine when climbing on or off to reduce
the chances of slipping and injury.

Follow all machine-mounted safety signs before starting, operating, maintaining or servicing the
machine.

The operator must be alert, physically fit and free from the influences of alcohol, drugs or
medications that might affect his eyesight, hearing, reactions or judgment.

Do not use controls or hoses as hand holds when climbing on or off the machine. The hoses and
controls can move and do not provide solid support. Movement of the controls may cause
inadvertent and unexpected movement of the machine or its equipment.

Be sure the area of the operator's compartment, all mounting steps and grab handles are free of
oil, grease, loose objects, ice and mud to lessen the possibility of slipping. All damaged steps or
grab handles should be repaired immediately. Remove or secure all maintenance and personal
items so they will not interfere with the operator or jam the controls.

DRESSTA OM515C520C99/1E

SECTION 2 SAFETY PRECAUTIONS

Page 4

2.2. BEFORE STARTING THE ENGINE

Never start the engine indoors unless proper exhaust ventilation is provided to remove deadly
exhaust gases. Once the engine is operating, move the machine outdoors as soon as possible.

Perform a visual check of the machine before starting the engine. Look for such things as
improper fluid levels, oil leaks, lack of safety equipment, concentration of dirt and loose, damaged
or missing parts. Do not start the engine until any unsafe conditions are corrected.

Be sure all filler caps, dipsticks, plugs, latches, service doors, etc. are secure before starting.
Walk completely around the machine before entering the operator's compartment, clear the

immediate area surrounding the machine of personnel and obstructions.
Know the alternative exit route from the operator's compartment for use in an emergency.
Sit in the operator's seat before starting the engine. Keep hands and footwear free of grease, water

and mud to insure positive control movement.
Before starting the engine or when the machine is standing with the engine running idle; lock the

transmission shift lever in neutral (N), apply the parking brake, and lower the bucket if raised.
Before operating the machine, check that the frame locking bar and pin are stowed on the rear frame.

Broken or lost frame locking bar and pin should be repaired or replaced immediately so that this device
is always available for use.

When using a booster battery and jumper cables, switch off the master switch, then connect the
positive terminal on the booster battery to the positive terminal of the battery on the machine. Connect
the negative terminal on the booster battery to the negative terminal of the battery on the machine.

2.3. OPERATING THE MACHINE

Release the parking brake before moving the machine. The brake could burn or be damaged if the
machine is driven with the brake applied.

Before driving the machine, adjust the seat and fasten the seat belt. Never wear the seat belt across
the abdomen.

Always carefully check overhead clearance before operating in areas with overhead obstructions such
as guy wires, power lines, bridges, tree branches and building doors).

Do not smoke when using the ether injector. Do not use the ether injector when the air temperature is
above freezing. Follow the correct method for starting the engine.

Before moving the machine, sound the horn to warn the nearby personnel.
Check the brakes, steering and attachment controls. All systems must be fully operative.
After starting and while operating, observe instruments and warning lights frequently. Investigate any

unusual indications or noises in the machine.

OM515C520C99/1E DRESSTA

SAFETY PRECAUTIONS SECTION 2

Page 5

OPERATING THE MACHINE

Before work know the locations of underground cables, water mains, gas lines, etc. A broken gas line
or electrical cable could cause personal injury or death.

Avoid undercutting high banks because the bank may cave in. Ramp up and remove the top layers
first.

Avoid operating too close to an overhang, deep ditch, or excavation because the machine's weight
may cause the edge to collapse and result in personal injury.

If the ground driven steering light comes on, immediately stop the machine in a safe place. Shut off the
engine and apply the parking brake. Correct the cause before operating again.

Keep the work area free from obstructions and as smooth as possible.
Turn on the machine's lights at night and times of poor visibility to see and be seen.
When loading trucks, be careful not to hit the truck with the loader or its bucket.
If engine has a tendency to stall for any reason under load or at idle, stop the machine immediately

and correct the malfunction.
Trucks should be loaded from the driver's side whenever possible. When the truck is being loaded, be

sure the driver either stays in the cab (on cab-protected trucks) or away from the truck and loader.
If the machine begins to tip over because of an overload, immediately lower the bucket to regain

stability.
Do not swing a load over the heads of other workers or a truck cab.
A machine's weight and the vibration it creates can cause the edge of a high wall to collapse. Keep

your machine back from the edges of banks and excavations. If this cannot be avoided, face the
machine towards the bank's edge while operating.

Operating in rough virgin terrain with such hazards as trees, logs, large rocks and brush calls for
special attention. Avoid falling branches and upturning roots.

When pushing over trees never allow the machine to climb up the root structure, especially when the
tree is being felled. Use extreme care when pushing over any tree with dead branches.

Operate at speeds low enough to ensure complete control of the machine. Travel slowly in congested
areas or on rough ground, slopes or near drop-offs or on snow, ice or slippery surfaces.

Maintain a safe distance between your machine and other vehicles according to the condition of the
road and load.

Keep the machine as close to the side of the road as is possible to provide for oncoming or passing
vehicles. Pass other vehicles only when the road is clear and there is enough room and reserve power
to pass.

Never try to get on or off the machine while it is moving. A serious injury or death could result.

DRESSTA OM515C520C99/1E

SECTION 2 SAFETY PRECAUTIONS

Page 6

OPERATING THE MACHINE

Never shift the transmission direction lever into neutral when travelling downhill. The machine may go
out of control and a rollover could result or the transmission, torque converter or engine could be
damaged when the transmission is again placed in gear. Always put the transmission in the low range
position before starting downhill. Use the accelerator pedal and brake pedal to slow the machine.

Never haul passengers. Only the operator should be on the machine when it is moving.
If the brake system warning light and buzzer come on during operation, immediately stop the machine

in a safe place. Apply the parking brake. Correct the cause before operating again.
Lock the levers when roading the machine so as not to actuate the levers accidentally.
Maintain clear vision of all work and travel areas. Keep the windows and mirrors clean and repaired.
Look in the mounted equipment control intended travel direction to be sure the personnel and allied

equipment do not interfere with the machine's work pattern. Do not operate if exposed personnel enter
the immediate work area.

When traveling fast or downhill never apply the brake and transmission disconnect pedal as this shifts
the transmission into neutral (N). The machine could go out of control or the power train could be
damaged when the pedal is released and the transmission is shifted into gear again.

Do not drive the machine without checking the brakes for correct operation.
Avoid sidehill travel whenever possible. Drive straight up and down the hill. If the machine starts

slipping sideways, turn downhill immediately, and lower the bucket.
Do not overspeed the engine. Excessive speeds can be hazardous and harmful to the power train.

Select the proper gear before starting downhill. Control the speed with the brakes.
Avoid crossing obstacles such as ditches, ridges, curbs, logs, rocks, and railroad tracks. If you cannot

avoid them, reduce speed and cross at an angle.
Never use the bucket as a brake except in an emergency.
Do not adjust the seat while the machine is moving because a loss of control may result. Stop the

machine, apply the parking brake and then adjust the seat.
Never allow anyone to stand on the ladder when the bucket is raised or the machine is moving.
Carry the bucket low for maximum visibility and stability when traveling.
Use extra caution when moving with the bucket raised. The stability is reduced as the bucket is raised.
Know the traffic flow patterns of the job site. Obey flagmen, signs and signals.
There is no substitute for good judgment when working on a slope. Slope operation should be limited

according to the ground and traction conditions, the load being carried, and the speed of the machine.

OM515C520C99/1E DRESSTA

SAFETY PRECAUTIONS SECTION 2

Page 7

2.4. GENERAL MAINTENANCE PRECAUTIONS

Replace any missing or defaced product graphics. When parts which have product graphics on them
are replaced, be sure to install new product graphics. New product graphics are available from the
Authorized Distributor of Construction Equipment.

Never let anyone near the machine's articulation pivot. If the machine is turned, they could be crushed.
Before servicing the machine use the frame safety bar to prevent accidental articulation.
Before servicing the machine, be sure the engine is off, the bucket is lowered, the transmission shift

lever is locked in neutral (N), the electrical system master switch is off and the key is removed. Tag the
machine.

Use only approved parts for repairs and maintenance. Failure to do so could compromise personal
safety, machine performance, and reliability.

Before working under the machine, block the tires to prevent machine movement.
It is not possible to anticipate all conceivable ways or conditions under which this machine may be

serviced or to provide precautions for all the possible hazards that may result. Safety is always the
most important rule. Constantly be aware of dangers involved in working on the machine and take
proper precautions. Standard and accepted safety precautions and equipment should be used.

Never attempt to start servicing close to the operating fan as it may result in serious injury.
When changing cutting edges, securely support the bucket for your protection.
If the bucket is provided with teeth, use special hammer for installation to prevent teeth breakage.

Wear safety goggles.
Lift and handle all heavy parts with lifting devices of adequate capacity. Secure the parts with proper

slings and hooks. Use lifting eyes provided. Warn the nearby personnel to stand clear.
Keep work area clean and dry. Remove water and oil spills immediately to reduce the chance

of slipping and injury.
Do not pile up oily or greasy rags; they are a fire hazard. Store them in an approved, closed metal

container.
Do not carry loose objects in your pockets because they might catch on the machine and result in

a fall or injury.
Use the proper tool for the job. Be sure all tools are in good condition. Do not use tools which are

worn, bent or have mushroomed heads because they can lead to injury.
Do not use the loader bucket or forks to lift personnel or as a work platform.
When service requires access to areas that cannot be reached from the ground or service platform on

the machine, use a ladder or platform of adequate size and capacity.
Never adjust relief valves higher than the specified pressure because this may damage the machine

and lead to injury. When checking pressures, use the correct gauge for the expected pressure.
Consult the Authorized Distributor of Construction Equipment

DRESSTA OM515C520C99/1E

SECTION 2 SAFETY PRECAUTIONS

Page 8

GENERAL MAINTENANCE PRECAUTIONS

Jacking up the machine can be hazardous if performed improperly. Use jacking equipment with
sufficient capacity. Be sure the jacking points are strong enough for the expected load. Be sure the
supports for the jacks are stable. Before jacking up the machine, block the tires on the opposite side of
the machine. Because the rear axle pivots, securely block it in position. Do not run the engine with the
machine on jacks. For your safety, support the machine before servicing if.

This machine is assembled using high strength fasteners. Replacement fasteners must be of the
same size and strength as the originals.

Refer to the parts catalog for this machine. Tighten fasteners to the proper torque.
When cutting, grinding, pounding, prying, or whenever material could fly or fall, wear proper protective

equipment (such as goggles, hard hat, safety shoes, and heavy gloves).
During servicing do not allow anyone in the operator's compartment who is not trained and assisting in

the servicing.
When it is necessary to make any checks or adjustments with the engine running, use two people.

A trained operator must be at the controls to safeguard the mechanic making the checks
or adjustments. Be sure the transmission shift lever is locked in neutral (N), the parking brake is
applied and the frame halves are locked together.

Never stand near the bucket or tires while the engine is running.
If compressed air or water under pressure is used for cleaning parts, wear safety goggles. Limit air

pressure to 200 [kPa] and water pressure to 270 [kPa].
Never run the engine when cleaning or lubricating the machine because serious injury could result

from contacting moving parts. Use a nontoxic, nonflammable commercial solvent for cleaning parts
unless otherwise specified.

Avoid use of gasoline, diesel fuel, kerosene or other flammable solvents for cleaning parts.
Never place these solvents in an open pan.
Use gloves and safety goggles when draining hot fluids.
For your safety lower the bucket before servicing the machine. Be sure no one is standing near the

bucket when it is being lowered.
Do not service the air conditioning system (if equipped) unless you are completely familiar with air

conditioning and the safety precautions for handling liquid refrigerant which can cause severe frostbite.
Contact the Authorized Distributor of Construction Equipment

Before working on the engine or electrical system turn off the starting switch and the master switch
and take the keys out. Tag the cables and controls to warn against starting.

Keep the engine exhaust manifold(s) and exhaust system clear of combustible material to reduce the
chance of fire.

Never remove any guards or shields with the engine running because of the danger of contacting
rotating parts.

OM515C520C99/1E DRESSTA

SAFETY PRECAUTIONS SECTION 2

Page 9

GENERAL MAINTENANCE PRECAUTIONS

Before working on the hydraulic system, be sure the system pressure is relieved. To do so lower the
bucket on the ground, move boom control lever in float position and switch off the engine.

Do not use hands to search for hydraulic leaks. Hydraulic oil escaping under pressure from a very
small hole can be almost invisible yet have sufficient force to penetrate the skin. Use a piece of
cardboard or wood to search for suspected leaks. If injured by escaping oil, see a doctor immediately
because of the possibility of infection or reaction to the oil.

Never work or walk under a raised bucket without proper blocking.
Use extra caution when adjusting the loader's bucket leveler or boom kick-out. Use two trained people

and guard against accidental movement of the machine or loader linkage.
The roll-over protective structure ROPS provides operator protection in the event of machine rollover

or upset. It is designed to bend during a rollover to protect the operator from sudden impact loads. Do
not attempt to repair a ROPS after an accident. Repaired structures do not provide the original
strength and protection. Contact the Authorized Distributor of Construction Equipment for information
on ROPS (or cab) replacement. Do not operate the machine again until the ROPS has been replaced.
Periodically inspect the ROPS for fatigue cracks. Cracks indicate a weakened structure which should
be replaced for your protection. Bolts fastening cab or ROPS must be torqued to
a specific value. Do not cut, grind, weld, drill or tap holes in the ROPS This could weaken the structure
or affect the overall energy absorption capability. Always wear the seat belt during all operation in
order to realize protection of the ROPS (or cab).

