DRESSTA 560C Operator's Manual

OM560C99/1E

OPERATOR’S MANUAL

560C

SERIAL NUMBERS

15001 AND UP

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 1, 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.

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.

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

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
instrument 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.

SECTION CONTENTS

1. INTRODUCTION

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

1.2. Serial Numbers ....................................................................................................................... 4

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 ......................................................................................................................6

4. OPERATING

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

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

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

4.4. Suspension Seal ................................................................................................................... 19

4.5. Seat Belt ............................................................................................................................... 21

4.6. Cab Heating and Ventilation .................................................................................................. 22

4.7. Air Cleaner Service Indicator and Hydraulic Reservoir Sight Gauge.....................................24

4.8. Dome Lights with Switches .................................................................................................. 24

4.9. Cab Door Latch .................................................................................................................... 24

4.10. Access Panel “T” Handle ...................................................................................................... 25

4.11. Electrical Master Switch ....................................................................................................... 25

4.12. Starting and Stopping the Engine ......................................................................................... 26

4.13. Driving the Machine .............................................................................................................. 29

4.14. Shifting Gears ....................................................................................................................... 32

4.15. Steering ................................................................................................................................. 32

4.16. Stopping the Machine ........................................................................................................... 33

4.17. Parking the Machine ............................................................................................................. 33

4.18. Loader Operations ................................................................................................................ 34

4.19. Loader Techniques ............................................................................................................... 37

4.20. Economical Operation of the Machine ................................................................................. 44

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 ..................................................................................................................... 24

5.9. Drive Axles ............................................................................................................................ 30

5.10. Electrical System .................................................................................................................. 32

5.11. Engine ................................................................................................................................... 35

5.12. Ether Injector ......................................................................................................................... 39

5.13. Fuel System .......................................................................................................................... 40

5.14. Hydraulic System .................................................................................................................. 43

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

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

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

5.18. Transmission and Torque Converter .................................................................................... 48

5.19. Cab ........................................................................................................................................ 51

5.20. Loader Equipment ................................................................................................................. 51

6. SPECIFICATIONS

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

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

6.3. Schematic of Wheel Loader Drive Train ................................................................................. 4

6.4. Schematic of Torque Converter and Transmission Hydraulic System .................................. 5

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

6.6. Brake Hydraulic System Schematic ....................................................................................... 8

6.7. Wiring Diagram ..................................................................................................................... 10

6.8. Specifications ........................................................................................................................ 15

6.9. 560C Loader Equipment ....................................................................................................... 19

6.10. Torque Values for Standard Metric Fasteners ...................................................................... 20

6.11. Torque Values for Standard English Fasteners .................................................................... 21

6.12. Torque Values for Split Flange Connections ........................................................................ 22

6.13. Torque Values for Hydraulic Tubes and Fittings ................................................................... 23

6.14. Torque Values for Hose Clamps ........................................................................................... 23

6.15. Torque Values for Air Conditioning Tubes and Fittings ......................................................... 24

6.16. Torque Values for Air Conditioning 0-ring Connections ........................................................ 24

6.17. Special Torques .................................................................................................................... 25

6.18. Service Tools ........................................................................................................................ 26

SECTION 1

INTRODUCTION

INTRODUCTION SECTION 1

SECTION CONTENTS

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

1.2. Serial Numbers ....................................................................................................................... 4

DRESSTA OM560C99/1E

INTRODUCTION SECTION 1

Page 3

1.1. INTRODUCTION

Fig. 1.1. 560 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

GENERAL

Throughout this manual there will be two types of cross references. One type is to a heading in
another section. The other is to a heading within the same section. Unless it is otherwise stated,
references will be to the same 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 instructions. "Left" and "right" indicate the left and right sides of the
machine when facing forward in the operator's seat. See Fig. 1.1.

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

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.

DRESSTA OM560C99/1E

SECTION 1 INTRODUCTION

Page 4

INTRODUCTION

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.

1.2. SERIAL NUMBERS

Fig.1.2. Location of Chassis and ROPS-FOPS Cab Serial Number plates

1. Chassis Serial Number Plate

2. ROPS-FOPS Cab Serial Number Plate

The chassis serial number plate and ROPS-FOPS Cab Serial Number Plate are located in the cab
in the locations shown in Fig. 1.2. The chassis serial number is also stamped on the left rear
corner of the rear frame under the engine access door.

Fig.1.3. Location of stamped chassis serial number

OM560C99/1E DRESSTA

INTRODUCTION SECTION 1

Page 5

SERIAL NUMBERS

Fig.1.4. Engine Serial Number Plate

All other main components having serial numbers are each equipped with a separate serial number
plate.

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

DRESSTA OM560C99/1E

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

DRESSTA OM560C99/1E

SAFETY PRECAUTIONS SECTION 2

Page 3

2.1. GENERAL

WORK SAFETY - 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.

Operation 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. Operator’s seat must be equipped with safety belt. Also, the machine must be
equipped with safety triangle and wedges.
If the machine is equipped with a suction fan (or a reversible fan in the suction position), check the
engine exhaust system periodically for leaks. Exhaust gases are dangerous to the operator. On
machines equipped with a cab without a suction fan, keep sliding windows open to outside air.
The operator must not wear loose fitting or hanging clothing, belts of jewelry and shoes with non­slipping soles as well as a hard hat (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. 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. Remove or secure all
maintenance and personal items so they will not interfere with the operator or jam the controls.

DRESSTA OM560C99/1E

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, 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 alternate exit routes from the operator's compartment for use in an emergency.

Before operating the machine, check that the frame locking bar and pins are stowed on the rear
frame. Broken or lost frame locking bar and pins should be repaired or replaced immediately so that
this device is always available for use.

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

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 it 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 nearby personnel.
Check the brakes, steering and attachment controls. All system must be fully operative.
After starting and while operating, observe instruments and warning lights frequently. Investigate

any unusual indications or noises in the machine.
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 backs 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.

OM560C99/1E DRESSTA

SAFETY PRECAUTIONS SECTION 2

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OPERATING THE MACHINE

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 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.

Do not operate the machine in a condition of extreme fatigue or illness. Be especially careful at the
end of a work shift.

Never try to get on or off the machine while it is moving. A serious injury or death could result.
Never shift the transmission 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 low range
position before starting downhill. Use the brake/decelerator 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 or buzzer comes on during operation, immediately stop the

machine in a safe place. Apply the parking brake. Correct the cause before operating again.

DRESSTA OM560C99/1E

SECTION 2 SAFETY PRECAUTIONS

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OPERATING THE MACHINE

Keep the bucket in carry position when roading the machine and take care not to actuate
accidentally the levers.

Maintain clear vision of all work and travel areas. Keep windows and mirrors clean and repaired.
Look in the 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 with disengaging the drive 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 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.

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.

OM560C99/1E DRESSTA

SAFETY PRECAUTIONS SECTION 2

Page 7

GENERAL MAINTENANCE PRECAUTIONS

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 operating fan as it may result in serous injury.
When changing cutting edges, securely support the bucket for your protection.
If the bucket is provided with teeth, use wooden hammer for installation to prevent teeth breakage.

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

slings and hooks. Use lifting eyes provided. Warn 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 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

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, transfer the load to approved blocks before
servicing the machine.

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

DRESSTA OM560C99/1E

SECTION 2 SAFETY PRECAUTIONS

Page 8

GENERAL MAINTENANCE PRECAUTIONS

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 the 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 master switch and take the ignition
key 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.

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.

OM560C99/1E DRESSTA

SAFETY PRECAUTIONS SECTION 2

Page 9

GENERAL MAINTENANCE PRECAUTIONS

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 (R.O.P.S.) 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 R.O.P.S. after an accident. Repaired structures do not provide the
original strength and protection. Contact the Authorized Distributor of Construction Equipment for
information on R.O.P.S. (or cab) replacement. Do , not operate the machine again until the R.O.P.S.
has been replaced. Periodically inspect the R.O.P.S. for fatigue cracks. Cracks indicate a
weakened structure which should be replaced for your protection. Bolts fastening cab or R.O.P.S.
must be torqued to specific value. Do not cut, grind, weld, drill or tap holes in the R.O.P.S. 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 R.O.P.S.( 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 the 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 the tire to 35 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.

Hydraulic accumulators are filled with nitrogen and operate under high pressure. For safe operation
observe the following precautions:

− if the accumulator is damaged or operates incorrectly refer to authorized service station for
servicing

− the accumulator must be filled with nitrogen only by personnel authorized for servicing high
pressure equipment

− never tap the accumulator nor expose to fire. Do not perform any welding nor cutting holes in it

− relieve nitrogen completely thru vent valve prior to repair or disposal.

DRESSTA OM560C99/1E

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 the 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 electrical system disconnect switch, and remove the key .

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. Wheel Loader has CE mark - declaration of conformity with EEC directive of March 18,1998.

2. Wheel Loader has TBG certificate (Tiefbau-Berufsgenossenschaft) No 612.17/242 Sp-061
awarded on March 30,1998.

3. The Loader complies with „B” Safety Mark Requirements according to State Certificate No
015/98 (being upgraded).

4. The Loader was given TÜV Hannover Laboratory DE 10-893 641 11 Noise Level Certificate on
17 March 1998.

5. Wheel Loader in standard configuration is not adapted to operation in terrain where a mixture of
gasses, vapors, aerosols or dust with air create explosion hazard zones.