When transporting the machine, lock the frame halves together with the frame locking bar and pins.
Corrosion inhibitors are volatile and flammable. Use them only in a well ventilated area. Keep flames

and sparks away. Do not smoke. Store container in a cool, well ventilated place.
For your safety never push or tow a disabled machine farther than absolutely necessary. When using

a chain or cable, be sure it is strong enough for the expected load and properly secured to the drawbar
pin or towhook. Avoid kinking. Do not pull with a kinked chain or cable because the high stresses could
cause failure in a kinked area. Wear heavy gloves when handling chain or cable. When pulling with a
chain or cable, take up the slack slowly to avoid jerking. A chain or cable which fails under load can
whip and cause serious injury. Do not pull or tow unless the operator's compartment is guarded
against or out of reach of a whipping chain or cable. Hitch only to the drawbar pin or towhook. Prior to
towing release the parking brake.

Rims and tires must be repaired in specialized shops featuring proper technology. Improper repairs
may result in malfunctions and accidents.

Never inflate a flat tire without inspecting the tire and rim for damage. Be sure the components are
properly assembled. Unmounted tires being inflated or deflated should be placed in a tire safety cage.
Inflate a tire to 100 – 140 [kPa] and check that all components are properly seated. Never stand
directly in front of a tire and rim assembly while inflating. Use a clip-on chuck with a hose long enough
to allow person inflating the tire to stand to the side. Serious injure could result if the tire and rim were
to separate.

DRESSTA OM515C520C99/1E

SECTION 2 SAFETY PRECAUTIONS

Page 10

2.5. WHEN PARKING

Avoid parking on a slope. If necessary to park on a slope, park at a right angle to the slope and block
the tires.

Park the machine in place free from grease and fuel to prevent tire damage.
Never leave the machine with the engine running or the bucket raised. When parking a machine, shut

off the engine, lower the bucket to the ground, lock the transmission shift lever in neutral (N), apply the
parking brake, turn off the starting switch and the electric system master switch, and remove the keys.

Park the machine in a nontraffic area. If parking near or in traffic lanes cannot be avoided, identify the
machine in accordance with traffic rules.

Always lock the machine, including any anti-vandalism attachments when leaving it unattended.
If the loader is equipped with a multi-purpose bucket, close the clam before dismounting.
When operating in bad weather and storm lightning is nearby, dismount and seek shelter away from

the machine. Lightning will be attracted to the machine and cause serious injury or death.
ADDITIONAL INFORMATION

1. The vibration level measured at the operator’s seat does not exceed the admissible value
of 1.25 [m/s2] according to PN-91/N-01352 standard.

2. The noise level measured at the operator’s seat during intensive operation does not exceed the
admissible value of 85 [dB] (A) according to PN-86/M-47015.

3. Sound level LA produced by a machine does not exceed a value of 85 [dB] (A) according
to PN-86/M-47016.

4. A loader can be operated in temperature ranging from -34 [oC] to +49 [oC].

A wheel loader in standard configuration is not adapted to operation in terrain where a mixture of

gasses, vapors, aerosols or dust with air creates explosion hazard zones.

5. A wheel loader in CE configuration was given TÜV Hannover Laboratory DE 10-893 641 16 Noise
Level Certificate on 17 May 1999. The level of noise produced by a brand new machine reached
104 [dB] (A) when measured according to ISO-6395 standard (admissible value according to
EEC/662/86 directive is 107 [dB] (A)).

OM515C520C99/1E DRESSTA

SAFETY PRECAUTIONS SECTION 2

2.6.SAFETY GRAPHICS LOCATION

Page 11

Fig. 2.1. Safety Graphics Location

DRESSTA OM515C520C99/1E

SECTION 2 SAFETY PRECAUTIONS

Page 12

SAFETY GRAPHICS LOCATION

2.6.1. SAFETY GRAPHICS

Decal 1 - On the rear frame near the center articulation pivot and on the instrument panel in

the operator’s cab

Decal 2 - On the rear frame near the center articulation pivot

Decal 3 - Near the ladders and steps

OM515C520C99/1E DRESSTA

SAFETY PRECAUTIONS SECTION 2

Page 13

SAFETY GRAPHICS LOCATION

Decal 4 - Near the radiator filler cap

Decal 5 - On the hydraulic reservoir

Decal 6 - In the operator’s cab

DRESSTA OM515C520C99/1E

SECTION 2 SAFETY PRECAUTIONS

Page 14

SAFETY GRAPHICS LOCATION

Decal 7 - In the operator’s cab

Decal 8 - In the cab on the side window

Decal 9 - In the operator’s cab

Decal 10 - On the battery box

OM515C520C99/1E DRESSTA

SAFETY PRECAUTIONS SECTION 2

Page 15

SAFETY GRAPHICS LOCATION

Decal 11 - On the battery box

DRESSTA OM515C520C99/1E

SECTION 2 SAFETY PRECAUTIONS

Page 16

SAFETY GRAPHICS LOCATION

2.6.2. SAFETY GRAPHICS (Version CE)

Decal 1 - On the rear frame near the center articulation pivot and on the instrument panel in

the operator’s cab

Decal 2 - On the rear frame near the center articulation pivot

Decal 3 - Near the ladders and steps

OM515C520C99/1E DRESSTA

SAFETY PRECAUTIONS SECTION 2

Page 17

SAFETY GRAPHICS LOCATION

Decal 4 - Near the radiator filler cap

Decal 5 - On the hydraulic reservoir

Decal 6 - In the operator’s cab

DRESSTA OM515C520C99/1E

SECTION 2 SAFETY PRECAUTIONS

Page 18

SAFETY GRAPHICS LOCATION

Decal 7 - In the operator’s cab

Decal 8 - In the cab on the side window

Decal 9 - In the operator’s cab

Decal 10 - On the battery box

OM515C520C99/1E DRESSTA

SAFETY PRECAUTIONS SECTION 2

Page 19

SAFETY GRAPHICS LOCATION

Decal 11 - On the battery box

DRESSTA OM515C520C99/1E

SECTION 3

MACHINE TRANSPORT AND STORAGE

MACHINE TRANSPORT AND STORAGE SECTION 3

SECTION CONTENTS

3.1. Machine Transport ............................................................................................................. 3

3.1.1. General ................................................................................................................... 3

3.1.2. Transportation on Trailer, Railway Car or by Sea ................................................... 5

3.1.3. Transportation by Machine Own Drive .................................................................... 5

3.2. Lifting on Slings ................................................................................................................. 5

3.3. Moving a Disabled Machine ............................................................................................... 6

3.4. Machine Storage ............................................................................................................... 7

3.4.1. Preparing for Storage .............................................................................................. 7

3.4.2. Servicing During Storage ........................................................................................ 9

3.4.3. Preparing for Operation after Storage.................................................................... 10

DRESSTA OM515C520C99/1E

MACHINE TRANSPORT AND STORAGE SECTION 3

Page 3

3.1. MACHINE TRANSPORT

3.1.1. GENERAL

WARNING! During transportation of a machine the front and rear frame should be
blocked by means of a special locking bar and interlocking pins.

A frame locking bar and two pins (Fig. 3.1 and Fig. 3.2) - in the stowed position are provided on
the LH side of a loader. They are used to lock the front and rear frame of a loader to prevent
accidental frame turning during service and lifting on lifting slings.

METHOD OF LOCKING OF FRONT AND REAR FRAME OF LOADER
Prior to operating of the machine, place the locking bar in the stowed position as shown in Fig.

3.1. Repair or replace the frame locking bar and pins if damaged or lost to ensure frame locking,
(Fig. 3.2).

Fig. 3.1. Frame Locking Bar and Pins

in stowed position

Fig. 3.1.A. Frame Locking Bar and Pins

in stowed position (CE version)

Fig. 3.2. Frame Locking Bar and Pins

in locked position

Fig. 3.2.A. Frame Locking Bar and Pins

in locked position (CE version)

DRESSTA OM515C520C99/1E

SECTION 3 MACHINE TRANSPORT AND STORAGE

Page 4

MACHINE TRANSPORT

Always tie down securely a machine for transport to prevent movement.

WARNING! When transporting a machine be especially careful during loading
and unloading. Use low gear range and low speed. Load and unload the machine
on even surface that makes full support for the machine and transport facility.
Block the transport facility so that it cannot move. Make use of loading platform
of sufficient strength, small approach angle and appropriate height.

1. Clean clay, oil and other slippery material of the loader tires.

2. The hydraulic, cooling and braking system should be filled up.

3. The fuel tank should be filled with app. 10 [l] of fuel.

4. The parking brake should be applied. The pressure in the tires should conform to this
instruction, see "TIRES”, Section 6.

5. The batteries should be fully charged, the electric system master switch turned off.

6. The starting switch should be in the neutral position and the key removed.

IMPORTANT ! When transporting this machine on a high speed carrier or railaway car, seal the
exhaust pipe and air intake openinings to prevent turbocharger damage.

REAR LAMPS

Fig. 3.3. Rear Lamps

1. Bracket 2. Bolt 3. Hole

The rear lamps are mounted on pivotable brackets (1, Fig. 3.3). The lights positioned as shown in
the drawing above, conform to the traffic regulations. To change the rear lights position:

1. Unscrew and remove bolt (2).

2. Turn bracket (1) into the required position.

3. Reinstall the bolt in hole (3) and tighten.

IMPORTANT: It is recommended to change the position of lamps (to fold brackets) before
machine transport to prevent damage.

OM515C520C99/1E DRESSTA

MACHINE TRANSPORT AND STORAGE SECTION 3

Page 5

MACHINE TRANSPORT

3.1. 2. TRANSPORTATION ON TRAILER, RAILWAY CAR OR BY SEA

1. When using automotive trailer or railway car for transportation of a machine, you should take
into account state, local and railway regulations obligatory in a particular country or region. If
necessary, co-ordinate the details of transportation and safety measures with the competent
authorities.

2. During transportation by sea, when it is necessary to carry a loader by means of a crane, use
the method of fastening the loader that will ensure maximal safety of persons loading the
machine and will not result in damage of the machine. The lifting slings used for fastening the
loader should be attached only to special lifting lugs marked with special plates on the
machine (Fig. 3.4).

3.1. 3. TRANSPORTATION BY MACHINE OWN DRIVE

1. Passage conditions must be coordinated with the local road traffic administration.

2. Observe the traffic regulations ensuring a safe travel.

3. Do not drive a loader at long distances.

4. Place the boom and bucket in transport position.

5. Interlock the working system control levers and unlock the articulated frame by setting the
frame locking bar in the stowed position as shown in Fig. 3.1. and 3.1.A.

6. Detailed information on safety precautions when driving – see "SAFETY PRECAUTIONS”,
Section 2.

3.2. LIFTING ON SLINGS

Fig. 3.4. Method of Handling 515C Loader by a Crane (for a machine equipped with

15.5R25 Tires and 1.53 [m3]. bucket)

1. Frame Locking Bar

Machine’s weight Q = 9000 [kG]

DRESSTA OM515C520C99/1E

SECTION 3 MACHINE TRANSPORT AND STORAGE

Page 6

LIFTING ON SLINGS

Fig. 3.4A. Method of Handling 520C Loader by a Crane (for machine equipped

with 20.5R25 Tires and 2.29 [m3] bucket)

1. Frame Locking Bar

Machine’s weight Q = 10800 [kG]

3.3. MOVING A DISABLED MACHINE

Towing this machine is not recommended. To move a disabled machine, use a trailer or low-boy
truck if possible. If towing is necessary, such as freeing a stuck machine, tow it only as far as
necessary. Towing machine backwards is recommended. When towing, the engine must be
running (if operative) to enable turning and braking of the machine.

Towing of machines equipped with ground driven system is easier. Prior to towing release spring
parking brake (refer to "PARKING BRAKE”, Section 5) and unlock frames by placing locking bar
in the stowed position as shown in Fig. 3.1 and 3.1A.

WARNING: When pulling with a chain or cable, take up the slack slowly to avoid
jerking. A chain or cable which fails under load can whip and cause serious
injury. Stand clear. Do not pull or tow unless the operator's compartment is
guarded against or out of reach of a whipping chain or cable.

WARNING: Observe safety precautions specified in this manual. Refer to
"SAFETY PRECAUTIONS”, Section 2.

Hook a towing line or cable of adequate strength to the towing lug. The towing load should not
exceed a force of 80 [kN].