OM560C99/1E DRESSTA

SAFETY PRECAUTIONS SECTION 2

2.6.SAFETY GRAPHICS LOCATION

Page 11

Fig. 2.1. Safety Graphics Location

L, R – Graphics attached on left hand side or right hand side of the machine

DRESSTA OM560C99/1E

SECTION 2 SAFETY PRECAUTIONS

Page 12

SAFETY GRAPHICS LOCATION

2.6.1. SAFETY GRAPHICS

Decal 1 - On the engine side access panels

Decal 2 - Near the ladders and steps

Decal 3 - On the hydraulic reservoir

OM560C99/1E DRESSTA

SAFETY PRECAUTIONS SECTION 2

Page 13

SAFETY GRAPHICS LOCATION

Decal 4 - Near the radiator filler cap

Decal 5 - On the battery box

Decal 6 - On the battery box

DRESSTA OM560C99/1E

SECTION 2 SAFETY PRECAUTIONS

Page 14

SAFETY GRAPHICS LOCATION

Decal 7 - On the rear frame near the center

articulation pivot

Decal 8 - On the right post in the cab

OM560C99/1E DRESSTA

SAFETY PRECAUTIONS SECTION 2

Page 15

SAFETY GRAPHICS LOCATION

Decal 9 - On the left post in the cab

Decal 10 - On left post in the cab

Decal 11 - In the cab

DRESSTA OM560C99/1E

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 ........................................................4

3.1.3. Transportation by Machine Own Drive .........................................................................4

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

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

3.4. Machine Storage ......................................................................................................................6

3.4.1. Preparing for Storage ...................................................................................................6

3.4.2. Servicing During Storage ..............................................................................................8

3.4.3. Preparing for Operation ................................................................................................9

DRESSTA OM560C99/1E

MACHINE TRANSPORT AND STORAGE SECTION 3

Page 3

3.1. MACHINE TRANSPORT

3.1.1. GENERAL

ATTENTION! During transportation of the machine the front and rear frame
should be blocked by means of special connector and interlocking pins.

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

METHOD OF LOCKING OF FRONT AND REAR FRAME OF THE 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

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

ATTENTION! When transporting the machine be especially careful during
loading and unloading. 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. 60 l of fuel.

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

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

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

ATTENTION ! When transporting this machine on a high speed carrier or railaway car, seal the
exhaust pipe openining to prevent turbocharger damage.

Fig. 3.2. Frame Locking Bar and Pins

in locked position

ATTENTION ! When the reserve level of fuel is signalled, drive on trailer bed or ramps of grade
exceeding 10° reverse to prevent aeration of the engine fuel system.

DRESSTA OM560C99/1E

SECTION 3 MACHINE TRANSPORT AND STORAGE

Page 4

MACHINE TRANSPORT

REAR LIGHTS

Fig. 3.3. Rear Lights

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

1. Undo and remove bolt 2.

2. Turn bracket 1 in required position.

3. Reinstall the bolt in hole 3 and tighten.

ATTENTION: It is recommended to change position of lights (brackets) before machine transport
to prevent damage.

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

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

2. During transportation by the sea, when it is necessary to carry the loader by means of a crane,
use the method of fastening the loader that will ensure maximum 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,
refer to Fig. 3.4.

3.1. 3. TRANSPORTATION BY MACHINE OWN DRIVE

ATTENTION ! Long distance driving is forbidden. Short distance driving is permitted under special

circumstances, i.e. from unloading place to workplace.

1. The passage conditions must be coordinated with local road traffic administration.

2. Observe traffic regulations ensuring safe travel.

3. Place boom and bucket in carry position.

4. Interlock the working system control lever and unlock the articulated frame by setting the
connector in the neutral position as shown in Fig. 3.1.

5. Detailed information on safety precautions when operating – see Section 2 SAFETY
PRECAUTIONS.

OM560C99/1E DRESSTA

MACHINE TRANSPORT AND STORAGE SECTION 3

Page 5

3.2. LIFTING ON SLINGS

Fig. 3.4. Method of Handling (for standard machine configuration)

1 - Frame Locking Bar
Q= 41800 kg – Machine Weight
A = 20500 kg – Front Axle
B = 21300 kg – Rear Axle

DRESSTA OM560C99/1E

SECTION 3 MACHINE TRANSPORT AND STORAGE

Page 6

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
stowed position as shown in Fig. 3.1 Use chains or cables of adequate strength, be sure they are
properly secured to the draw bar pin.

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.

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 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 "COOLING SYSTEM" in Section 5.

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

4. Correct any defects found. Consult authorized service of manufacturer

5. Clean or replace the air cleaner filter elements. Refer to "AIR CLEANING SYSTEM" in 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
"COOLING SYSTEM" in Section 5 for the proper anti-freeze and conditioner concentrations.

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

7. Drain the water from the fuel tank. Refer to "FUEL SYSTEM" in Section 5. Clean fuel filter

installed in the filler neck.

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

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:

OM560C99/1E DRESSTA

MACHINE TRANSPORT AND STORAGE SECTION 3

Page 7

MACHINE STORAGE

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.

CAUTION: 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 the fuel tank. The "VCI" provides
corrosion protection by contact with the metal, and in a closed system, the vapors provide
sufficient protection for areas that are not in contact with the oil. When using VCI per HMS B00­0006 pour 120 of volatile corrosion inhibitor for each 100 l of total fuel capacity. The "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 1400 to 1600 rpm for 4 minutes and then stop the engine.

13. Lubricate all points of the machine as outlined in the "SERVICE GUIDE" in 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 the
crankcase is 10 l add 150 ml VCI).

16. Start the engine and run it idle at 1400 to 1600 rpm 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
opening to insure a good seal.

19. Pour 120 ml VCI to the intake manifold to prevent corrosion of the space between piston and
bottom part of the head.

20. It is recommended to pour 390 ml VCI type 1 oil per HMS B00-0006 (KDC 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 the areas provided for storing or dispensing fuel and oil, not
near any heat source and preferably where the temperature range is between 0° to +21 °C . Be
sure the batteries are fully charged.

DRESSTA OM560C99/1E

SECTION 3 MACHINE TRANSPORT AND STORAGE

Page 8

MACHINE STORAGE

IMPORTANT: Do not place battery on 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 rods 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
MACHINE EQUIPPED WITH LOW MAINTENANCE BATTERIES.

Be sure 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 Construction Equipment Distributor.

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

intake, fuel tank vent lines, etc.

3. Install fully charged batteries. Refer to "BATTERIES" in 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.

WARNING: Check that batteries are level in the holders and securely held. The
hold-down fasteners should hold the batteries firmly but not tight enough 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. Electrical master switch must be in off position and key removed.

OM560C99/1E DRESSTA

MACHINE TRANSPORT AND STORAGE SECTION 3

Page 9

MACHINE STORAGE

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

5. Perform steps 7 thru 21 per item 3.4.1.

3.4.3. PREPARING FOR OPERATION

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

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

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

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

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

inflation pressure. Refer to "TIRES AND RIMS" in Section 6.

6. Remove all seals from the machine: crank-case and hydraulic breathers, engine air intake, fuel

tank vent lines, etc.

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

SYSTEM" in Section 5.

8. Remove and replace fuel filters. Refer to REPLACEMENT OF FUEL FILTERS Section 5.

9. Fill the fuel tank with approved diesel fuel. Refer to "REFILL CAPACITIES" in Section 5.

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

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

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 THE ENGINE AFTER OIL CHNAGE OR LONG

STORAGE" in Section 4.

14. Start the engine in accordance with STARTING AND STOPPING THE ENGINE Section 4 and

SERVICE GUIDE recommendations (daily service) Section 5.

DRESSTA OM560C99/1E

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. Suspension Seat .................................................................................................................. 19

4.5. Seat Belt ............................................................................................................................... 21

4.6. Cab Heating and Ventilation .................................................................................................. 22

4.6.1. Defroster Fan ......................................................................................................... 22

4.6.2. Heater ..................................................................................................................... 22

4.6.3. Air Conditioner ........................................................................................................ 23

4.7. Air Cleaner Service Indicator and Hydraulic Reservoir Sight Gauge ................................... 24

4.8. Dome Lights with Switches .................................................................................................. 24

4.9. Cab Door Latch .................................................................................................................... 24

4.10. Access Panel “T” Handle ...................................................................................................... 25

4.11. Electrical Master Switch ....................................................................................................... 25

4.12. Starting and Stopping the Engine ......................................................................................... 26

4.12.1. Normal Start (ambient temperature above 0° C) ................................................... 26

4.12.2. Cold Weather Start (using ether injector) .............................................................. 28

4.12.3. Starting After Oil Change or Longer Storage ......................................................... 28

4.12.4. Stopping the Engine ............................................................................................... 29

4.13. Driving the Machine .............................................................................................................. 29

4.14. Shifting the Gears ................................................................................................................. 32

4.15. Steering ................................................................................................................................. 32

4.16. Stopping the Machine ........................................................................................................... 33

4.17. Parking the Machine ............................................................................................................. 33

4.18. Loader Operations ................................................................................................................ 34

4.18.1. Boom Control Lever Positions ............................................................................... 34

4.18.2. Automatic Boom Kick -Out ...................................................................................... 35

4.18.3 Bucket Control Lever Positions .............................................................................. 36

4.18.4. Automatic Bucket Leveler ....................................................................................... 37

4.19. Loader Techniques ............................................................................................................... 37

4.19.1. Loading, Transporting and Piling ............................................................................ 37

4.19.2. Digging, Clearing and Leveling ............................................................................... 40

4.20. Economical Operation of Mach ine ....................................................................................... 44

DRESSTA OM560C99/1E

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. Sound judgment 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. 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 steering controls, brake
controls, hydraulic controls, instruments and safety equipment. Make all necessary repairs or
adjustments before operating the machine.

Do not place the 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. After 15 seconds oil pressure
must be correct. Do not run the engine idle more than 10 minutes. To prevent any possible damage
to the alternator , the electrical system master switch must be in ON position when engine is
running. The switch must be in 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 tires 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.
Never use water alone in the cooling system.
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 OM560C99/1E

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.

OM560C99/1E DRESSTA

OPERATING SECTION 4

UNIVERSAL SYMBOLS FOR INSTRUMENTS AND CONTROLS

Page 5

Fig. 4.1. Universal Symbols for Instruments and Controls

DRESSTA OM560C99/1E

SECTION 4 OPERATING

Page 6

UNIVERSAL SYMBOLS FOR INSTRUMENTS AND CONTROLS

OM560C99/1E 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. Cautio9n

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

58. Parking Lights

OPERATING SECTION 4

Page 7

DRESSTA OM560C99/1E

SECTION 4 OPERATING

Page 8

UNIVERSAL SYMBOLS FOR INSTRUMENTS AND CONTROLS

59. Contour Light

60. Work Light

61. Search Light

62. Flash Light

63. Turning 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. Roll Back of Multi-Purpose Bucket

83. Hold of Multi-Purpose Bucket

84. Dump of Multi-Purpose Bucket

85. Closing of Grapple

86. Hold of Grapple

87. Opening of Grapple

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.

OM560C99/1E DRESSTA

OPERATING SECTION 4

Page 9

INSTRUMENTS AND CONTROLS

WARNING! 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 – QSK 19C Engine

Fig. 4.3. Instrument Panel – KT19C Engine

DRESSTA OM560C99/1E

SECTION 4 OPERATING

Page 10

INSTRUMENTS AND CONTROLS

Fig. 4.4. Instrument Panel – RH Side

QSK 19C Engine KT 19-C Engine

1. Low Engine Coolant Warning Light

2. Service Brake Filter Warning Light

3. Transmission Filter Warning Light.

4. Hydraulic Filter Warning Light.

5. Fuel Level Light.

6. Ground Driven Steering Warning Light (If Equipped)

7. Parking Brake Warning Light.

8. Engine Coolant Temperature Warning Light

9. Service Brake Warning Light.

10. Torque Converter Oil Temperature Warning Light.

11. Engine Coolant Temperature Gauge.

12. Torque Converter Temperature Gauge.

13. Engine Oil Pressure Gauge.

14. Voltmeter.

15. Hourmeter.

16. Tachometer (If Equipped).

17. Ignition Switch.

18. Front Auxiliary Lamps Switch (If Equipped).

19. Front Work Lamps Switch.

20. Low Level Lamp Switch (if Equipped).

21. Ether Start and Rear Work Lamps Switch (If Equipped).

22. Transmission Disconnect / Bulb Check Switch on Instrument Panel

23. Engine Diagnostic ECM Select Switch.

24. Engine Diagnostic ECM Check Switch.

25. Engine Stop Light (Red).

26. Engine Warning Light (Yellow).

27. Engine Fluid Light (Orange).

28. Parking Brake Switch

29. 24 V Receptacle

30. Engine Diagnostic Connector (Second Connector Located Above Engine Fuel Pump)

IMPORTANT: Components No’s 23, 24,25, 26, 27 and 30 are included in the machine equipped
with QSK-19-C engine only.

1. LOW ENGINE COOLANT WARNING LIGHT
This light will come on if the coolant level in the radiator top tank reaches minimum level. If this light
comes on, stop the engine, allow coolant to cool down in the cooling system and add coolant to the
proper level or correct leaks found beforehand, if any, and refill the radiator to the proper level.

OM560C99/1E DRESSTA

OPERATING SECTION 4

Page 11

INSTRUMENTS AND CONTROLS

2. SERVICE BRAKE FILTER WARNING LIGHT

The light will come on when oil flow through the filter is restricted. It means that the filter element is
contaminated and must be replaced. The light may come on when starting cold machine and
should go off when the oil is warmed in the system.

3. TRANSMISSION FILTER WARNING LIGHT

The light will come on when oil flow through the filter is restricted. It means that the filter element is
contaminated and must be replaced. The light may come on when starting cold machine and
should go off when the oil is warmed in the system.

4. HYDRAULIC FILTER WARNING LIGHT

The light will come on when oil flow through the filter is restricted. It means that the filter element is
contaminated and must be replaced. The light may come on when starting cold machine and
should go off when the oil is warmed in the system.

5. FUEL LEVEL LIGHT

The light indicates that 60 l of fuel (app. 1 hour of operation) is available for operation and the fuel
tank must be filled.

6. GROUND DRIVEN STEERING WARNING LIGHT

This warning light is not included in standard configuration of the machine. If the machine is
equipped with ground driven system ( that enables steering of the machine at loss of pressure in
steering system) the light will come on when the system is activated. The vehicle must be in motion
to activate the ground driven steering system.

7. PARKING BRAKE WARNING LIGHT

The light will indicate if the parking brake is applied. At the same time a buzzer will sound.

WARNING: Release the parking brake before starting the machine.

8. ENGINE COOLANT TEMPERATURE WARNING LIGHT

The light will indicate when the coolant temperature exceeds allowable limit. If the light comes on,
maneuver the machine to the side and operate the engine at low idle. If the light stays on,
investigate the cause and take corrective action before operating the machine again.

9. SERVICE BRAKE WARNING LIGHT

The light will indicate:

− drop of pressure in brake cooling system below allowable limit,

− failure of one of the brake circuits,

− drop of pressure in brake system below allowable limit,

− drop of nitrogen pressure in nitrogen accumulators below allowable limit.

Also, a buzzer will come on. Stop the machine immediately and remove the cause of the failure. To

maintain optimum performance nitrogen accumulators must be filled with nitrogen (at gas side).
Nitrogen pressure is 8.78 to 9.84 MPa ( for temperature range 10 to 43° C). Accumulators are
equipped with electrical switches indicating loss of nitrogen pressure below the allowable limit.
Warning light 9 will come on and buzzer will sound when pressure drops below the allowable value.
Starting the machine is followed with rapid oil and nitrogen pressure rise in accumulators and short
period when the light is on might not be noticed by the operator. The signal is supported by an
electronic device and may be cancelled by the representative of Authorized Service upon filling the
accumulators with nitrogen. Indication of nitrogen low pressure in accumulators does not exclude
machine operation, however, it means reduced efficiency or loss of emergency braking with the
engine running.

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INSTRUMENTS AND CONTROLS

WARNING: If loss of nitrogen pressure in accumulators is signaled, inform

service personnel immediately to fill accumulators.

10. TORQUE CONVERTER OIL TEMPERATURE WARNING LIGHT
The light will come on if the torque converter oil temperature exceeds allowable limit.

WARNING: 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,

− dirty suction filter.

11. ENGINE COOLANT TEMPERATURE GAUGE
The gauge indicator should remain within green area equivalent to 71 to 93 °C temperature range.
Do not operate the machine if the gauge indicator is above or below this area. If the temperature
remain high in spite of interruption in engine, check: coolant level, the condition of the radiator, fan
water pump and thermostat.

12. TORQUE CONVERTER TEMPERATURE GAUGE
The gauge indicator should remain within green. If the temperature is too high, follow the
recommendations specified in “Torque converter oil temperate warning light”

13. ENGINE OIL PRESSURE GAUGE
Engine lubricating oil pressure at low idle is 0.11 MPa, at high idle is 0.31 to 0.48 Mpa. Green area is
the normal operating range. If gauge pointer enters red area stop the engine immediately and
correct the malfunction.

14. VOLTMETER
The voltmeter has two areas. It the pointer is in “alternator” area it means battery charging. If the
pointer is in “battery” area it indicates a full battery charge. With the engine operating at idle speed,
the gauge pointer should be within this area. With the engine operating at higher speed, the gauge
pointer should go in upper area (alternator), otherwise it means no battery charging. Check the
batteries, alternator and remove the malfunction.

15. HOURMETER
The gauge (electronic) is activated by the engine oil pressure. It records the actual hours of engine
operation.

16. TACHOMETER. (IF EQUIPPED)
The gauge indicates engine crankshaft r.p.m.

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OPERATING SECTION 4

Page 13

INSTRUMENTS AND CONTROLS

17. IGNITION SWITCH.

Fig. 4.5. Ignition Switch Positions

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

Ignition switch position:
ACC – to the left – not used,
OFF - after inserting the key- disconnects the electrical circuit,
RUN - to the right – activates electrical circuits,
START- to the right with automatic return to RUN when released – engine startup.

WARNING: Do not hold the key in START position for more than 30 second.
Allow a 2 minute interval between cranking. Never place the key in START
position when engine is running.

18. FRONT AUXILIARY LAMPS SWITCH

Not equipped in standard machine. If equipped, push the switch up to turn the front roof mounted
lights and place in center position to switch them off.

19. FRONT WORK LAMPS SWITCH (only in CE configuration)

Push the switch up to turn on the passing lights , place in the central position to switch the parking
lights on. When placed in the lower position it switches the lights off.