OM515C520C99/1E DRESSTA

MACHINE TRANSPORT AND STORAGE SECTION 3

Page 7

MOVING A DISABLED MACHINE

Fig. 3.5. Towing Lugs

3.4. MACHINE STORAGE

3.4.1. PREPARING FOR STORAGE

When a machine is taken out of service and stored for a period of time exceeding 30 days, steps
must be taken to protect the machine. Wash and dry the machine and place in a dry enclosure.
An enclosure will protect the machine from rapid temperature changes and lessen the amount of
condensation that forms in hydraulic components, engine, fuel tank, axles and transmission.
Leaving equipment outdoors exposed to the elements will materially shorten its life. If it is not
possible to put the machine in an enclosure, cover it with a tarpaulin. After the machine has been
positioned for storage and the engine shutdown, perform the following operations:

1. Visually inspect the machine for external leakage and other defects.

2. Clean the radiator, refer to "CLEANING THE RADIATOR", Section 5.

3. Thoroughly clean the machine, be sure to rinse off any caustic residue.

4. Correct any defects found. Consult Authorized Distributor of Construction Equipment.

5. Clean or replace the air cleaner filter elements. Refer to "AIR CLEANING SYSTEM", Section 5.

6. The cooling system should be completely drained, chemically flushed, and refilled with

a conditioned water/anti-freeze solution suitable for the lowest temperature anticipated. Refer
to "ANTIFREEZE", Section 5 for the proper anti-freeze and conditioner concentrations.

IMPORTANT: To avoid corrosion, under no circumstances should the machine with air
conditioner or cab heaters (if equipped) be stored with a dry cooling system.

7. Drain the water from the fuel tank. Refer to "FUEL TANK", Section 5. Clean the fuel strainer

installed in the filler neck.

8. Remove and replace the fuel filters. Refer to "FUEL SYSTEM", Section 5.

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SECTION 3 MACHINE TRANSPORT AND STORAGE

Page 8

MACHINE STORAGE

9. It is recommended to use fuel stabilizer in quantity specified by the manufacturer. Stabilizer
will prevent degrading of fuel, sludge buildup, and stop the growth of bacteria in fuel during
storage. Fuel stabilizer may be purchased from:

FUEL PREP 1000
NALCO CHEMICAL COMPANY
2901 BUTTERFIELD ROAD
OAK BROOK, ILLINOIS 60521, USA
or Machine Distributor

WARNING: Corrosion inhibitors are volatile and flammable. Use them only in
a well-ventilated area. Keep flames and sparks away. DO NOT SMOKE. Store
a container in a cool, well-ventilated place.

WARNING: Avoid prolonged exposure to volatile corrosion inhibitors because
eye and skin irritation may occur.

10. It is recommended to use volatile corrosion inhibitor (VCI) in a fuel tank. VCI provides
corrosion protection by contact with metal, and in a closed system, the vapors provide
sufficient protection for areas that are not in contact with fuel. When using VCI per HMS B00­0006 pour 120 [ml] of volatile corrosion inhibitor for each 100 [l] of total fuel capacity. VCI
may be purchased from:

NOX RUST VCI #105 OIL
DAUBERT CHEMICAL COMPANY
1200 JORIES BLVD.
OAK BROOK, ILLINOIS 60521, USA
or Machine Distributor

11. Deaerate the fuel system. Refer to "FUEL SYSTEM”, Section 5.

12. Start the engine and run idle at half throttle for 3 minutes and then stop the engine.

13. Lubricate all points of the machine as outlined in the "SERVICE GUIDE", Section 5.

IMPORTANT: Be sure to oil or grease all linkage connections, joints, nuts, pins, shafts, and
bushings not covered in the "SERVICE GUIDE".

14. Drain the engine oil, replace the engine oil filters and fill them with proper grade of oil. Refer
to ENGINE, Section 5.

15. Add 15 [ml] VCI for each liter of engine oil to the crankcase. (example: if the total capacity of
a crankcase is 10 [l] add 150 [ml] VCI).

16. Start the engine and run it idle at half throttle for 30 seconds and then stop the engine.

17. Remove the air precleaner.

18. Seal all external openings (i.e. engine exhaust outlet, filler caps, breathers, etc.) with tape
wide enough to cover the opening, regardless of its size.

NOTE: When sealing with tape, be sure to extend tape approximately one inch (25 [mm]) beyond
an opening to insure good sealing.

19. Pour 60 [ml] VCI to the intake manifold to prevent corrosion of the space between piston and
the bottom part of the engine head.

OM515C520C99/1E DRESSTA

MACHINE TRANSPORT AND STORAGE SECTION 3

Page 9

MACHINE STORAGE

20. It is recommended to pour 50 [ml] VCI type 1 oil per HMS B00-0006 Standard to the hydraulic
reservoir.

21. Remove the batteries and place them on wooden skids. Then store them in a cool, clean,
dry, well-ventilated place away from areas provided for storing or dispensing fuel and oil, not
near any heat source and preferably where the temperature range is between 0 [°C] to +21
[°C] . Be sure the batteries are fully charged.

IMPORTANT: Do not place battery on a concrete floor or in temperature below 0 [°° C].
IMPORTANT: If the machine is stored with dry charged batteries or no batteries, the alternator

output lead (+) must be disconnected and insulated. Failure to do so may result in permanent
damage to the alternator.

22. If the bucket is detached for storage, secure the cylinder piston rod to the machine to avoid
damage.

23. Coat all machined and unpainted surfaces with chassis grease to prevent rust. It is
recommended to use AKORIN N-2 grease.

24. If it is desirable to leave the tires on the machine, jack the machine up and place it on blocks
leaving the tires in suspension. Deflate and cover the tires. Tires should not be exposed to
direct sunlight or any fuel or solvent vapors.

WARNING: Use extra caution when jacking up the machine. Jacking up the
machine can be hazardous if performed improperly. Use jacking equipment of
sufficient capacity. Be sure the jacking points are strong enough to support the
machine. Be sure the jack is stable and well supported. Before jacking up the
machine, block the tires which will not be lifted. Lock the frame halves together
with the locking bar and pins. If the rear tires are being lifted, block the rear axle
to prevent it from pivoting unexpectedly. DO NOT run the engine with the
machine on jacks.

3.4.2. SERVICING DURING STORAGE

ONE-MONTH REPETITIVE SERVICE PERIOD
Be sure the batteries are fully charged. Never allow batteries to run down below 3/4 full charge.

WARNING: DO NOT charge batteries in a closed area. Provide proper ventilation
to guard against explosion of an accumulation of the gas given off in the
charging process.

SIX-MONTH REPETITIVE SERVICE PERIOD

1. Visually inspect the engine and radiator for leakage and other defects. Correct all defects,

consult Authorized Construction Equipment Distributor if necessary.

2. Remove all seals from the machine ports: crank-case and hydraulic breather plugs, engine air

intake, fuel tank vent lines, etc.

3. Install fully charged batteries. Refer to "BATTERIES", Section 5.

WARNING: Be sure the electrical system master switch is off when connecting or
disconnecting batteries to minimize the chance of sparks and explosion.

DRESSTA OM515C520C99/1E

SECTION 3 MACHINE TRANSPORT AND STORAGE

Page 10

MACHINE STORAGE

WARNING: Check that batteries are level in the holders and securely held. The
hold-down fasteners should hold the batteries firmly but not too tight to warp or
damage either the hold-down bar or batteries.

WARNING: Battery cables must be so arranged to enable easy removal of all
pugs. Lay the cables so they do not chafe against the hold-down bar. Always
connect the negative ground cable last to minimize the chance of sparks or an
explosion. The electric system master switch must be in the OFF position and
the key removed.

4. Check the coolant level in the radiator and add proper concentrations of antifreeze, if
required. Refer to "CHECKING COOLANT LEVEL”, Section 5.

5. Perform steps 7 thru 21 per item 3.4.1.

3.4.3. PREPARING FOR OPERATION AFTER STORAGE

1. Visually inspect the machine for external leakage and other defects.

2. Clean the radiator, refer to "CLEANING THE RADIATOR", Section 5.

3. Thoroughly clean the machine, being sure to rinse off any caustic residue.

4. Correct any defects found. Consult Authorized Construction Equipment Distributor

if necessary.

5. If the machine was jacked up (refer to 3.4.1. item 24) inflate the tires to the normal operating

inflation pressure. Refer to "TIRES", Section 6.

6. Remove all seals from the machine: filler plugs, breathers, engine air intake and exhaust, etc.

7. Remove the air cleaner filter elements for cleaning or replacement. Refer to "AIR CLEANING

SYSTEM", Section 5.

8. Remove and replace the fuel filters. Refer to "CHANGING THE OF FUEL FILTERS”,

Section 5.

9. Fill the fuel tank with approved diesel fuel. Refer to "REFILL SPECIFICATIONS AND

CAPACITIES", Section 5.

10. Lubricate all points of the machine as outlined in the "LUBRICATION", Section 5.

IMPORTANT: Be sure to oil or grease all linkage connections, joints, nuts, pins, shafts, and
bushings not covered in the "SCHEDULED MAINTENANCE GUIDE".

11. Change the engine oil and fuel filters. Refer to ENGINE, Section 5.

WARNING: Be sure the electrical system master switch is off when connecting or
disconnecting batteries to minimize the chance of sparks or explosion.

12. Install fully charged batteries. Refer to "BATTERIES", Section 5.

WARNING: Check that batteries are level in the holders and securely held. The
hold-down fasteners should hold the batteries firmly but not too tight to warp or
damage either the hold-down bar or batteries. Lay the cables so they do not
chafe against the hold-down bar or the fasteners.

OM515C520C99/1E DRESSTA

MACHINE TRANSPORT AND STORAGE SECTION 3

Page 11

MACHINE STORAGE

WARNING: Never start the engine indoors unless proper exhaust ventilation is
provided. Once the engine is running, move the machine outdoors as soon as
possible. Exhaust gases are dangerous and can cause unconsciousness and
death.

13. Start the engine, refer to "STARTING AND STOPPING THE ENGINE”, Section 4 and
"SCHEDULED MAINTENANCE GUIDE” recommendations (daily service), Section 5.

DRESSTA OM515C520C99/1E

SECTION 4

OPERATING

OPERATING SECTION 4

Page 3

SECTION CONTENTS

4.1. General ................................................................................................................................... 3

4.2. Universal Symbols for Instruments and Controls ................................................................... 4

4.3. Instruments and Controls ....................................................................................................... 8

4.4. Cab Door and Windows ....................................................................................................... 20

4.5. Operator’s Seat .................................................................................................................... 21

4.6. Seat Belt ............................................................................................................................... 24

4.7. Cab Heating and Ventilation .................................................................................................. 25

4.7.1. Defroster Fan ......................................................................................................... 25

4.7.2. Heater ..................................................................................................................... 25

4.7.3. Air Conditioner ........................................................................................................ 26

4.8. Air Cleaner Service Indicator ............................................................................................... 27

4.9. Electric System Master Switch............................................................................................. 27

4.10. Dome Lights with Switches .................................................................................................. 28

4.11. Starting and Stopping the Engine ......................................................................................... 28

4.11.1. Normal Start (ambient temperature above 0 [°C]) ................................................. 28

4.11.2. Cold Weather Start (using ether injector, ambient temperature below 0 [°C]) ...... 29

4.11.3. Stopping the Engine ............................................................................................... 30

4.12. Driving the Machine .............................................................................................................. 30

4.13. Shifting the Gears ................................................................................................................. 32

4.14. Steering ................................................................................................................................. 32

4.15. Stopping the Machine ........................................................................................................... 33

4.16. Parking the Machine ............................................................................................................. 34

4.17. Loader Operations ................................................................................................................ 34

4.17.1. Boom Control Lever Positions ............................................................................... 34

4.17.2. Automatic Boom Kick -Out ...................................................................................... 36

4.17.3 Bucket Control Lever Positions .............................................................................. 37

4.17.4. Automatic Bucket Leveler ...................................................................................... 38

4.17.5. Multi-purpose Bucket Control Lever Positions (if equipped) .................................. 38

4.18. Loader Techniques ............................................................................................................... 41

4.18.1. Loading, Transporting and Piling ............................................................................ 41

4.18.2. Digging, Clearing and Leveling ............................................................................... 47

4.19. Economical Operation of Machine .......................................................................................... 54

4.20. Quickcoupling............................................................................................................................54

4.20.1. Quickcoupling with 3-Spool Valve............................................................................55

4.20.2. Quickcoupling with a 2-Spool Valve ...................................................................... 56

4.21. Ride Stabilizing Mechanism .....................................................................................................56

4.21.1. Driving a Machine equipped with RMS System .......................................................57

4.22. High-Dump Bucket....................................................................................................................57

4.22.1. High-Dump Bucket Control .....................................................................................57

4.22.2. Operating the High-Dump Bucket........................................................................... 57

DRESSTA OM515C520C99/1E

OPERATING SECTION 4

Page 3

4.1. GENERAL

Stay alert and aware of what you are doing. Use common sense. Do not operate when ill or
fatigued.

Know your machine.
For your safety, read the Operator's Manual carefully and follow all instructions and precautions.

Read carefully Section 2 and follow safety precautions specified therein.
Before starting or operating this machine, read the following general precautions. These are listed

there to help you protect the machine and to remind you of protection for yourself and those around
you. Common sense and observance of these rules will help make your job a safer one. Perform a
visual check of the machine before starting the engine. Look for such things as missing protective
devices, leaks, improper fluid levels, trash buildup and loose, damaged or missing parts. DO NOT
start the engine until any unsafe conditions are corrected.

Keep the transmission in low gear when going downhill. Never coast downhill with the transmission
in neutral because the machine could go out of control and tip over. Always drive the machine
slowly when on hillsides, ramps or rough terrain. Be extremely careful when working around
trenches or banks. Failure to do so could cause the machine to roll over.

Before starting operation, check the machine for correct function of the steering controls, brake
controls, hydraulic controls, instruments and safety equipment. Make all necessary repairs or
adjustments before operating the machine.

Do not place a machine under load without the proper engine oil pressure and operating
temperature. After starting the engine, move the accelerator pedal to the low idle position.

Allow the engine to run at low idle for 3 to 5 minutes at 1000 [RPM] until normal oil pressure
registers on the gauge to obtain complete distribution of the lubricating oil. Do not run the engine idle
more than 10 minutes. To prevent any possible damage to the alternator, the electric system
master switch must be in the ON position when the engine is running. The switch must be in the
OFF position when the engine is shut down at the end of each day or when the operator leaves the
machine unattended.

Never park in places contaminated with grease or oil to prevent tire damage.
Never park in swampy area as it may cause freeze-up of the tires.
Never pour cold coolant into the radiator when the engine is hot unless conditions make it absolutely

necessary. Use extreme caution as hot coolant could cause burns. Keep your face away from the
filler neck. Under such conditions, start the engine and let it idle while slowly pouring coolant into the
radiator. The engine is recommended to be allowed to cool down
to 50 [°C].

Pouring cold coolant into a hot engine may cause damage to the cast components of the engine.
Fill the fuel tank at the end of each day’s work to reduce condensation.
When towing with a long chain or cable, take up the slack slowly to avoid jerking. Before shutting

down operate the engine at idle (no load) for 3 to 5 minutes. This will aid in cooling the engine and
turbocharger.

DRESSTA OM515C520C99/1E

SECTION 4 OPERATING

Page 4

4.2. UNIVERSAL SYMBOLS FOR INSTRUMENTS AND CONTROLS

The use of universal symbols will pictorially identify various instruments and controls. These
symbols are an effort to overcome language differences for all operators in a positive way, thus
enhancing their safety through quicker recognition of the instruments and controls while operating
the equipment.

Study the following symbols so you will know their meaning immediately and at a glance.
NOTE: Some symbols may not pertain to your machine.

OM515C520C99/1E DRESSTA

OPERATING SECTION 4

UNIVERSAL SYMBOLS FOR INSTRUMENTS AND CONTROLS

Page 5

Fig. 4.1. Universal Symbols for Instruments and Controls

DRESSTA OM515C520C99/1E

SECTION 4 OPERATING

Page 6

UNIVERSAL SYMBOLS FOR INSTRUMENTS AND CONTROLS

OM515C520C99/1E DRESSTA

UNIVERSAL SYMBOLS FOR INSTRUMENTS AND CONTROLS

Description to Fig. 4.1.

1. Left

2. Right

3. Positive

4. Negative

5. Invariable by Sliding

6. Invariable by Turning

7. Caution

8. Caution-High Pressure

9. Grease Lubricant

10. Oil Lubricant

11. Hourmeter

12. Horn

13. Attach Point

14. Brake (General)

15. Parking Brake (General)

16. Parking Brake On

17. Parking Brake Off

18. Wheel Machine – Forward and Reverse

19. Articulated Frame Locking

20. Engine Start

21. Engine Speed

22. Engine Stop

23. Throttle

24. Engine Oil Fill

25. Engine Oil Level

26. Engine Oil Pressure

27. Engine Oil Temperature

28. Engine Oil Filter

29. Engine Starting Aid

30. Fuel Fill

31. Fuel Level

32. Fuel Reserve

33. Fuel Filter

34. Air Pressure

35. Air Filter

36. Coolant Fill

37. Coolant Level

38. Coolant Pressure

39. Coolant Temperature

40. Power Train Oil Fill

41. Power Train Oil Level

42. Power Train Oil Pressure

43. Power Train Oil Temperature

44. Power Train Oil Filter

45. Power Train Oil Pressure Diagnostic Point

46. Hydraulic Oil Fill

47. Hydraulic Oil Level

48. Hydraulic Oil Pressure Diagnostic Point

49. Hydraulic Oil Filter

50. Test

51. Brake Fluid Fill

52. Brake Fluid Level

53. Battery Charge Indicator

54. Battery Disconnect

55. Voltmeter

56. Road Lights

57. Low Level Lights

OPERATING SECTION 4

Page 7

DRESSTA OM515C520C99/1E

SECTION 4 OPERATING

Page 8

UNIVERSAL SYMBOLS FOR INSTRUMENTS AND CONTROLS

58. Parking Lights

59. Contour Light

60. Work Light

61. Search Light

62. Flash Light

63. Turn Signal Light

64. Front Floodlights

65. Rear Floodlights

66. Dome Light

67. Instrument Panel Illumination Light

68. Backup Light

69. Emergency Light

70. Windshield Wiper

71. Rear Window Wipers

72. Window Washer

73. Mirror Heating

74. Fan

75. A/C

76. Receptacle 24 V

77. Electric Lighter

78. Neutral Position

79. Slow

80. Outside Air for Heating (Blue)

81. Recirculation Air for Heating (Red)

82. Multi-Purpose Bucket Roll Back

83. Multi-Purpose Bucket Hold

84. Multi-Purpose Bucket Dump

85. Grapple Closing

86. Grapple Hold

87. Grapple Opening

88. Boom With Bucket Raise

89. Boom With Bucket Hold

90. Boom With Bucket Lower

91. Boom With Bucket Float

92. Bucket Roll Back

93. Bucket Dump

94. Ground Driven System

95. Change of Direction: Forward - Reverse

96. RSM - Ride Control

97. Quick Coupler Connected

98. Quick Coupler Disconnected

4.3. INSTRUMENTS AND CONTROLS

GENERAL
Before operating the machine you must be thoroughly familiar with the location and use of all

instruments and controls.

WARNING: Understand all control functions before starting the engine.

Each reference number in the illustrations of this section has a corresponding reference number
and explanation in the text.

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INSTRUMENTS AND CONTROLS

IMPORTANT! Check all instruments and warning lights indicating operation of individual systems
of the machine prior to starting and at frequent intervals during operation.

Fig. 4.2. Instrument Panel

Fig. 4.2.A. Instrument Panel – (CE Version)

1. Hourmeter

2. Engine Oil Pressure Warning Light

3. Engine Coolant Temperature Warning Light

4. Parking Brake Warning Light

5. Engine Coolant Temperature Gauge

6. Fuel Level Gauge

6A. Turn Signal Warning Light
6B. Engine Oil Pressure Gauge

7. Ether Start Button

8. Instrument Panel Illumination Light

9. Starting Switch

10. Rear Parking and Front Work Lights Switch (Front, Rear Parking Lights/Low Beam Lights Switch in CE

Version)

11. Work Lights Switch (Front and Rear Work Lights Switch in CE Version) and Bulb Check Switch

11A. Emergency Lights Switch

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INSTRUMENTS AND CONTROLS

12. Quickcoupling Solenoid Valve Switch

13. Tachometer or Speedometer
13A. Tachometer
13B. Rear Window Heating Switch
13C. Flash Light Switch

14. Voltmeter

15. Torque Converter Temperature Gauge

16. Service Brake Warning Light

17. Torque Converter Oil Temperature Warning Light

18. Ground Driven Steering Warning Light (If Equipped)

19. Warning Lights (If equipped)

20. 24 V Receptacle

21. Audible Alarm (Buzzer under the Instrument Panel)

22. Transmission Direction Lever Lock Switch
22A. RSM System Switch

1. HOURMETER
The hourmeter electrically records the actual hours of engine operation. It is activated when the
engine is running. It eliminates guess work when determining proper lubrication and maintenance
periods.

2. ENGINE OIL PRESSURE WARNING LIGHT
The light will come on when the engine oil pressure is too low. At the same time a buzzer will
sound.

IMPORTANT: When the light comes on, stop the engine immediately to prevent damage to the
engine. Do not start the engine again until the problem has been corrected.

3. ENGINE COOLANT TEMPERATURE WARNING LIGHT
The light will indicate when the coolant temperature exceeds the allowable limit. If the light comes
on, maneuver the machine to the side and operate the engine at low idle. Do not shut the engine
down. If the light stays on, investigate the cause and take corrective action before operating the
machine again.

4. PARKING BRAKE WARNING LIGHT
The light will indicate if the parking brake is applied. At the same time a buzzer will sound.

IMPORTANT: Release the parking brake before moving a machine. The brake could burn or be

damaged if the machine is driven with the brake applied.

5. ENGINE COOLANT TEMPERATURE GAUGE
The gauge pointer should remain within the green area equivalent to 71 to 93 [°C] temperature
range. During normal loader operation the pointer readings may vary between the minimum and
maximum limited by the green area of the gauge. Continuous operation of the engine below the
minimal temperature means insufficient engine lubrication. Too low coolant temperature causes
excessive exhaust fumes and an increase in fuel consumption. If the ambient temperature is low it
may be necessary to cover the radiator grill partly in order to keep the proper temp. of the coolant
(the pointer should stay within the green area of the meter). The gauge pointer should also remain
in the green area under full load conditions. If the temperature remains too high in spite of
interruptions of engine operation, check the coolant level, the condition of the radiator, fan, water
pump and thermostat.

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INSTRUMENTS AND CONTROLS

6. FUEL GAUGE

This gauge is electrically operated and indicates the available fuel supply in the fuel tank. The gauge
is accurate only when the machine is level.

6A. TURN SIGNAL WARNING LIGHTS
The lights start blinking when the turn signal switch is put on.

6B. ENGINE OIL PRESSURE GAUGE
The gauge indicates engine oil pressure.

7. ETHER START BUTTON (if equipped)

This switch injects a spray of ether to facilitate start of the engine in low air temperatures. Press the
switch to release a measured shot of starting fluid into the engine. Refer to Section 4.11.2 for more
information.

IMPORTANT: DO NOT use the ether injector when air temperature is above 0 [°C]. Follow the
correct method for starting the engine.

8. INSTRUMENT PANEL ILLUMINATION LIGHT

The light illuminates the lower part of the instrument panel with the starting switch when the parking
lights are on.

9. STARTING SWITCH.

Fig. 4.3. Starting Switch Positions

The starting switch is used to connect and disconnect the circuits of the electric system and
switching on and off the engine and is equipped with a key.

Starting switch positions:
ACC – to the left – not used,
OFF - after inserting the key- disconnects the electric circuits,
RUN - to the right – activates the electric circuits,
START- to the right with automatic return to RUN when released – engine startup,
Midposition between RUN and START - warning lights check - activates all warning lights,

IMPORTANT: Do not hold the key in START position for more than 30 second. Allow a 2–3

minute interval between cranking. Never place the key in START position when engine is running.

DRESSTA OM515C520C99/1E

SECTION 4 OPERATING

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INSTRUMENTS AND CONTROLS

10. REAR PARKING AND FRONT WORK LIGHTS SWITCH (FRONT AND REAR PARKING AND
PASSING LIGHTS SWITCH IN CE VERSION)
It switches on and off the rear parking and front work lights or, in CE machine, it switches on or off
the front and rear parking lights and passing lights of a loader.

11. REAR WORK LIGHTS SWITCH (FRONT AND REAR WORK LIGHTS SWITCH IN CE
VERSION) / BULB CHECK SWITCH.
It switches on or off the rear work lights (the front and rear work lights in CE machine). It is also
used to check the condition of the warning lights.

11A. EMERGENCY WARNING LIGHTS SWITCH
It switches on or off the emergency lights.

12. QUICKCOUPLING SOLENOID VALVE SWITCH
The switch has 2 positions:

• position ON (locked): in this position the solenoid valve remains electrically inactive. The
quickcoupling pins are pushed out to lock the coupling,

• position OFF (unlocked): in this position the solenoid valve is activated. The quickcoupling pins
are retracted (refer section 4.20, QUICKCOUPLING) and the coupling is disengaged.

13 and 13A. TACHOMETER OR SPEEDOMETER (IF EQUIPPED)
The tachometer indicates engine crankshaft [RPM]. A machine can be equipped with
a speedometer which replaces the tachometer and indicates machine speed in [km/h].

13B. REAR WINDOW HEATING SWITCH
It switches on and off the rear window heating.

13C. FLASHLIGHT SWITCH
It switches on and off the flashlight mounted on the cab roof.

14. VOLTMETER

The voltmeter indicates the condition of the batteries. At low idle speed, the gauge pointer should be
within the first green area, which indicates a good battery charge. If the voltage drops below the first
green area, the batteries should be checked. With the engine operating above low idle speed, the
gauge pointer should be within the second green area, which is the normal operating range. If the
pointer drops below or exceeds the second green area, the batteries and /or voltage regulator or
alternator with integral regulator should be checked.

15. TORQUE CONVERTER OIL TEMPERATURE GAUGE

The gauge indicator should remain within green area. If the temperature is too high, follow the
recommendations specified below in "TORQUE CONVERTER OIL TEMPERATURE WARNING
LIGHT"

16. SERVICE BRAKE WARNING LIGHT

The light indicates failure of one of the brake circuits. Also, a buzzer will come on.

17. TORQUE CONVERTER OIL TEMPERATURE WARNING LIGHT

The light will come on if the torque converter oil temperature exceeds the allowable limit.