WARNING! Always operate with work lights switched on when visibility is
reduced (fog, down, at night). Rear lights are switched on simultaneously with
front lights. Remember, lights are designed not only for the operator but also for
personnel working nearby, indicating position and movement of the machine.

20. LOW LEVEL LIGHTS SWITCH

If the machine is equipped with additional lights mounted on the front frame supports, push the
switch up to turn on the low level lights and place in the central position to turn off the lights. Not
equipped in the standard configuration of the machine.

21. ETHER START AND REAR WORK LAMPS SWITCH

The switch has three positions:
a) in the upper position switches on the rear work lights. Switch the lights when loading at night or

in fog. Do not switch the lights when traveling on public roads,

b) in the central neutral position - switches off rear lights,
c) in the lower position switches ether injection to inlet manifold of the engine. Injected dose does

not depend on time the switch is held in the lower position. When released the switch
automatically returns to the central position. For additional information refer to COLD
WEATHER STARTING (not equipped in the standard configuration of the machine).

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INSTRUMENTS AND CONTROLS

CAUTION: DO NOT use the ether injector when air temperature is above
freezing (0°°). Follow the correct method for starting the engine. Refer to
Section 5 ETHER INJECTOR.

22. TRANSMISSION DISCONNECT/BULB CHECK SWITCH
Used for selection method of braking and to check that instrument and warning lights are working. It
has three positions:

− braking with transmission connected,

− braking with transmission disconnected,

− warning and illumination lights check (lower position).

Before operating the machine the operator should check that instrument and warning lights are
working, i.e. bulbs are not burnt or bulb circuits broken. Therefore, before starting operation move
the switch in down position for 2 to 3 seconds. Additional information on using the switch, see
Section 5 SERVICE BRAKES.

23. ECM FAULT CODE DISPLAY SWITCH
This switch has three positions. The upper and lower position enables to display successive fault
codes. The switch automatically returns to the central position.

24. ECM MEMORY SWITCH
The switch can be placed in two positions: the upper position (normal), the lower position fault
memory (memory on)
ECM registers all abnormal engine and its systems parameters (high temperature of coolant, low
coolant level, low oil pressure, etc)
Active faults (persisting) may be displayed using lights 25,26,27. Inactive faults (instantaneous) may
be read using computer.

25. WARNING LIGHT (RED)
This light indicates serious malfunction of the engine. Stop the engine immediately, or the engine
will be stopped by ECM module.

26. WARNING LIGHT (YELLOW)
This light indicates minor malfunction of the engine, the engine can still be operated but for its
protection ECM may reduce some parameters (power, rpm). The failure must be repaired as soon
as possible.

27. WARNING LIGHT (ORANGE)
The light indicates low coolant level. Low coolant level results in deterioration of some parameters
resulting in stopping the engine.

NOTE: The engine protection system records separate fault codes when an out-of-range condition
is found for any of the sensors in the engine protection system. (Coolant temperature, coolant level,
oil temperature, and oil pressure - Refer to the "ENGINE OPERATOR'S MANUAL" for more
information).

28. PARKING BRAKE KNOB
This knob applies and releases the parking brake. Pull the knob to apply the parking brake. The
parking brake is released with hydraulic cylinder supplied from the brake system. The brake is
spring applied. In case of pressure loss the brake release with this knob is not possible. For the
method of emergency brake release see Section 5 PARKING BRAKE . The parking brake warning
light 7 Fig. 4.2 and 4.3 will light and alarm is activated when the brake is applied.

NOTE: Before moving the machine release the parking brake.

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OPERATING SECTION 4

Page 15

INSTRUMENTS AND CONTROLS

29. PORTABLE LAMP RECEPTACLE

Used for connecting portable lamp with cable (included in machine accessories)

30. ENGINE DIAGNOSTIC CONNECTOR

This connector is used to connect diagnostic kit (computer) for full engine diagnostics, display and
canceling faults form ECM memory.

Fig. 4.6. Side Control Panel

31. Blower Fan Control Switch

32. Heater Temperature Control Knob

33. A/C Control Knob

34. Master Switch

35. Defroster Fan Switch (If Equipped)

36. Windshield Wiper Control Switch

37. Rear Window Wipers Control Switch (If Equipped)

38. Windshield Washer Button

39. Rear Window Washer Button

40. Air Control Knob

41. Air Intake Mode Knob

31. BLOWER FAN CONTROL SWITCH

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

− OFF

− LO

− HI

Place the switch in the desired position.
If the outside air is extremely dusty, set the fan speed switch to the "HI" position. This will

pressurize the cab and prevent the dust from entering.

32. HEATER TEMPERATURE CONTROL KNOB

Turn the knob to the left to reduce temperature, to increase temperature turn he knob to the

right.

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INSTRUMENTS AND CONTROLS

33. A/C CONTROL KNOB
Turn the knob to the right for increased cooling, to decrease turn he knob to the left. A

machine in the standard configuration is not equipped with A/C.

34. MASTER SWITCH
This switch is used to switch heating or A/C on.
It has three positions:

− neutral,

− heating,

− A/C.

35. DEFROSTER FAN SWITCH (IF EQUIPPED)
This switch is used to control defroster fan speed circulating the air in the cab

This switch has three positions:

− OFF,

− LO,

− HI.

Place the switch in the desired position.

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

avoid injury.

36. WINDSHIELD WIPER CONTROL SWITCH
This switch controls the speed of the windshield wiper motor,it has three positions:

− OFF

− LO

− HI

Place the switch in the desired position.

37. REAR WINDOW WIPERS CONTROL SWITCH (IF EQUIPPED)
This switch controls the speed of the rear window wiper motors, it has three positions:

− OFF,

− LO,

− HI.

Place the switch in the desired position.

38. WINDSHIELD WASHER SWITCH BUTTON
This switch controls the windshield washer. Push the switch button down to activate the
washer, release the button to stop the washer. Always activate the washer before switching on
wiper not to scratch the windshield.

39. REAR WINDOW WASHER SWITCH BUTTON (IF EQUIPPED)
This switch controls the rear window washer. Push the switch button down to run the washer.
Release the button to stop the washer. Always activate the washer before switching on wiper
not to scratch the window.

40. AIR CONTROL KNOB

This knob is used to control quantity and direction of air (heated or cooled) supplied to the
cab.

OM560C99/1E DRESSTA

OPERATING SECTION 4

INSTRUMENTS AND CONTROLS

41. AIR INTAKE MODE KNOB

It is used to change mode of air intake: outside (fresh) or inside heated (recalculation)

Page 17

Fig. 4.7. Controls

28 - Parking Brake Knob (description above)
42 - Brake Pedal
43 - Transmission Neutral Lock Lever
44 - Transmission Gear Range Lever
45 - Transmission Direction Lever
46 - Steering Wheel
47 - Steering Wheel Height Adjustment Knob
48 - Auxiliary Equipment Lever
49 - Bucket Control Lever
50 - Boom Control Lever
51 - Accelerator Pedal
52 - Horn Button
54 - Hazard Light Switch With Control Light
55 - Directional Signal Switch

42. BRAKE PEDAL

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

WARNING! Do not “pump” the brakes. Repeatedly pressing and releasing the
brake pedal will reduce the oil pressure in the system and result in reduced
braking.

As required, there is possibility of braking as described above with transmission connected and
disconnected. Braking with transmission disconnected is with all transmission clutches released.
Therefore full power of the engine can be used to operate the machine hydraulics . Braking with
transmission disconnected is more efficient because eliminates detrimental effect of rotating
masses on braking. Selection of braking method is made with switch 22, Fig. 4.2. and 4.3.

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Page 18

INSTRUMENTS AND CONTROLS

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

43. TRANSMISSION NEUTRAL LOCK LEVER
The lever locks the transmission direction lever in neutral position. To release the direction lever
from the neutral position, push the lock lever up.

WARNING! Before leaving the machine, lock the transmission direction lever in
neutral position with the lock lever.

44. TRANSMISSION GEAR RANGE LEVER
This lever is used to select the gear range according to operation conditions. Refer to SHIFTING
GEARS for additional information.

45. TRANSMISSION DIRECTION LEVER
This lever is used to select machine direction. Refer to SHIFTING GEARS for additional information.

WARNING! Before leaving the machine, lock the transmission direction lever in
neutral position with the lock lever.

46. STEERING WHEEL
The wheel loader is equipped with hydraulic steering system. Movement of the steering wheel
actuates the steering valve which directs oil to steering cylinders. For a right turn rotate the wheel
clockwise and for the left turn, rotate the wheel counterclockwise. Steering system operates as long
as steering wheel is turned . No effort exerted on steering wheel stops turning and machine
maintains preset direction.

47. STEERING WHEEL HEIGHT ADJUSTMENT KNOB
Steering wheel height can be varied by loosening the knob, moving the steering wheel to the desired
height and then tightening the knob.

48. AUXILIARY EQUIPMENT LEVER
Not equipped in standard configuration of the machine. Located near to bucket control lever close to
the operator.

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

50. BOOM CONTROL LEVER
The lever controls raising and lowering operations of the boom. Refer to BOOM CONTROL LEVER
POSITIONS for additional information.

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

52. HORN BUTTON
Depress the button to sound horn, release the button to stop.

OM560C99/1E DRESSTA

OPERATING SECTION 4

INSTRUMENTS AND CONTROLS

53. CONTROL LEVER LOCKING PLATE (FIG. 4.8)

Page 19

Fig. 4.8. Control Lever Locking Plate

1- Locking Plate 2 - Locking Bar

Locking plate 1 is used to lock the control levers in the neutral position. In the drawing the plate is
shown in the non-locked position.