IMPORTANT: If the light comes on during operation, reduce the work load by operating in
a lower gear. If the light stays on, stop the machine and run the engine until the temperature drops
to app. 90 [°°C]. Find the reason of oil overheating:

• transmission oil low level,

• dirty radiator,

• dirt suction filter.

OM515C520C99/1E DRESSTA

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INSTRUMENTS AND CONTROLS

18. GROUND DRIVEN STEERING WARNING LIGHT (IF EQUIPPED)
If a machine is equipped with the ground driven system (that enables steering of the machine at
loss of pressure in the steering system) the light will come on when the system is activated.
A buzzer will also come on.

WARNING: If the ground driven steering warning light start blinking, stop the
engine and apply the parking brake. Do not start the engine until the failure has
been corrected.

19. WARNING LIGHTS (IF EQUIPPED)
This clustered indicator contains the following 5 warning lights (located from the bottom of the
indicator up):

a). transmission oil filter warning light: it come on when the filter element is contaminated and must

be replaced,

b). hydraulic oil filter warning light: it comes on when the filter element is contaminated and must be

replaced,

c). air cleaner warning light: it comes on when the cleaner elements are contaminated and must be

washed or replaced.

d). low engine coolant warning light: it comes on when the coolant in the radiator top tank reaches

its minimal level,

e). hydraulic oil temperature warning light: it comes on when the oil temperature is too high.

20. 24V RECEPTACLE
Used for connecting portable lamp with cable (included in the machine accessories).

21. AUDIBLE ALARM (BUZZER)
It is located under the instrument panel. It sounds if any of the following warning lights starts
glowing:

• engine oil pressure warning light,

• parking brake warning light,

• service brake warning light,

• ground driven steering warning light (if equipped).

22. TRANSMISSION DIRECTION LEVER LOCK SWITCH.
This switch locks the transmission direction lever in its neutral position if shifted into the furthest left
position. To release the lock, shift it to the right.

22A. RSM System Switch
This switch has 2 positions:
ON - the ride stabilizing system is switched on,

OFF - the ride stabilizing system is switched off.

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SECTION 4 OPERATING

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INSTRUMENTS AND CONTROLS

Fig. 4.4. Steering and Controls (for standard configuration)

Fig. 4.5. Steering and Controls (for upgraded configuration)

23 - Transmission Gear Range Lever
24 - Transmission Direction Lever
25 - Turn Signal and Emergency Light Switch
26 - Boom Control Lever
27 - Bucket Control Lever
28 - Auxiliary Equipment Lever
29 - Accelerator Pedal
30 - Steering Wheel
31 - Horn Button
32 - Brake Pedal
33 - Brake and Transmission Disconnect Pedal
34 - Hydraulic Pilot Control Valve Lock Switch
35 - Control Levers Lock Plate (Fig. 4.7)
36 - Float Position Lock Switch
37 - Bucket and Boom Pilot Control Valve Lever

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OPERATING SECTION 4

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INSTRUMENTS AND CONTROLS

NOTE: items 26,27,35 refer to the standard machine

items 34, 36, 37 refer to the upgraded machine

23. TRANSMISSION GEAR RANGE LEVER
This lever is used to select the gear range according to the operating conditions. Refer to
Par. 4.13 for additional information.

24. TRANSMISSION DIRECTION LEVER
This lever is used to select machine direction. Refer to Par. 4.13 for additional information.

WARNING: When parking a machine, lock the transmission direction lever in
neutral (N) by applying the transmission direction lever lock switch.

25. TURN SIGNAL LEVER WITH EMERGENCY LIGHT SWITCH
The turn signal lever with emergency light switch is clamped on the LH side of the steering column.
When pulled back toward the operator’s seat it activates the left turn signal lights. When pushed
away from the operator’s seat it activates the right turn signal lights. The corresponding arrow
indicator light (left of right) on top of the turn signal switch will also flash. Pull the lever to the left to
make both turn signal lights flash at the same time (in CE version the emergency lights and the turn
signal warning lights are located on the instrument panel - see item 6A, 14B).

26. BOOM CONTROL LEVER
The lever controls raising and lowering operations of the boom. Refer to Par. 4.17.1 for additional
information.

27. BUCKET CONTROL LEVER
The lever controls roll back and dumping operation of the bucket. Refer to Par. 4.17.3 for additional
information.

28. AUXILIARY EQUIPMENT LEVER
The lever is located:

a) on the LH side of the bucket control lever in machines of standard configuration,
b) on the RH side of the boom and bucket control lever in machines in CE configuration.

The lever is integrated with a 3-spool control valve equipped as an optional attachment with optional
mounted equipment such a multi-purpose bucket, quickcoupling etc.

It performs the following functions:
a) with a multi-purpose bucket:

• when shifted forward it opens the bucket,

• when shifted back it closes the bucket.

b) with a quickcoupling tool carrier:

• when shifted forward it locks the quickcoupling,

• when shifted back it unlocks the quickcoupling.

29. ACCELERATOR PEDAL
Depress the pedal to increase engine speed, release the pedal to decrease engine speed. Pedal
returns automatically to the low idle position.

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INSTRUMENTS AND CONTROLS

30. STEERING WHEEL HEIGHT ADJUSTMENT KNOB

The steering wheel operates the steering valve, which directs hydraulic fluid into the steering
cylinders. When the steering wheel is turned clockwise, the steering cylinders articulate the
machine so a right turn can be made. When the steering wheel is turned counterclockwise, the
machine is articulated so a left turn can be made. The machine continues as long as you turn the
steering wheel. When you stop turning the steering wheel, the machine will remain in the articulated
position it is in.
In the upgraded machine steering column height and its inclination can be adjusted (total
adjustment ranges up to 80 [mm] and 40 [°] respectively). Adjustment can be made after releasing
lever (1, Fig. 4.6). Pull the lever up to extend the steering column. Push it down to change the
inclination.

Fig. 4.6. Steering Column Adjustment (Upgraded Machine)

1. Lever

31. HORN BUTTON

Depress the button to sound the horn, release the button to stop.

32. BRAKE PEDAL

This pedal actuates the machine service brakes. Depress the pedal, gradually increasing pressure
until a desired braking action is achieved. The faster pressure is applied to the pedal, the stronger is
the braking action.

33. BRAKE AND TRANSMISSION DISCONNECT PEDAL

This pedal works in the same manner as the brake pedal except that it also relieves clutch pressure
in the transmission. When this pedal is depressed, no power can be transmitted through the
transmission and full engine power can be used to operate the machine hydraulics while braking.

WARNING! Do not press the transmission disconnect pedal when traveling fast
or going downhill because this shifts the transmission into neutral. Loss of
control or damage to the power train could result when the pedal is released
and transmission re-engages.

OM515C520C99/1E DRESSTA

OPERATING SECTION 4

INSTRUMENTS AND CONTROLS

34. HYDRAULIC PILOT CONTROL VALVE LOCK SWITCH (Fig. 4.8)
The switch has two positions:

• ON: hydraulic pilot valve is locked

• OFF: hydraulic pilot valve can be operated

35. CONTROL LEVER LOCKING PLATE (Fig. 4.7)

Page 17

Fig. 4.7 Control Lever Locking Plate (Standard Version)

35. Locking Plate

Locking plate (35) is used to lock the control levers in the neutral position and guard them against

accidental activation. In the illustration above the plate is shown in the non-locked position. To lock it
turn the plate round 180 [°].

WARNING! When roading the machine, engage the hydraulic control lever

locking plate. Accidental actuation of the levers may cause personal injury or
damage of the machine.

36. FLOAT POSITION PILOT VALVE LOCK SWITCH
This switch has 2 positions:

• ON: keeps the boom in the float position,

• OFF: releases the float position lock.

Fig. 4.8. Hydraulic Pilot Control Lever Lock Switch (34) and Pilot Valve "Float"

Position Lock Switch

1. ON 2. OFF

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Page 18

INSTRUMENTS AND CONTROLS

37. BUCKET AND BOOM PILOT CONTROL LEVER

The lever controls raising and lowering as well as rollback and dumping operations of the bucket.
Refer to Par. 4.17.1 and 4.17.3 for additional information.

38 39 40 41 42 43 44 45

Fig. 4.9. Side Control Panel

38. Fan Control Switch

39. Heater/Air Conditioner Temperature Control Knob

40. Main Switch

41. Windshield Wiper Switch

42. Windshield Washer Switch

43. Defroster Fan Switch

44. Rear Window Wiper Switch (if equipped)

45. Rear Window Washer Switch (if equipped)

38. FAN CONTROL SWITCH

This switch controls the speed of the heater fan circulating air inside the cab. It has three positions:

• OFF,

• LO.

• HI.

Move the switch to the desired position.
If the air outside is very dusty, switch the fan into “HI" position. This will create high pressure inside

the cab, which will prevent dusty air from coming into the cab.

39. HEATER /AIR CONDITIONING TEMPERATURE CONTROL

If lower temperature is required, turn the knob to the left. If higher temperature is required turn the

knob to the right.

40. MAIN SWITCH

It switches either the air conditioning or heating. It has three settings:

• neutral,

• heater,

• air conditioning

WARNING! Switch off the defroster fan before adjusting the direction of flow to

avoid injury.

41. WINDSHIELD WIPER CONTROL SWITCH

This switch controls the speed of the windshield wiper motor. It has three positions:

• OFF,

• LO,

• HI.

Move the switch to the desired position for low or high speed wiper operation.

OM515C520C99/1E DRESSTA

OPERATING SECTION 4

Page 19

INSTRUMENTS AND CONTROLS

42. WINDSHIELD WASHER SWITCH
This switch controls the windshield washer. Push the switch button down to run the washer.

Release the button to stop the washer. Use the washer prior to switching on the wipers to protect
the windshield from being scratched.

43. DEFROSTER FAN SWITCH
This switch is used to control the air (hot or cold) supplied onto the windows of the cab.

44. REAR WINDOW WIPER CONTROL SWITCH (IF EQUIPPED)
This switch controls the speed of the rear window wiper motors. It has three positions:

• OFF,

• LO,

• HI.

Move the switch to the desired position for low or high speed wiper operation.

45. REAR WINDOW WASHER SWITCH (IF EQUIPPED)
This switch controls the rear window washers. Push the switch button down to run the washer.
Release the button to stop the washer. Use the washer prior to switching on the wipers to protect
the windshield from being scratched.

46. PARKING BRAKE LEVER (Fig. 4.10)
The parking brake lever is located to the rear right of the operator’s seat on the floorboard. To apply
the parking brake, pull the lever up. To release, lift the lever and depress the button, then lower the
lever. Apply the parking brake before leaving the machine.
It is recommended that the parking brake only be used to hold the machine after it has come to
a stop. However, should the brake system ever fail, the parking brake may be used to make an
emergency stop.

IMPORTANT: Release the parking brake before moving the machine. The brake could burn or be
damaged if the machine is driven with it applied.

46

Fig. 4.10. Parking Brake Lever

DRESSTA OM515C520C99/1E

SECTION 4 OPERATING

Page 20

4.4. CAB DOOR AND WINDOWS

LEFT HAND CAB DOOR HANDLE AND WINDOW LATCHES (Fig. 4.11)
To open the door, push down on handle (2). The handle will automatically return.
To open the windows, turn latch (1) and slide the window up or down as required.
To close the windows, slide the window up or down as required and put latch (1) in the catch.

WARNING: Do not operate the machine with left hand cab door opened.

Fig. 4.11. Left Hand Cab Door

1. Window Latch 2. Door Handle

CAB DOOR LATCH (Fig. 4.11A, CE VERSION)

Fig. 4.11A. Cab Door Latch

The cab door may be locked in an open position. The latch is particularly useful for cab ventilation
when operating in high ambient temperatures.
The latch will be released automatically if the door is pulled energetically to close.

OM515C520C99/1E DRESSTA

CAB DOOR AND WINDOWS

CAB RIGHT HAND WINDOW (Fig. 4.12)

1

Fig. 4.12. Cab Right Hand Window

OPERATING SECTION 4

Page 21

1. Knob

To open the window press the knob (1) and push the window open, the window may be locked by
tightening the catch at the top of the window.

NOTE: Do not lock the window open far enough when operating to interfere with the hood when the
machine articulates.

4.5. OPERATOR’S SEAT

A loader can be equipped with different types of operator’s seats (solid base or suspension).

WARNING: Do not adjust the seat position while the machine is moving, because
a lose of control may result. Stop the machine, apply the parking brake and then
adjust the seat position.

SOLID BASE OPERATOR’S SEAT (Fig. 4.13)
For operator’s convenience in reaching the controls and improved operating visibility, the operator’s
seat can be adjusted to various positions.

The seat adjustment lever is attached to the bottom left front side of the seat. To adjust the seat
forward or rearward, pull the lever under the seat and slide the seat in the desired direction.

The height can be adjusted by removing the bolts that secure the inner post to the outer post and
lining up the holes in both posts at a higher or lower setting. Be sure to put in and tighten the bolts.

DRESSTA OM515C520C99/1E

SECTION 4 OPERATING

Page 22

CAB DOOR AND WINDOWS

Fig. 4.13. Solid Base Operator’s Seat and its Adjusting Controls

1. Seat

2. Inner Height Adjustment Post

SUSPENSION SEAT (VIKING-BOSTROM)

Fig. 4.14. Suspension Seat Adjusting Controls (Viking-Bostrom)

1. Preload Adjustment Ratchet Lever

2. Back Seat Angle Adjustment Catch

3. Outer Height Adjustment Post

4. Seat belt

3. Seat belt

4. Forward and Rearward Control Lever

For operator’s convenience in reaching the controls and improved operating visibility, the operator’s
seat can be adjusted to various positions. Pull lever (4) back and slide the seat to the desired
forward or rearward position. Release the lever to lock the seat.

To adjust the angle of the back seat cushion, lift up the seat back and tilt it to one of its three
positions. Release the cushion allowing the catches on the seat back to engage in bracket
notches (2).The suspension preload should be adjusted to the operator’s weight for proper ride
control. While sitting in the seat, turn ratchet lever (1) clockwise to increase the preload. Turn the
ratchet counterclockwise to decrease the preload.

OM515C520C99/1E DRESSTA

SUSPENSION SEAT (GRAMMER)

OPERATING SECTION 4

Page 23

CAB DOOR AND WINDOWS

Fig. 4.15. Suspension Seat (Grammer)

1. Weight Indicator

2. Weight Adjustment Knob

3. Seat Travel Lever

4. Backrest Profile Adjustment Knob

5. Backrest Profile Adjustment Knob

6. Armrest Profile Adjustment Knob

7. Backrest Angle Adjustment Lever

This is a suspension seat with several adjustments to provide the maximal comfort to the operator.
Adjustment to the operator’s weight – seated in the operator’s seat turn adjustment knob (2)

clockwise or counterclockwise until proper weight value corresponding to the operator’ s weight
appears in weight indicator window (1).

Seat travel adjustment - pull up the lever (3) (on the right hand side of the seat) and slide the seat
forward or rearward to the desired position and lock with the lock lever.

Seat height adjustment - lift the seat cushion up or press it down and hold it with both hands until
it settles at the desired height.

Backrest angle adjustment - pull up lever (7) to release the lock. Upon the adjustment of the
backrest angle (pressing the backrest) apply the lock.

Backrest profile adjustment – performed with two knobs: knob (4) located on the left hand side of
the seat and knob (5) located on the right hand side of the seat. Turn knob (4) to change the
backrest profile in the middle part, turn knob (5) to change the lower and upper part of the backrest
profile.

Armrest angle adjustment – performed with screws (6) located under the armrests (tilt back the
armrests to facilitate adjustment).

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SECTION 4 OPERATING

Page 24

4.6. SEAT BELT

The seat belt is for operator's safety and should be worn at all times while operating the machine.
Adjust the seat to the desired position before fastening the seat belt.

WARNING: DO NOT use bleach, dye, or solvents on the seat belt, because this
may weaken the webbing and result in personal injury. Clean the seat belt with
warm water and a mild detergent. Replace belts with worn, frayed, torn, faded,
stiff, or rotted webbing.

WARNING: Before driving the machine, adjust the seat and fasten the seat belt
Adjust the seat belt to fit snugly and low around the hips to lessen the chance
and severity of injury in the event of an accident. NEVER wear the seat belt
across the abdomen.

Fig. 4.16. Seat Belt

1. Belt 2. Buckle 3. Tang

Fasten the belt and remove it in the following manner:

1. Adjust the seat so that the brake pedal can be depressed all the way with the operator's back

against the backrest.

2. With the seat unoccupied, tense belt (1) lightly across the seat and install. Check that there are

no kinks in the belt.

3. Sit in the seat. Hold buckle (2) and insert tang (3) into the buckle. Check that the bet has locked

by pulling it.

4. When removing the belt, raise the tip of the buckle lever to release it.

When leaving the operator's seat, release the seat belt and hang it over the arm rest.
Fasten the belt across your body without kinking it. Adjust the lengths of the belt on both the buckle
and tang ends so that the buckle is located at the mid-point of your body front.

Adjust the belt length in the following manner:

1. To shorten the belt, pull the free end of the belt at either the buckle or tang end or at both ends.

2. To lengthen the belt, pull the belt while holding it at a right angle to the buckle or tang.

OM515C520C99/1E DRESSTA

OPERATING SECTION 4

SEAT BELT

Fig. 4.17. Adjusting the Belt Length

4.7. CAB HEATING AND VENTILATION

Page 25

4.7.1. DEFROSTER FAN

Fig. 4.18. Defroster Fan

The fan is designed for cab ventilation (air circulation) and defrosting or defogging the windshield.
The switch has two positions and is located on the side control panel (43, Fig. 4.19).

WARNING! Turn off the motor before adjusting defroster fan to avoid hand
injury.

4.7.2. HEATER

For cab heating, ventilation and air conditioning integrated heater and air conditioner installed in the
right hand side of the cab wall is used. The heater and air conditioner controls are situated in the
side control panel.

DRESSTA OM515C520C99/1E

SECTION 4 OPERATING

Page 26

CAB HEATING AND VENTILATION

38 39 40 41 42 43 44 45

Fig. 4.19. Side Control Panel

38. Fan Control Switch

39. Heater/Air Conditioner Temperature Control Knob

40. Main Switch

41. Windshield Wiper Switch

For description of controls refer to Par. 4.3.

4.7.3. AIR CONDITIONER

42. Windshield Washer Switch

43. Defroster Fan Switch

44. Rear Window Wiper Switch (if equipped)

45. Rear Window Washer Switch (if equipped)

Fig. 4.20. Block Diagram of A/C Connections

The wheel loader may be equipped with air conditioner to reduce air temperature and relative
humidity inside the cab. An air conditioner consists of the following principal components:

1. Compressor – V-belt driven thru pulley mounted on the engine

2. Condenser – radiator mounted

3. Dehumidifier – mounted on a bracket on the RH side of the rear frame

4. Evaporator – RH side cab wall mounted

5. Expansion valve – integrated with the evaporator

The a/m components are connected with hoses 6 – 9. The A/C system is filled with R-134A gas.

NOTE: If A/C system refilling is required contact Construction Equipment Authorized Distributor.
The system must be filled in accordance with the manufacturer’s instructions.

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4.8. AIR CLEANER SERVICE INDICATOR

Fig. 4.21. Service Indicator

1. Service Indicator

The indicator is located in the upper front part of the hydraulic reservoir (behind the cab). During
operation, the red band will gradually rise in the indicator window as dirt accumulates in the air filter
elements. When the filter elements reach the maximum allowable restriction, the red band will
completely fill the indicator window and automatically lock in this position. The red band will remain
fully exposed even after stopping the engine. When this happens, filter element service is required.
Press the reset button on top of indicator after the elements have been serviced.

4.9. ELECTRIC SYSTEM MASTER SWITCH

Fig. 4.22. Electric System Master Switch Fig. 4.22A. Electric System Master Switch

(CE Version)

The switch is located on the LH side of the hydraulic tank behind the cab and is connected in series
between the battery positive terminal (+) and receivers, thus turning "ON" or "OFF" battery voltage
to all electric systems. The master switch must always be turned to the "ON" position when the
engine is running to prevent any damage to the alternator and/or electric system. On machines in
CE version the switch is located at the back on the left hand side.

WARNING: Before servicing the machine, turn off the electric system master
switch and remove the key. Tag the machine to warn against starting the engine.

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Page 28

4.10. DOME LIGHT WITH SWITCHES

Dome light is installed in the roof of the cab on the right and left hand side of the operator’s head.
The light is equipped with a switch. Two lights are installed on machines in CE version.

4.11. STARTING AND STOPPING THE ENGINE

4.11.1. NORMAL START (AMBIENT TEMPERATURE ABOVE 0 [ °°C])

WARNING: DO NOT jump on or off the machine. Keep two hands and one foot,
or two feet and one hand in contact with the steps and hand holds at all times.
Always face the machine when climbing on or off to reduce the chances of
slipping and injury.

1. Check that the parking brake switch is applied (machine stopped)

2. Check that transmission direction lever is locked in the "N" (neutral) position.

3. Turn the master electric system switch "ON" (Refer to Fig. 4.22, 4.22.A).

4. With your back against the back rest of the operator's seat, adjust the seat position so that the

brake and decelerator pedal can be easily depressed (Refer to Fig. 4.6).

5. Sound the horn to clear the area of personnel.

NOTE: All the warning lights should light up while the starting key is between RUN and START
position. Replace any bulb that fails to light up.

NOTE: The engine will not start while the direction lever is in any position other than "N" (neutral).

Fig. 4.23. Starting and Stopping the Engine

1. Transmission Direction Lever

2. Accelerator Pedal

3. Starting Switch

4. Parking Brake Lever

6. Turn the starting key from RUN to START position (Fig. 4.3) to start the engine with accelerator

pedal released (idle speed).

7. Keep the key till the engine starts but no longer than 30 seconds. Then release the key

immediately, it returns automatically to the RUN position.

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Page 29

STARTING AND STOPPING THE ENGINE

IMPORTANT: To prevent damage to the cranking motor and avoid low battery output, do not

continuously crank engine for more than 30 seconds. Allow a recovery period of 2 minutes between
crankings.

WARNING: Never start the engine indoors unless proper exhaust ventilation is
provided to remove deadly exhaust gases. Once the engine is running, move
the machine outdoors as soon as possible. Exhaust gases are hazardous and
can cause unconsciousness and death.

NOTE: Engine oil pressure must register 15 seconds after startup. If no oil pressure is registered

stop the engine immediately.

8. If a cold engine is being started, increase its speed slowly to ensure proper lubrication of the
bearings.

IMPORTANT: Do not run the engine at idle speed more than 10 minutes as it may cause engine
damage.

9. Allow the engine to run idle for 3 to 5 minutes before placing it under load.

IMPORTANT: When starting the engine after engine oil change or after the engine has been shut
off for 30 days disconnect the fuel shut-off valve electric wire and crank the engine until oil pressure
registers on the gauge and the oil pressure warning light goes out. Connect the fuel
shut-off valve wire again. Start the engine as described above.

4.11.2. COLD WEATHER START (USING ETHER INJECTOR, AMBIENT
TEMPERATURE BELOW 0 [°°C])

NOTE: Never operate ether injector switch except when starting the engine.

WARNING! Ether starting fluid is highly flammable. Follow the precautions on the
container. An explosion can result if sparks or flame contact ether or if the
container is stored where the temperature exceeds 70 [°°C].
Observe the following precautions:
a) Do not use the ether injector when the air temperature is above freezing.
b) Never smoke when using ether starting fluid or installing the container.
c) Do not store fluid containers in the operator's compartment. Store the

containers in a cool, well-ventilated place.
d) Keep the fluid containers out of reach of children.
e) Do not breathe the hazardous ether vapor.
f) Do not let ether contact your skin, as it can cause frostbite.
g) Never puncture the fluid container or put it into fire. Dispose of empty

containers properly.
h) For your safety, remove the ether container when welding, grinding, or using

a torch on the machine.
I) Follow the correct method for starting the engine.

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STARTING AND STOPPING THE ENGINE

When starting the engine in low temperatures, do as follows:
Perform the steps 1 thru 5 of Par. 4.11.1.

6. Press the accelerator pedal down half the full stroke.

7. Crank the engine and simultaneously press the ether start button to fill the ether chamber in the
valve with a measured shot of starting fluid. Pressing the ether start button once will release
a single dose of ether into the engine. If the ambient temperature is below -18 [°C] additional
doses of ether may be needed.

IMPORTANT: If the engine does not start with maximum of two ether injections determine and
correct the cause before attempting to start the engine again.

If the engine will not start or runs roughly it may be due to one of the following:
a). Air may be in the fuel system,

b). The ether injector is not functioning correctly.

8. After the engine has started release the accelerator pedal.

NOTE: Proper engine oil pressure must register on the gauge 15 seconds after startup. If no oil
pressure is registered stop the engine immediately.

9. Check all the instruments for proper operation.

4.11.3. STOPPING THE ENGINE

1. Allow the engine to cool down after operation at full load. Run the engine with no load at idle for

about 3 to 5 minutes before shutting it down to ensure a gradual and even cooling.

IMPORTANT: Failure to do so may result in damage to the engine and turbocharger.

2. Shut down the engine by turning the starting key to the OFF position (Fig. 4.3). Before leaving

the machine remove the key and turn off the electric system master switch into OFF position
(Fig. 4.22, 4.22.A).

4.12. DRIVING THE MACHINE

WARNING! Before operating the machine observe strictly the following
precautions:
a) never haul passengers in the cab - the loader is equipped with a cab for the

operator only,

b) never allow anyone to stand on steps or on the platform when driving and

operating the machine,
c) sit in the operator’s seat before operating any controls or switches,
d) keep your hands and footwear free of grease, water and mud to insure

positive control movement,
e) before driving the machine, adjust the seat and seat belt to fit snugly and low

around the hips,
f) sound the horn to warn the nearby personnel,
g) never try to get on or off the machine when it is moving,
h) check all the instruments, gauges and warning light for correct operation

OM515C520C99/1E DRESSTA

OPERATING SECTION 4

4.12. DRIVING THE MACHINE

Fig. 4.24. Driving and Stopping the Machine (Standard Version)

Page 31

Fig. 4.25. Driving and Stopping the Machine (Upgraded Version)

1. Transmission Gear Range Lever

2. Transmission Direction Lever

3. Brake Pedal

4. Accelerator Pedal

5. Boom and Bucket Pilot Control Valve Lever

6. Parking Brake Lever

7. Bucket Control Lever

8. Boom Control Lever

1. Depress brake pedal (3).

2. Release parking brake lever (6).

3. Using lever (8 standard version) or lever (5 upgraded version), raise the boom until the bucket is
off the ground and in the carry position.