54. HAZARD LIGHTS WITH CONTROL LIGHT

Switch on hazard lights in case of malfunction of loader in a hazardous place e.g. building site.
Red light comes on when hazard lights are switched on.

55. DIRECTIONAL SIGNAL SWITCH

Used to switch on right or left turn signal (forward or backward movement of the switch).
Green lights come on when the directional signal is switched on.

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.

4.4. SUSPENSION SEAT

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.

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 as described below.

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SECTION 4 OPERATING

Page 20

SUSPENSION SEAT

Fig. 4.9. Suspension Seat

1. Weight indicator

2. Weight adjustment knob

3. Height adjustment knob

4. Backrest angle adjustment lever

5. Seat travel lever

6. Backrest profile adjustment knob

7. Backrest profile adjustment knob

8. Armrest angle adjustment screw

This is a suspension seat with several adjustments to provide maximal comfort to the operator.
Adjustment to 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 is
in the weight indicator window 1.

Seat travel adjustment - pull up the lever 5 (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 - turn knob 3 clockwise to lift the seat cushion and counterclockwise to
lower the seat cushion.

Backrest angle adjustment - pull up lever 4 to release the lock. Upon adjustment of backrest
angle (pressing the backrest) apply the lock.

Backrest profile adjustment – performed with two knobs: knob 6 located on the left hand side of
the seat and knob 7 located on the right hand side of the seat. Turn knob 6 to change backrest
profile in the middle part, turn knob 7 to change lower and upper part of backrest profile.

Armrest angle adjustment – performed with screws 8 located under armrests (tilt back armrests
to facilitate adjustment).

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OPERATING SECTION 4

Page 21

4.5. 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. 4.10. 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 the 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.

DRESSTA OM560C99/1E

SECTION 4 OPERATING

Page 22

SEAT BELT

Fig. 4.11. Adjusting the Belt Length

4.6. CAB HEATING AND VENTILATION

4.6.1. DEFROSTER FAN

Fig. 4.12. 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. (Fig. 4.6. item 35). Move the
switch up to operate the fan.

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

4.6.2. HEATER

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

OM560C99/1E DRESSTA

OPERATING SECTION 4

CAB HEATING AND VENTILATION

Fig. 4.13. Side Control Panel

Page 23

31. Heater Fan Control Switch

32. Heater Temperature Control Knob

33. Air Conditioner Temperature Control Knob

34. Main Switch

35. Window Defroster Fan Switch (If Equipped)

36. Windshield Wiper Switch

For description of controls refer to Section 4.3

4.6.3. AIR CONDITIONER

37. Rear Window Wiper Switch

38. Windshield Washer Switch

39. Rear Window Washer Switch

40. Air Control Knob

41. Air Intake Mode Control Knob

Fig. 4.14. Block Diagram of A/C Connections

The wheel loader may be equipped with an 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 LH side of the engine

2. Condenser - radiator mounted

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

4. Evaporator – RH side cab wall mounted

5. Relief valve – integrated with evaporator

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

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

DRESSTA OM560C99/1E

SECTION 4 OPERATING

Page 24

4.7. AIR CLEANER SERVICE INDICATOR

Fig. 4.15. Service Indicator and Hydraulic Reservoir Sight Gauge

1. Service Indicator 2. Hydraulic Reservoir Sight Gauge

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. Press the reset button on top of indicator after
the elements have been serviced.

4.8. DOME LIGHTS WITH SWITCHES

Dome lights are installed in the roof of the cab on the right and left hand side of operator’s head.
The lights are equipped with switches.

4.9 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.

Fig. 4.16. Cab Door Latch

1 - Arm 2 - Pin

OM560C99/1E DRESSTA

OPERATING SECTION 4

Page 25

CAB DOOR LATCH

To lock the door depress the arm (with a foot) when the door is in fully open position. The pin 2 will
engage the cutout of arm 1.

The door will be released automatically when moved further to open (until the limiting strip is fully
tightened).

4.10. ACCESS PANEL “T” HANDLE

The access panels to service the hydraulic reservoir filters, the air cleaner elements, and the
batteries are all locked and unlocked using the "T” handle. It is stored in rubber holder attached to
the RH side of the instrument panel.

Fig. 4.17. Access Panel “T” Handle

4.11. ELECTRICAL MASTER SWITCH

Fig. 4.18. Electrical System Master Switch

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 electrical 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 electrical system.

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

DRESSTA OM560C99/1E

SECTION 4 OPERATING

Page 26

4.12. STARTING AND STOPPING THE ENGINE

4.12.1. 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. Place objects on the machine from the ground level before
climbing on.

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

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

3. Turn the master electrical system switch "ON".

4. With your back against the back rest of the operator's seat, adjust the seat position so that the
brake and decelerator pedal(s) can be easily depressed.

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

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

Fig. 4.19. Starting and Stopping the Engine

17 - Ignition Switch
21 - Ether Start and Rear Work Lamps Switch
28 - Parking Brake Knob
48 - Auxiliary Equipment Control Lever

49 - Bucket Control Lever
50 - Boom Control Lever
51 - Accelerator Pedal

6. Turn the ignition key from RUN to START position to start the engine with accelerator pedal
released (idle speed).

ATTENTION: 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.

ATTENTION: Engine oil pressure must register 15 seconds after startup. If no oil pressure is
registered stop the engine immediately.

6a. QSK 19C ENGINE ONLY. Turn the ignition key from RUN to START position to start the engine.

In this key position lights 25, 26, 27, Fig. 4.2. on the instrument panel come on. After 2 seconds
the lights go off in the following order: 26, 25, 27, which indicates no malfunctions has been
found by the ECM in the engine electronic control system.

OM560C99/1E DRESSTA

OPERATING SECTION 4

STARTING AND STOPPI NG THE ENGINE

If a malfunction is found by ECM in the system (sender malfunction, low oil pressure, low
coolant level, etc) it is stored in memory as active malfunction.
To read active malfunction codes turn the ignition key to the OFF position, place switch 24 in
CHECK top position, then turn the ignition key to the RUN position.
Place 23 SELECT switch in top or bottom position. In this position the malfunction code is
displayed, Fig. 4.20.

Exemplary malfunction code displayed:

Page 27

Fig. 4.20. Malfunction Code Displayed

P - 1 Second Pause
23 - Engine Malfunction Code Switch Stored In ECM Memory
24 - ECM Memory Activation Switch

Malfunction code 115 – engine speed sender
For the list of malfunction codes – see ENGINE MANUAL
If any active malfunctions are found contact Construction Equipment Authorized Distributor.

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.

ATTENTION: 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.

ATTENTION: 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.

If the engine fails to start make another attempt to start it after app. 2 minutes.

IMPORTANT: Low emission Cummins engine QSK-19C undergoes automatic cycle of warming
until coolant temperature attains 10C. During that period of time the engine runs at 1000 rpm, and
accelerator pedal is not active, depressing the accelerator pedal is not followed by an increase of
speed.

DRESSTA OM560C99/1E

SECTION 4 OPERATING

Page 28

STARTING AND STOPPI NG THE ENGINE

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

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

4.12.2. COLD WEATHER START (USING ETHER INJECTOR, AMBIENT
TEMPERATURE BELOW 0OC)

When starting the engine in low temperatures, do as follows:

1. Perform the steps 1 thru 7 of NORMAL START.

2. Move ether injector switch to the ON position for a couple of seconds then release it
immediately. Refer to Fig. 4.2 and 4.3., item 21. Do NOT hold it in the ON position for more than
5 seconds. Ether dose does not depend upon time the switch is held. The switch will return to
neutral position when released.

If the engine does not start, repeat this procedure 2-3 times.This may occur at low ambient

temperatures.

3. When the engine starts, release the ignition key and the key will automatically return to the RUN
position.

ATTENTION: 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 the 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.

Do not hold the key in the start position more than 30 seconds. A machine in its standard
configuration is designed for starting in ambient temperatures above –20° C. For starting in lower
temperatures special version of wheel loader is needed.

4.12.3. STARTING AFTER OIL CHANGE OR LONGER STORAGE.

When starting the engine after running out of fuel, first fill the fuel tank and then, fill the fuel filter with
fuel before starting.

When starting the engine after each engine oil change or after the engine has been shut off for
more than five days, perform the following steps to insure the engine receives proper lubricating oil
flow through the lubricating system.

1. Perform the steps 1 thru 5 of NORMAL START.

2. Disconnect the electrical wire from the fuel pump solenoid valve.

OM560C99/1E DRESSTA

OPERATING SECTION 4

Page 29

STARTING AND STOPPI NG THE ENGINE

2a. QSK19C engine only. Disconnect the EPS connector of the engine speed sensor. Refer to Fig.

4.21.

Fig. 4.21. ECM Connector of Engine Speed Sensor

3. Using the ignition switch, crank the engine until the oil pressure monitor light goes out.

4. Reconnect the electrical wire to the fuel pump solenoid valve.
4a. QSK19C engine only. Connect the EPS connector of the engine speed sensor.

5. Start the engine as described under "NORMAL START".

4.12.4. STOPPING THE ENGINE

1. Apply the parking brake, lock the transmission direction lever in the neutral position and lower
the bucket.

2. Allow the engine to cool down. Run the engine with no load at idle speed for about 3 to 5
minutes

3. Reduce the engine speed to the idle speed.

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

4. Shut down the engine by turning the ignition key to the OFF position. Before leaving the cab
remove the key and lock the cab.

5. Turn off the electrical system master switch and remove the key before leaving the machine
unattended.

4.13. DRIVING THE MACHINE

After starting the engine in temperature above 0° C do not start operations immediately. First, carry
out the following operations and checks:

1. Depress accelerator pedal 51 lightly and run the engine at the midrange idle speed for about 3
to 5 minutes.

2. Warm the engine up to the operating temperature. Continue to run the engine with light load until
the engine coolant temperature gauge and torque converter oil temperature gauge pointers
settle in the green area.
Warm-up may be reduced as follows:
a) apply the parking brake,
b) move transmission shift lever to 3rd forward,
c) increase the engine speed gradually to maximum speed and run the engine until the pointer

of torque converter temperature gauge is in the upper part of the green area,

DRESSTA OM560C99/1E

SECTION 4 OPERATING

Page 30

DRIVING THE MACHINE

d) move the transmission shift lever into the neural position and run the engine until the pointer

of torque converter temperature gauge drops to the lowest position,

e) Perform steps b) to d) until the pointer stops in the lower position of the green area.

3. Upon the completion of the engine warm-up check the warning lights for correct operation.

4. Check if the exhaust fumes color is normal or whether there is any abnormal noise or vibration.
After starting the engine in the ambient temperature below 0oC perform the following steps before

driving the machine.

1. Warm-up the engine. The following are the approximate warm-up times with the engine idling.

Ambient temperature

-20°C -10°C 0°C

Warm-up time 15 minutes 10 minutes 5 minutes

Avoid sudden acceleration of the engine before the warming-up procedure is completed. Do not idle
the engine continuously for more than 10 minutes.

2. When the engine is warm completed warm up the equipment hydraulic system as follows:
a) Move the boom control lever slowly to the RAISE position and raise the bucket slightly,
b) Move the boom control lever slowly to the LOWER position and lower the bucket slightly,
c) Repeat the above procedure several times gradually increasing stroke of the boom lift

cylinders,
d) Repeat steps a) to c) with the bucket control lever
With the accelerator pedal depressed by 1/3 of the full stroke perform the following steps.

3. Raise the bucket 10 - 30 cm above the ground level, push the bucket control lever to the roll
back position to actuate the overflow valve for approximately 5 seconds, then return the lever to
the neutral position and hold it for approximately 2 seconds. Repeat this procedure to warm up
the equipment hydraulic system.

Increase the engine speed gradually up to high idle.

ATTENTION: If the machine is operated immediately after strating the engine without the warming
procedure, the equipment may undergo accelarated wear.

IMPORTANT: After starting and prior to operaton check carefully indications of all instruments and
warning lights, corrects found irregularities if nay.

OM560C99/1E DRESSTA

OPERATING SECTION 4

DRIVING THE MACHINE

Fig. 4.22. Starting and Stopping the Machine

Page 31

22 - Transmission and Instrument Panel Lights
Check Switch
28 - Parking Brake Switch
42 - Brake Pedal
43 - Transmission Neutral Lock Lver

44 - Transmission Gear Range Lever
45 - Transmission Direction Lever
49 - Bucket Control Lever
50 - Boom Control Lever
51 - Accelerator Pedal

WARNING! Before operating the machine observe strictly the following
precautions:
a) never haul passengers in the cab if 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 instruments, gauges and warning lights for correct operation

To start moving perform the following steps in accordance with Fig. 4.22:

1. Depress and hold down brake pedal 42.

2. Release parking brake 28.

3. Raise the boom with lever 50 until the bucket is off the ground and in carry position.

4. Rollback the bucket with lever 49.

5. Unlock transmission direction lever 45 and place it in the required direction forward or reverse.

ATTENTION: If the machine is equipped with a back-up alarm, the alarm will sound when the
direction lever is placed in REVERSE.

6. Place the transmission gear range lever 44 in the 1st gear (foremost position).

7. Release brake pedal 42 and gradually depress accelerator pedal 51 until the machine starts
moving.

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SECTION 4 OPERATING

Page 32

4.14. SHIFTING GEARS

The transmission has three forward gear ranges, three reverse gear ranges, and neutral, which are
manually selected with transmission gear range lever 44 and direction lever 45.
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.

Fig. 4.23. Shifting Gears

1,2,3 – Gears
F- Forward

N - Neutral
R – Reverse

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.

ATTENTION: 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 maximum speed before up-shifting. For speed ranges in the respective
gears refer to TRANSMISSION, Section 6.

4.15. STEERING

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

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

GROUND DRIVEN STEERING (IF EQUIPPED)
If there is a drop in hydraulic steering pressure, the ground driven steering will be actuated
automatically and warning light on the instrument panel will flash. The amount of the oil supplied by

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OPERATING SECTION 4

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STEERING

the ground driven pump depends upon the machine ground speed (pump driven by 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.

4.16. STOPPING THE MACHINE (FIG. 4.22)

Perform the steps the in following order:

1. Fully release accelerator pedal 51.

2. Apply brake pedal 42 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 drive disconnected with switch 22 when travelling
fast or going downhill. When released, it automatically makes transmission
clutches to re-engage. With ground speed higher than the maximal speed at the
previously shifted gear the machine will brake suddenly what may result in loss
of control or damage to the power train.

3. Place transmission direction lever 45 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 28.

5. Place bucket control lever 50 in the detented position - bucket roll back.

6. Push forward boom control lever 50 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 the 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 electrical system master switch, and remove the key.

4.17. PARKING THE MACHINE

When parking the machine observe the following rules:
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.
Always lock the machine, including any anti-vandalism attachments, when leaving the machine
unattended.

DRESSTA OM560C99/1E

SECTION 4 OPERATING

Page 34

PARKING THE MACHINE

Avoid parking on a slope, however, if parking on a hillside is necessary, park at the right angle to the
slope of the hill and block the tires as shown in Fig. 4.24.

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

Fig. 4.24. Hillside Parking

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

4.18. LOADER OPERATIONS

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

4.18.1. BOOM CONTROL LEVER POSITIONS (FIGURE 4.25.)

Fig. 4.25. Boom Control Lever Positions

A. Raise
B. Hold

C. Lower
D. Float

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.

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")

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OPERATING SECTION 4

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LOADER OPERATIONS

Raise A

To raise the boom assembly, pull the lever back as far as it will go. A detent in the valve locks the
lever in this 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

The control lever, when not in a detected position, will automatically return to "HOLD" when
released. The boom will remain stationary in this position.

Lower C

Push the lever part way forward to lower the boom. The lever will automatically return to "HOLD"
when released.

Float D

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.

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.

4.18.2. AUTOMATIC BOOM KICK-OUT (FIG. 4.26.)

Fig. 4.26. Automatic Boom Kick Out

1. Proximity Switch

2. Bar

3. Bracket
C – Bar-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. Proximity switch 1 is mounted to the front frame and is adjustable (in and out)
to achieve proper clearance C to bar 2. Bar 2 is slide mounted on bracket 3 and is locked in position
corresponding to the required height of the boom. The bracket is bolted to the inside of the left boom
arm up near the boom pivot. As the boom is raised to its preselected height, bar 2 has moved out of
the magnetic field of proximity switch 1, 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. Bar-to-switch clearance C necessary for
proper operation of proximity switch is 7 mm to 8 mm.

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LOADER OPERATIONS

Adjustment of automatic boom kick-out

To change the automatic boom kick-out position, raise the boom arms to the desired stopping
height (factory set stopping height is maximum boom height). Loosen the bolt holding bar 2 in place
and slide it in bracket 3 so as it is positioned directly in front of proximity switch. Tighten the bolt
holding the bar. 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.

4.18.3. BUCKET CONTROL LEVER POSITIONS (FIGURE 4.27)

Fig. 4.27. Bucket Control Lever Positions

E. Rollback B. Hold C. Dump

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").

Roll back E

To roll the bucket back- load the bucket and pull the lever all the way back. 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 forward. When the lever is released, it will automatically return
to hold position B.

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OPERATING SECTION 4

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LOADER OPERATIONS

4.18.4. AUTOMATIC BUCKET LEVELER

Fig. 4.28. Automatic Bucket Leveler

1. Trip Bar 2. Proximity Switch C – Bar-To-Switch Clearance

The principle of operation is as follows:
The bucket control lever may be maintained automatically in roll back position E (Fig. 4.27) with a
solenoid latch. Stopping the lever in this position is possible only when the induction proximity
switch 2 closes the circuit. When trip bar 1 attached to the bucket cylinder rod uncovers the switch,
the magnetic field is broken, solenoid latch is released which results in automatic retrun of the
bucket control lever to hold position B, Fig. 4.27. Operation of loader linkage using the leveler is as
follows. The operator after raising the boom to the required height and dumping the bucket places
the bucket control lever in roll back position E , Fig. 4.27 (detented position) and lowers the boom
with boom control lever placing it in F position, Fig. 4.27. The bucket control lever will be maintained
by the solenoid in roll back position E , Fig. 4.27 until proximity switch 2, Fig. 4.28 has been
uncovered by trip bar 1. The length of the trip bar is so selected that it will occur when the bucket is
in position prepared for the next cycle, when the bucket is in horizontal position and is resting on the
ground.

Bar-to-switch clearance C necessary for the proper operation of the proximity switch is 7 mm to 8
mm. No other adjustments are needed.