4. Using lever (7 standard version) or lever (5 for upgraded version), close the bucket.

5. Place transmission gear range lever (1) in the first gear position.

6. Move the transmission hinge lock plate to the right. Then place the transmission direction lever
(2) in the desired position forward or reverse.

NOTE: If the machine is equipped with a back-up warning alarm, the alarm will sound when the
lever is placed in reverse.

7. Release brake pedal (3) and gradually depress accelerator pedal (4).

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4.13. SHIFTING GEARS

The transmission has three forward gear ranges, three reverse gear ranges, and neutral, which are
manually selected with transmission gear range lever (1, Fig. 4.25) and direction lever
(2, Fig. 4.25). The transmission is full powershift type and any gear range or direction can be
changed at any time without stopping the machine.

The first gear is the lowest and main working range. The second gear can be used when working in
loose material or hauling at short distances. The third gear is used to road the machine at longer
distances at maximal machine speeds. The direction lever must be in neutral "N" before the engine
can be started. Reverse also has 3 gears.

Fig. 4.26. Shifting Gears

1. Gear Ranges 2. Travel Directions

DOWN-SHIFTING
Down-shifting should never be made at a vehicle ground speed higher than the maximal speed for
the gear you intend to shift down to. Failure to do so results in sudden braking of the machine. For
speed ranges in the respective gears refer to TRANSMISSION, Section 6.

IMPORTANT: Down-shifting from 3 to 1 or 2 when driving at maximum speed may result in drive
train damage.

UP-SHIFTING
An up-shift from "1" to "2" or from "2" to "3" can be made at any speed. To get proper acceleration,
speed up the machine to the maximal speed before up-shifting. For speed ranges in the respective
gears refer to TRANSMISSION, Section 6.

DIRECTION-SHIFTING
Decelerate the engine for all direction changes, by applying the accelerator and brake pedal. This
will result in a smoother directional change rather than using the transmission disconnect pedal.

4.14. STEERING

The machine is articulated and steering is accomplished by hydraulic power which pivots the front
and rear frame at the center articulation pivot. Turn the steering wheel until reaching the desired
angle of turn. Hydraulic power holds the angle of the turn until the steering wheel is turned again.

WARNING! Never allow anyone near the center articulation pivot with engine
running.

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STEERING

GROUND DRIVEN STEERING (IF EQUIPPED)
If there is a drop in hydraulic steering pressure, the ground driven steering will be actuated
automatically and a warning light on the instrument panel will flash. The amount of oil supplied by
the ground driven pump depends upon the machine ground speed (pump driven by the
transmission output shaft). The steering response is reduced as the machine slows down.

WARNING! If the ground driven steering warning light comes "ON", immediately
maneuver the machine to a safe place. Shut down the engine and apply the
parking brake. Correct the problem before operating the machine again.

WARNING! The steering response with ground driven steering system actuated
depends upon the machine ground speed. The steering response is reduced as
the machine slows down.

4.15. STOPPING THE MACHINE (Fig. 4.25)

Perform the steps the in following order:

1. Fully release accelerator pedal (4).

2. Apply brake pedal (3) until the machine comes to a complete stop. Braking efficiency depends
upon the amount of pressure exerted on the brake pedal, the higher pressure the more efficient
braking.

WARNING!: Never brake with the drive disconnected (33, Fig. 4.4 or 4.5) when
traveling fast or going downhill. Releasing the brake pedal automatically makes
the transmission clutches to re-engage. With ground speed higher than the
maximal speed at the previously shifted gear the machine will brake suddenly,
which may result in a loss of control or damage to the power train.

3. Place transmission direction lever (2) in "N" (neutral) position and lock the lever in this position.

WARNING!: The transmission can remain in gear when the machine is brought to
a temporary stop during operation. However, the operator must remain seated
with the seat belt fastened.

4. Apply parking brake (6).

5. Place bucket control lever (7, Fig. 4.24 or 5, 4.25) in the detented position - bucket roll back.

6. Push forward boom control lever (8, Fig. 4.24 or 5, 4.25) to lower the boom and rest the bucket
on the ground. The bucket will be leveled automatically.

WARNING!: Never leave the machine unattended with the engine running or the
bucket raised. When parking a machine: stop the engine, lower the bucket to the
ground, lock the transmission shift lever in neutral (N), apply the parking brake,
turn off the electric system master switch, and remove the keys.

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4.16. PARKING THE MACHINE

WARNING!: When parking the machine observe the following rules:
a) Park the machine in a non-traffic area. If parking in traffic lanes cannot be

avoided, provide appropriate flags, barriers, flares, and warning signals. Also
provide advance warning signals in the traffic lane for approaching traffic.

b) Always lock the machine, including any anti-vandalism attachments, when

leaving the machine unattended.

C) Avoid parking on a slope, however, if parking on a hillside is necessary, park

at the right angle to the hill and block the tires as shown in Fig. 4.27.

NOTE: Avoid parking the machine in puddles of oil, grease or gasoline because this damages the

tires.

Fig. 4.27. Hillside Parking

NOTE: Park the machine on level ground to obtain accurate coolant, lubricant, hydraulic, fuel level
checks.

4.17. LOADER OPERATIONS

The loader equipment is hydraulically operated. When the bucket circuit is being operated, oil flow
to the boom is cut off.

IMPORTANT: Holding the control lever in any position except B "hold" and D “float" for an
extended period of time after the hydraulic cylinder rod has reached the limit of its travel will
produce excessive heat in the hydraulic system which may affect loader performance.

4.17.1. BOOM CONTROL LEVER POSITIONS (Fig. 4.28.)

Fig. 4.28. Boom Control Lever Positions (Standard Version)

A. Raise B. Hold C. Lower D. Float

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OPERATING SECTION 4

LOADER OPERATIONS

Fig. 4.29. Boom Control Lever Positions (Upgraded Version)

Page 35

A. Raise
B. Hold

C. Lower
E. Bucket Rollback

F. Bucket Dump
P. Forward Direction of the Lever

In standard version the boom control is located to the far right of the operator's seat. It has four
positions: A, B, C, D (“raise", "hold", "lower", and "float").

In upgraded version, a single lever controlling both the boom and the bucket movement is located
on the right of the operator’s seat. It has three positions for boom control: “raise", "hold", "lower",
and three positions for bucket control: “rollback", "dump" and "hold". The hold position is common
for both the bucket and the boom.

RAISE (A, Fig. 4.28, 4.29)
To raise the boom assembly, pull the lever back as far as it will go. A solenoid latch in the valve
locks the lever in detented position. The return to "HOLD" must be done manually or will be done
automatically when the boom reaches the preset stopping height of the automatic boom kick -out.

HOLD (B, Fig. 4.28, 4.29)
The control lever, when not in a detented position, will automatically return to "HOLD" when
released. The boom will remain stationary in this position.

LOWER (C, Fig. 4.28, 4.29)
Push the lever part way forward (in standard version) or all the way forward (in upgraded version) to
lower the boom. The lever will automatically return to "HOLD" when released.

WARNING! Do not leave the machine with a raised boom. The boom may drop
down even if the engine is shut down. (Refer to CHANGING THE HYDRAULIC
SYSTEM OIL, Section 5.14.2).

FLOAT (D, Fig. 4.28, FOR STANDARD VERSION)
The boom assembly can be lowered at any time by moving the lever to C “lower" or D “float"
position. Push the lever all the way forward for this position. This position is detented so the lever
must be pulled back manually to the "hold" position. Use the “float" position to follow the contour of
the ground when leveling or to lower the boom by gravity.

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LOADER OPERATIONS

FLOAT (UPGRADED VERSION)
When the float switch is on (Fig. 4.8), the boom will gradually lower. This position is locked with
a spring. To shift back to "hold" the switch must be put off. Use the “float" position to follow the
contour of the ground when backdragging or leveling hard ground.

WARNING! It is forbidden to lower the boom from fully raised position by moving
the control lever to “float" position. Due to weight of loader linkage it may be
dangerous for nearby personnel and damaging to the machine.

4.17.2. AUTOMATIC BOOM KICK-OUT (Fig. 4.30.)

Fig. 4.30. Automatic Boom Kick Out

1. Proximity Switch

2. Adjustment Plate

3. Locking Bolt
C. Plate-to-Switch Clearance

The electronically operated kick-out control system stops boom travel automatically at a
preselected height. This eliminates unnecessary boom travel during operation and provides for a
more efficient cycle.

Adjustment plate (2) is bolted to the left boom arm and is adjustable. Proximity switch (1) is
mounted to the front frame. Proximity switch (1) creates a magnetic field circuit which is completed
by the proximity of adjustment plate (2) within the magnetic field. Once the boom is raised to its
preselected height, adjustment plate (2) has moved out of the magnetic field, breaking the circuit.
Breaking the magnetic field circuit causes the boom control lever to move out of the detented
"RAISE" position and into the "HOLD" position, thereby stopping the travel of the boom arms. Plate­to-switch clearance "C" necessary for the proper operation of the proximity switch is 7 to 8 [mm].

ADJUSTMENT OF AUTOMATIC BOOM KICK-OUT
To change the automatic boom kick-out position, raise the boom arms to the desired stopping
height. Place the boom control lever in the "HOLD" position. Loosen locking bolt (3) on sensor plate
(2). Move adjustment plate (2) until it is just out of the magnetic field of proximity switch (1). Tighten
locking bolt (3) on adjustment plate (2). Start the machine and test the adjustment. Repeat this
procedure until the automatic kick-out height is obtained.

WARNING! Use extra caution when adjusting loader’s bucket leveler or boom
kick-out. Use two trained people and guard against accidental movement of the
machine or loader linkage. No personnel is allowed within the reach of loader
linkage. Never work or walk under raised bucket without proper blocking.

OM515C520C99/1E DRESSTA

OPERATING SECTION 4

LOADER OPERATIONS

4.17.3. BUCKET CONTROL LEVER POSITIONS (Fig. 4.31)

Fig. 4.31. Bucket Control Lever Positions (Standard Version)

E. Rollback B. Hold C. Dump

Page 37

The bucket control lever is situated on the RH side of the operator’s seat and close to the boom
control lever (closest to the operator's seat). It has three positions E, B, F ("roll back, "hold", and
"dump").

Refer to Par. 4.17.1 (Fig. 4.29) for the location and positions of the bucket and boom control lever
(upgraded version). It can take 3 positions:

F - dump,
B - hold,
E - rollback.

IMPORTANT: Holding the control lever in any position except B "hold" and D “float" for an
extended period of time after the hydraulic cylinder rod has reached the limit of its travel will
produce excessive heat in the hydraulic system which may affect loader performance.

ROLL BACK E (Fig. 4.29 and 4.31)
To roll the bucket back (load the bucket) pull the lever:

a) in standard version: all the way back,
b) in upgraded version: to the left towards the operator.

When the automatic leveler is inoperative, the lever automatically returns to the hold position when
released. When the automatic leveler is operative, the lever will be locked automatically with the
solenoid latch. This latch can be released manually.

HOLD B
The control lever, if not in E detented position, will return automatically to hold position B when
released and will maintain the bucket in the required position.

DUMP F
To dump the bucket, push the lever:

a) in standard version: all the way forward,
b) in upgraded version; to the right, away from the operator.

When the lever is released, it will automatically return to hold position B.

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LOADER OPERATIONS

4.17.4. AUTOMATIC BUCKET LEVELER

Fig. 4.32. Automatic Bucket Leveler

1. Trip Bar 2. Proximity Switch with Adjustment Nut C. Bar-To-Switch Clearance

The automatic bucket leveler is located on the underside of the bucket cylinder and is preset to stop
the bucket in the horizontal or digging position. Trip bar (1) is attached to the cylinder rod. The trip
bar moves with the cylinder rod. Proximity switch (2) creates a magnetic field circuit which is
completed by the proximity of trip bar (1) within the magnetic field. Once the bucket is dumped,
move the bucket control lever to its detented "ROLL BACK" position. When the bucket reaches its
preset position, trip bar (1) has moved out of the magnetic field circuit created by the proximity
switch; it will automatically stop and the bucket control lever will return to the "HOLD" position. Bar­to-switch clearance "C" necessary for the proper operation of the proximity switch is 7 [mm] to 8
[mm]. It is adjusted with the proximity switch nuts.

ADJUSTMENT OF AUTOMATIC BOOM KICK-OUT
Place the bucket flat on the ground. Place the key in the starting switch in the "RUN" position. If the
electromagnetic field of proximity switch (2) is making contact with trip bar (1) mounted under the
cylinder rod, the bucket control lever will stay in the "HOLD" position. Slide the proximity switch
mounting "U" bolt back toward the base end of cylinder until contact of the electro-magnetic field is
broken. This will be the kick-out position for a level bucket.