4.19. 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.

4.19.1. LOADING,TRANSPORTING AND PILING

When loading from a bank or stockpiling, use the V-method shown in Figure 4.29, or the step
loading method shown in Figure 4.30. 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 Figure 4.29.

DRESSTA OM560C99/1E

SECTION 4 OPERATING

Page 38

LOADER TECHNIQUES

Fig. 4.29."V" Loading Method Fig. 4.30. 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. 4.29. Back away in an arc from the bank or stockpile as show in Figure 4.29
and Figure 4.30 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 its 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 height of the side of loader vehicle.

When bank loading, keep the cutting edge flat as shown in Figure 4.31. Tilting 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.
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. 4.31. Bank Loading

OM560C99/1E DRESSTA

OPERATING SECTION 4

LOADER TECHNIQUES

Page 39

Fig. 4.32. Loading Sequence

Transport filled bucket in the roll back position raised approximately 0.5 meter above the ground. A
loaded bucket must never be transported in the fully raised position. Keep the travel speed
reasonable for safe operation. Upon reaching the truck, raise the bucket high enough to clear the
truck body, Fig. 4.33. Dump load slowly to reduce the shock of weight transfer to the rear axle when
the bucket is emptied. Shake bucket only to loosen dirt from within.

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

DRESSTA OM560C99/1E

SECTION 4 OPERATING

Page 40

LOADER TECHNIQUES

Fig. 4.33. Dumping Into Truck

Put enough loose rock or dirt into the truck first to act as cushioning material before proceeding to
load larger rocks (Figure 4.34.)

Fig. 4.34. Dumping Large Rocks Into Truck

After the bucket empties, move the bucket control lever back into the rollback position. The lever will
be maintained in this detached position by the solenoid latch. If the bucket is clear off the truck body,
back the loader way from the truck, lower the boom and return to the loading site. The bucket will
automatically return to its pre-set working position.
Lower loaded or unloaded bucket to the ground when waiting for any length of time.

WARNING! Never travel with an unstable and solid rock.

4.19.2. DIGGING, CLEARING AND LEVELING

When digging or excavating lower the bucket to the ground. Adjust the angle of the cutting edge
when the machines moves forward, Fig. 4.35. Change inclination of the angle of the cutting edge
and cutting edge depth using 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.

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OPERATING SECTION 4

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LOADER TECHNIQUES

Fig. 4.35. Digging or Excavating

Clearing an excavation. Fig. 4.36 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. 4.36. Clearing an Excavation

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.

Method of digging and removing large rocks is shown in Fig. 4.37. It is easier to load the rock by
digging under the rock with the bucket. Push on the bucket and roll it back simultaneously.

Fig. 4.37. Large Rock Removal

DRESSTA OM560C99/1E

SECTION 4 OPERATING

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

Page 42

LOADER TECHNIQUES

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.

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.

Level the ground when driving backward. Lift the bucket and dump it slightly, Fig. 4.38 then use float
position of the boom. Then weight of the loading mechanism presses on the ground and scrapes
and spreads uniformly. The ground may be leveled as described above but with fixed boom
position. Selection of the method depends upon the local conditions and the operator.

Fig. 4.38. Backdragging and Leveling

Small or medium trees may be removed with bucket raised at operator’s eyes level and positioned
horizontally pushing the tree with the middle part of the bucket. Do not hit the tree with bucket.
Topple the tree, back the loader and lower the bucket to the ground and push the tree from the site.

Fig. 4.39. Position of the Bucket When Removing a Small Tree

A - Wrong B - Right

WARNING! Using the loader to carry large objects which do not fit the bucket is
NOT RECOMMENDED. Handling large objects can be extremely dangerous
because objects may roll or slide down the lift arms on to the operator. NEVER
lift large objects higher than the operator unless the machine has a device
which prevents the objects from falling back onto the operator.

OM560C99/1E DRESSTA

OPERATING SECTION 4

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LOADER TECHNIQUES

Sequence of bank loading is shown in Fig. 4.40.

Fig. 4.40. Bank Loading

Heavy roots of large trees may require cutting from several sides of the tree (Fig. 4.41). Upon
completion of cutting push the tree as described above for small trees removal. 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. 4.41. Removing Large Trees

The wheel loader can be used for removing objects employing breakout force. However, avoid
removing of spring materials because it may cause splitting of the material.

Employ breakout force available applying the load in the middle of the bucket width.
The wheel loader may be used for pushing and pressing against brick walls, etc. following the

procedure for a tree removal. For those operations the bucket must be positioned horizontally.
The wheel loader may be used for towing trailers or pulling the loads, if necessary, however

spinning of the wheels must be avoided.

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SECTION 4 OPERATING

Page 44

4.20. ECONOMICAL OPERATION OF THE MACHINE

Fuel consumption during operation of the loader depends on many factors as: engine
characteristics, load, terrain, operator’ s skill and experience, manner of operation.

A relatively conclusive indicator of fuel consumption is quantity of moved material per unit of
consumed fuel. To reach the most favorable value of this ratio observe the following principles of
loader operation:

− avoid long distance transporting of material,

− loading and pushing of material must be performed in a gear which ensures maximum drawbar

pull (at high torque converter efficiency),

− take care to fill the bucket correctly during operation, use 1st and 2nd gear, avoid maximum
speed of the engine,

− avoid stopping machine due stall of the engine.

OM560C99/1E DRESSTA

SECTION 5

MAINTENANCE

MAINTENANCE SECTION 5

SECTION CONTENTS

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

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

5.2.1. Ground Level Inspection ........................................................................................... 6

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

5.3.1. Service Points ........................................................................................................... 8

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

5.4.1. When Shipped .......................................................................................................... 9

5.4.2. When Serviced ......................................................................................................... 9

5.4.3. Lubricant Selection ................................................................................................... 9

5.4.4. Viscosities ................................................................................................................. 9

5.4.5. Refill Specifications and Capacities ....................................................................... 10

5.4.6. Lubricant, Coolant and Fuel Equivalents ................................................................ 11

5.4.7. Lubricating Fittings .................................................................................................. 12

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

5.5.1. Fuel System ............................................................................................................ 15

5.5.2. Cooling System ....................................................................................................... 15

5.5.3. Electrical System .................................................................................................... 15

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

5.6.1. Air Cleaner .............................................................................................................. 15

5.6.2. Outer Filter Element ................................................................................................ 16

5.6.3. Inner Filter Element ................................................................................................. 18

5.6.4. Service Indicator Orifice Fitting ............................................................................... 18

5.6.5. Precleaner Hood ..................................................................................................... 19

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

5.7.1. Service Brake System ............................................................................................ 19

5.7.2. Parking Brake .......................................................................................................... 22

5.8. Cooling System .................................................................................................................... 24

5.8.1. Water ...................................................................................................................... 24

5.8.2. Antifreeze ................................................................................................................ 24

5.8.3. Inhibitors/Conditioners ............................................................................................ 25

5.8.4. Radiator Cap ........................................................................................................... 26

5.8.5. Checking the Coolant Level .................................................................................... 26

5.8.6. Draining the System ............................................................................................... 27

5.8.7. Cleaning the System ............................................................................................... 27

5.8.8. Replacing the Coolant Filter .................................................................................... 27

5.8.9. Filling the System .................................................................................................... 29

5.8.10. Cleaning the Radiator ............................................................................................. 30

5.9. Drive Axles ............................................................................................................................ 30

5.9.1. Checking the Oil Level ............................................................................................ 30

5.9.2. Changing the Oil ..................................................................................................... 31

5.10. Electrical System .................................................................................................................. 32

5.10.1. Electric Wires ......................................................................................................... 32

5.10.2. Circuit Breakers ...................................................................................................... 32

5.10.3. Bulb and Lamp Replacement ................................................................................. 32

5.10.4. Batteries .................................................................................................................. 33

5.11. Engine ................................................................................................................................... 35

5.11.1. Checking the Crankcase Oil Level ......................................................................... 35

5.11.2. Draining the Crankcase Oil ..................................................................................... 35

5.11.3. Changing the Lubricating Oil Filters ........................................................................ 36

5.11.4. Filling with Oil .......................................................................................................... 36

5.11.5. Fan .......................................................................................................................... 37

5.11.6. Belts ........................................................................................................................ 37

DRESSTA OM560C99/1E

SECTION 5 MAINTENANCE

5.12. Ether Injector ......................................................................................................................... 39

5.13. Fuel System .......................................................................................................................... 40

5.13.1. Changing the Fuel Filters ........................................................................................ 40

5.13.2. Fuel Tank ................................................................................................................. 42

5.14. Hydraulic System .................................................................................................................. 43

5.14.1. Checking the Reservoir Oil Level ............................................................................ 43

5.14.2. Changing the Hydraulic System Oil ........................................................................ 44

5.14.3. Changing the Oil Filters ........................................................................................... 46

5.14.4. Servicing the Hydraulic Reservoir Breather ............................................................ 46

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

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

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

5.18. Transmission and Torque Converter .................................................................................... 48

5.18.1. Checking the Oil Level ............................................................................................. 48

5.18.2. Changing the Oil ...................................................................................................... 49

5.18.3. Changing the Oil Filters ........................................................................................... 49

5.18.4. Cleaning the Transmission Oil Strainer .................................................................. 50

5.18.5. Servicing the Breather ............................................................................................. 51

5.19. Cab ........................................................................................................................................ 51

5.20. Loader Equipment ................................................................................................................. 51

OM560C99/1E DRESSTA

MAINTENANCE SECTION 5

Page 3

5.1. GENERAL PRECAUTIONS

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.