4.17.5. MULTI-PURPOSE BUCKET CONTROL LEVER POSITIONS (IF EQUIPPED)

The multi-purpose bucket control lever controls the opening and closing of the clam on the bucket.
Before changing the bucket position raise the bucket 1 [m] above the ground. In standard version it
is located next to the bucket control lever closest to the operator’s seat 28, Fig. 4.4). In upgraded
version it is located on the right of the bucket and boom control lever (28, Fig. 4.5).

OPEN
Push the control lever forward to open the bucket clam. When released, the lever will automatically
return to the "HOLD" position.

HOLD
The control lever will return automatically to the "HOLD" position from either the "OPEN" or
"CLOSE" position when released. The bucket clam will remain in the same position it was in when
the control lever was released.

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LOADER OPERATIONS

CLOSE
Put the control lever back to close the bucket clam. When released, the lever will return to the
"HOLD" position.

When a machine is equipped with a multi-purpose bucket, it is also equipped with a clam position
indicator.

A clam opening product graphic (A, Fig. 4.33) is located on the upper left hand side of the bucket.
This product graphic indicates to what extent the clam is opened or closed.

"0" indicates closed, "2" indicated half open and "4" indicates a fully open clam.
To set the multi-purpose bucket as a bucket, pull the control lever back until the clam indicator is at

the "0" setting on the clam product graphic (A, Fig. 4.33).

Fig. 4.33. Multi-purpose Bucket set in "Bucket" Position.

A. Clam Product Graphic

To set the multi-purpose bucket as a scraper, open the clam until the indicator points to "2" or "4"
on the clam product graphic (A, Fig. 4.34). The more the clam is open, the deeper a cut can be
made.

Fig. 4.34. Multi-purpose Bucket set in "Scraper" Position.

A. Clam Product Graphic

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LOADER OPERATIONS

To use the multi-purpose bucket as a dozer, open the clam until the clam indicator is at the bottom
of the clam decal (A, Fig. 4.35).

Fig. 4.35. Multi-purpose Bucket set in "Dozer" Position.

A. Clam Product Graphic

Position "A", Fig. 4.36 is for level grading. Position "B", Fig. 4.36 is for a deeper cut and position "C",
Fig. 4.36 is for a lesser amount of cut.

Fig. 4.36. "Dozer Blade Pitch" Position.

A. Clam Product Graphic

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OPERATING SECTION 4

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LOADER OPERATIONS

To use the multi-purpose bucket as a clamshell, open the clam until the indicator is at the bottom or
completely open (A, Fig. 4.37).

Fig. 4.37. Multi-purpose Bucket set in "Clamshell" Position.

A. Clam Product Graphic

4.18. LOADER TECHNIQUES

Terrain, footing conditions, types of materials being worked and maneuvering space determine the
speed at which the loader can function. When the bucket is at work, keep the engine speed at full
throttle and operate in the first (1) gear transmission range.
Use gear range two (2) and three (3) for traveling purposes. The techniques for using the loader as
described below are not intended to be all inclusive. Each work situation will vary. Loader operation
may be altered for each particular application for its best efficiency. When possible, start all jobs
from relatively level ground. If necessary, level an area large enough to provide sufficient working
space. This prevents back and forth pitching of the loader and will result in easier operation. Avoid
wheel spin whenever possible; this wastes effort and causes ruts and piles that pitch and tilt the
loader. In cold weather, this material can freeze and cause additional difficulty the following day.

4.18.1. LOADING, TRANSPORTING AND PILING

1. When loading from a bank or stockpiling, use the V-method shown in Fig. 4.38, or the step

loading method shown in Fig. 4.39. Keep the trucks close to the work area to minimize loader
travel. Keep work areas clean and level. When possible, spot the next truck to be loaded on the
opposite side as shown in Fig. 4.38.

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LOADER TECHNIQUES

Fig. 4.38."V" Loading Method Fig. 4.39. Step Loading Method

Approach the bank or stockpile with the engine at full governed speed. Keep the bucket flat, working
into the material at or near ground level. As the bucket penetrates the material, raise the bucket
slightly. When the material boils to the top of the spillboard, roll the bucket all the way back, raise
the bucket to provide ground clearance and, at the same time, disengage the forward travel of the
loader as shown in Fig. 4.38. Back away in an arc from the bank or stockpile as show in Fig. 4.38
and 4.39 just far enough to allow turning of the loader for the approach to the truck. Digging in hard
material can be aided by "wiggling" the bucket edge immediately after penetration. Operate the
bucket control lever alternately between the roll back and dump positions. This action will loosen the
material and improve bucket loading. Coordinated operation of the two hydraulic control levers as
the bucket enters the material will yield satisfactory bucket loads. The boom assy need not be fully
raised to dump the bucket. Adjust the dump height to the height of the side of the loaded vehicle.

NOTE: The boom assembly need not be fully raised to load the bucket. Maximum bucket loading
can be obtained before the bucket reaches the operator’s eye level.

Approach the bank or stockpile with the engine at full governed speed. Keep the bucket flat, working
into the material at or near ground level. As the bucket penetrates the material, raise the bucket
slightly. When the material boils to the top of the spillboard, roll the bucket all the way back (Fig.

4.40 and 4.41).
Raise the bucket to provide ground clearance and, at the same time, disengage the forward travel

of the loader. Back away in an arc from the bank or stockpile as shown in Fig. 4.38 and 4.39 just far
enough to allow turning of the loader for the approach to the truck.

Fig. 4.40. Bank Loading (Working into Material)

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LOADER TECHNIQUES

1 2 3

Fig. 4.41. Stockpile Loading

1. Approach 2. Thrust and Load 3. Backaway

2. To use the multi-purpose bucket for scraping, position the bucket on the ground and open the

clam until the indicator points to "2" or "4" on the clam product graphic (A, Fig. 4.42) according to
the desired depth of cut.

Fig. 4.42. Multi-purpose Bucket set in "Scraper" Position.

A. Clam Product Graphic

3. To use a multi-purpose bucket as a bucket, roll the bucket forward or backward and move the

machine forth. The cutting edge will penetrate into the ground till the clam’s cutting edge gets into
full contact with the ground (Fig. 4.43).

Fig. 4.43. Starting to Load

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LOADER TECHNIQUES

Fig. 4.44. Loading Fig. 4.45. Full Bucket

Carry on driving the machine forward till the bucket is filled with spoil (Fig. 4.44). Then roll the
bucket back and close the clam (Fig. 4.45). Raise the bucket over the ground and transport the
spoil to the dumping area.

4. When bank loading, keep the cutting edge flat as shown in Figure 4.46. Rolling the bucket back
too far forces the flat of the cutting edge against the bank preventing the bucket from digging.
This non-productive maneuver causes waste of power and time and possible damage to the
bucket cylinders and linkage.

5. When stockpiling, move each load only once and keep travel distance down to a minimum.
When possible, locate stockpiles as close as possible without hindering other work on the site.

WRONG

RIGHT

Fig. 4.46. Bank Loading

6. Transport filled bucket in the roll back position close to the ground (Fig. 4.47). If it is necessary to
carry the bucket raised in transit, the operator should use increased caution. Perform all steering
and shifting as smoothly as possible. Use the lower transmission gear range for bucket loading
and the transportation of loads. The higher gear range may be used for making return trips to the
loading sites.

WARNING! Transport loads with bucket in the carry position only. A loaded
bucket must never be transported in the fully raised boom or with boom in
horizontal position.

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Fig. 4.47. Transporting full Bucket

7. Upon reaching the truck, raise the bucket high enough to clear the truck body. Reduce forward
speed and dump the load slowly (Fig. 4.48). This will reduce the shock of weight transfer to the
rear axle when the bucket is emptied. Shake the bucket and raise the boom to loosen dirt from
within.

When the bucket empties, close it. Back the loader away from the truck, lower the boom and
return to the loading site.

If the boom height is insufficient to clear the truck pack or the loaded container, build a ramp out
of hard ground.

Using the automatic boom kick-out and bucket leveler is particularly recommended in continuous
operation of even working cycle. For this kind of operation the positioning of the truck receiving
the spoil is of importance.

Fig. 4.48. Dumping Into Truck

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8. When transporting trees or other large objects, always balance the load as shown in Fig. 4.49.
Balance the load when picking it up to prevent twisting the boom assembly and linkage.

Fig. 4.49. Transporting Trees with Multi-purpose Bucket

9. Lower loaded or unloaded bucket to the ground when waiting for any length of time.

10. Put enough loose rock or dirt into the truck first to act as cushioning material before proceeding
to load larger rocks (Figure 4.50). Place large rocks into the center of the truck from the lowest
possible height.

Fig. 4.50. Dumping Large Rocks Into Truck

Plan excavating jobs so that most of the work can be done with the loader being driven forward,
rather than being backed out. Use as flat a ramp as possible. A steeper ramp can be used when
driving forward rather than in reverse.

Always feed the bucket into the ground gradually until the desired depth of cut is obtained. When
selecting the gear range and determining the depth of cut, allow for an increase in resistance as
the load increases. It may be necessary to raise the lift arms slightly to obtain greater traction.

Less loading effort is required when the material can be moved downhill.

WARNING! Never travel with an unstable and solid rock.

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in the utmost dump position as due to unfavorable distribution of forces a

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4.18.2. DIGGING, CLEARING AND LEVELING

1. When digging or excavating lower the bucket to the ground. Adjust the angle of the cutting edge
when the machine moves forward (Fig. 4.52). Change inclination of the angle of the cutting edge
and cutting depth using the boom and bucket control levers depending on bucket filling. Establish
the parameters to obtain the best bucket filling. When the bucket is full, roll it back and raise it
clear off the ground and carry the load to the desired dump area.

Fig. 4.51. Digging or Excavating

Clearing an excavation (Fig. 4.52) may be performed with the bucket partly in the dump position by

disposing of the material carried in the bucket.

It is recommended to clear an excavation a little above the ground level because after compaction

the ground will be level. Approach an excavation at the right angle and stop the front wheels at a
safe distance from the edge of the excavation.

Fig. 4.52. Filling an Excavation

WARNING! Never backdrag, push any objects (trees, rocks, etc) with the bucket

serious damage to loading mechanism can result. It is particularly unfavorable
when operating with boom raised.

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WARNING! Do not operate close to dangerous overhangs. Unskillful operation

of the loader may result in occurrence of overhangs that may slide on the
loader. Prevent occurrence of the overhangs or remove them using other
methods e.g. firing, digging from the top, etc.

Sequence of bank loading is shown in Fig. 4.53.

Fig. 4.53. Bank Loading

1. With the clam fully open, the multi-purpose bucket can be used as a bulldozer. Position the
bucket as shown in Fig. 4.54 for digging.

When the ground is hard or frozen and the area must be ripped before it can be worked, rip
a relatively small section and work it to grade before enlarging the cut. This will require ripping
each section only once, not every morning after the ground has refrozen. To prevent breaking or
bending scarifier teeth, never turn the loader while the scarifier teeth are in the ground.

Fig. 4.54. Bulldozing with Multi-purpose Bucket

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3. When clearing trees, raise the bucket high to gain leverage and make contact gently to reduce
possible harm to the operator and loader. The bucket must be positioned with bottom parallel
with the ground. DO NOT push with the top of the bucket (Fig. 4.55)

WARNING! When using the machine for site clearing and tree removal, protect
the operator from trees and branches.

Fig. 4.55. Position of the Bucket When Removing Small Tree

A. Wrong B. Right

Heavy roots of large trees may require cutting from several sides of the tree (Fig. 4.56). Use a cable
to topple and remove trees from soft ground. Topple the tree, back the loader and lower the bucket
to the ground and push the tree from the site.

Fig. 4.56. Removing Large Trees

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4. When clearing a rocky area, remove the small and loose rocks first, large and solid rocks can
then be loosened and moved with less difficulty.

When loosening large or solid rocks, greater force and penetration can be obtained by digging
under the rock with the bucket (Fig. 4.57). Lifting the rock with the bucket while pushing will increase
traction i reduce wheel spinning.
Never use the clamshell to remove buried or anchored objects.

Fig. 4.57. Large Rock Removal

When finishing a non-solid material, position the bucket as shown in Fig, 4.58 or Fig. 4.59 and
backdrag the loose material. This method is not recommended where abrasive material is
common.

Fig. 4.58. Backdragging and Leveling

Fig. 4.59. Backdragging and Leveling with Multi-Purpose Bucket

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By placing the multi-purpose bucket in the scraper position and opening the clam slightly, spreading
of material can be done on the "run". The amount of spread can be controlled by the amount of
clam opening (Fig. 4.60).

Fig. 4.60. Spreading with Multi-Purpose Bucket

5. With the clam fully open, the multi-purpose bucket can be used to bulldoze material. Position
the bucket as shown in Fig. 4.61 for level grading. Position the bucket as shown in Fig. 4.62 for
spreading or to obtain a lesser cut.

Fig. 4.61. Leveling with Multi-Purpose Bucket Fig. 4.62. Bulldozing with Multi-Purpose Bucket

6. Improper use of the multi-purpose bucket.

Much unnecessary damage can be done to multi-purpose buckets by subjecting them to uses for
which they were not designed. The following illustrates some of the ways a multi-purpose bucket
should NOT be used.

DO NOT use roll back force to pull stumps or buried objects from the ground – it may bend the
clam (Fig. 4.63).

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