A CAREFUL OPERATOR IS THE BEST INSURANCE AGAINST AN ACCIDENT

The procedures in this section contain many notes and precautions which should be followed along
with standard safety procedures to minimize the possibility of personal injury or improper service.

Improper service could compromise the machine's safety or cause it to function improperly, which
could result in personal injury or death. Review the precautions listed in Section 2 "SAFETY
PRECAUTIONS."

Do not attempt to do repairs you do not understand. Use your "Service Manual" or consult your
Authorized Distributor for information.

Do not jump on or off the machine. When working under the machine, turn off the electrical system
master switch , apply parking brake and tag controls to warn against starting the machine.

When servicing in the area of the engine fan or belts, take care to prevent accidental cranking of the
engine. Turn off and lock the electrical master switch and tag the machine.
It is not possible to anticipate all conceivable ways or conditions under which this machine may be
serviced or to provide precaution 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.

This machine is assembled using high strength fasteners. Do not substitute. Replacement
fasteners must be of the same size and strength as the originals (refer to Section 6
SPECIFICATIONS). Tighten fasteners to the proper torque value specified in Section 6
SPECIFICATIONS, unless otherwise specified.

Refer to Spare Parts Catalog of respective model for all replacement parts.
Use safety goggles, hard hats, safety shoes, heavy duty gloves and other protection during cutting,

grinding, chiseling, prying or any other process which could cause material removal or projectiles.
Many machined parts are hardened and can chip. Use the proper size and type of tool for the job

being done. Select a wrench that fits and be sure it is on straight. Keep your tools clean and in good
condition. Some procedures require the use of tools specially designed for that specific purpose.
Before substituting another tool or procedure, you must be completely satisfied that neither
personal safety nor the performance of the machine will be endangered.

Scheduled maintenance is a normal procedure necessary to provide machine’s proper operation.

WARNING! For your personal safety carry out all maintenance service in
accordance with specified scheduled maintenance guide and instructions.

To prolong the service life of your equipment follow the scheduled maintenance listed in 5.2. and

5.3.

DRESSTA OM560C99/1E

SECTION 5 MAINTENANCE

Page 4

5.2. SCHEDULED MAINTENANCE GUIDE

Every 10 Hours of Operation (daily maintenance)

1. Perform the ground level inspection per 5.2.1.

2. Check the hydraulic tank oil level and add oil if necessary. Refer to 5.14.1.

3. Check the transmission oil level and add oil if necessary. Refer to 5.18.1.

4. Check the coolant level in the radiator. When adding coolant check for DCA concentration and

freezing temperature in cold weather. Refer to 5.8.5.

5. Check the engine oil level. Refer to 5.11.1.

6. Visually check the condition of the fan blades and fan drive belt. Refer to 5.11.5 and 5.11.6.

7. Check and inflate the tires, if necessary. Refer to 5.17.

8. Check and clean the precleaner screen, if necessary. Refer to 5.6.5.

9. Check the service indicator and perform service if the filter contamination is signaled by the

indicator. Refer to 5.6.2 and 5.6.3.

10. Drain the water from fuel tank and fuel filter water separator. Refer to 5.13.1. and 5.13.2.

11. Refill the fuel tank at the end of each day's operation. Refer to 5.13.2.

Every 50 Hours of Operation

1. Perform the service as specified in "Every 10 hours of operation"

2. Check the air intake system (for leaks, hoses and clamps, filter contamination). Refer to 5.6.4.

3. Lubricate:

− the bucket link pins,

− the bucket pivots,

Refer to 5.4.7.
4*) Clean transmission system suction strainer. Refer to 5.18.4.
5*) Replace transmission system filters. Refer to 5.18.3.
6*)Replace hydraulic system filters. Refer to 5.14.3.

*) after initial 50 hours of operation only

Every 100 Hours of Operation

1. Perform the service as specified in "Every 50 hours of operation"

2. Clean the radiator core. Refer to 5.8.10.

3. Lubricate the transfer drive. Refer to 5.4.7.

4. Lubricate the steering cylinders pivots. Refer to 5.4.7.

5. Lubricate the center driveshaft. Refer to 5.4.7.

6. Lubricate the bolster pivots. Refer to 5.4.7.

Every 250 Hours of Operation

1. Perform the service as specified in "Every 50 hours of operation"

3. Check the coolant for DCA concentration and replace the coolant filter. Refer to 5.8.3., 5.8.8.

4. Check and clean the transmission and torque converter breather. Refer to 5.18.5.

5. Check and clean the hydraulic reservoir breathers. Refer to 5.14.4.

6. Check and clean the fuel tank breather. Refer to 5.13.2.

7. Check the engine crankcase breather hoses and breather. Refer to ENGINE OPERATOR

MANUAL

8. Change the engine crankcase oil. Refer to 5.11.2. and 5.11.4.

9. Change the engine crankcase oil filters .Refer to 5.11.3.

10. Replace the fuel filters. Refer to 5.13.1.

11. Replace the coolant filter. Refer to 5.8.8.

12. Lubricate:

− the boom pivots,

OM560C99/1E DRESSTA

MAINTENANCE SECTION 5

SCHEDULED MAINTENANCE GUIDE

− the bucket cylinder pivots,

− the boom cylinders pivots,

− the bucket link.

Refer to 5.4.7.

13. Check the condition and tension of the engine belts. Refer to 5.11.6.

14. Check the condition of the fan. Refer to 5.11.5.

15. Check the parking brake shoes and brake disc for wear. Refer to 5.7.2.

Every 500 Hours of Operation

1. Perform the service as specified in "Every 250 hours of operation"

2. Check and add oil in the drive axles. Refer to 5.9.1.

3. Check and add oil in the steering gear. Refer to 5.16.

4. Replace the transmission system filters. Refer to 5.18.3.

5. Replace the oil filter element of the brake cooling system. Refer to 5.7.1.

6. Lubricate the tracking system linkage pivots. Refer to 5.3.1.

Every 1000 Hours of Operation

Page 5

1. Perform the service as specified in "Every 500 hours of operation"

2. Check the parking brake operation. Refer to 5.7.2.

3. Change the oil in the transmission and brake system. Refer to 5.18.2., 5.7.1.

4. Clean the transmission strainer. Refer to 5.18.2.

5. Replace the oil in hydraulic system. Refer to 5.14.2.

6. Replace the hydraulic tank filter elements. Refer to 5.14.3.

7. Replace the oil in the drive axles (differential and planetaries). Refer to 5.9.2.

8. Lubricate:

− the driveshafts,

− the center articulation pivots, refer to 5.4.7.

9. Check and add electrolyte in the batteries, if necessary. Refer to 5.10.4.

Periodic (at least once a year or as required)

1. Check the condition of the hydraulic lines and electrical wires. Repair or replace if necessary.
Refer to 5.5.3.

2. Check the condition of the safety belt and replace if necessary. Weak spots and damage of the
seat belt are inadmissible. Refer to 5.15.

3. Check the bucket teeth and cutting edge for wear.

4. Check the condition and torque of the cab-to-frame mounting hardware. Refer to 6.17.
SPECIAL TORQUES

5. Clean the fuel tank strainer. Refer to 5.13.2.

6. Replace the ether container (if empty). Refer to 5.12.

7. Lubricate:

− the control levers,

− the parking brake linkage,

− the pedals,

− the superstructure hinges, etc.

8. Clean the air conditioner filter (if equipped)

9. Check the condition of discs and hardware mounting the wheels. Refer to 5.17.

10. Clean the air filter. Refer to 5.6.2. and 5.6.3.

DRESSTA OM560C99/1E

SECTION 5 MAINTENANCE

Page 6

SCHEDULED MAINTENANCE GUIDE

Every 1500 Hours of Operation or every year (per Engine Operation Manual)

1. Steam clean the engine.

2. Check the torque of turbocharger mounting nuts and torque if necessary.

3. Check the torque of engine mounting bolts and torque if necessary.

4. Check the water pump.

5. Check the condition of the engine hoses and replace if necessary.

6. Adjust the valve lash and injectors.

7. Grease the fan hub.

8. Clean the crankcase breather and replace if necessary.

9. Check the crankshaft end clearance.

Every 6000 Hours of Operation or every 2 years (per Engine Operation Manual)

1. Perform the service as specified in "Every 1000 hours and 1500 hours of operation".

2. Clean the cooling system and change the coolant. Refer to 5.8.6., 5.8.7., 5.8.9.

3. Check the condition of the fan hub.

4. Check the condition of the idler pulley assembly.

5. Check the condition of the water pump.

6. Check the condition of the turbocharger.

7. Check the condition of the vibration dumper.

8. Clean and calibrate the injectors.

10. Inspect the fan idler.

5.2.1. GROUND LEVEL INSPECTION

1. Loader Equipment: condition, efficiency.

2. Radiator: condition, evidence of leakage and condition of the grill

3. Hydraulic components: condition, leakage, operation.

4. Drive train: condition, leakage, noise, clearance.

5. Wheels: condition of tires, mounting on wheel rims.

6. Engine compartment: fuel, lubrication and the cooling system for leaks.

7. Control panels: check the condition and operation of instruments, gauges and warning lights

8. ROPS: the condition of the ROPS cab, operator’s seat with seat belt, access openings. No
defects are permissible that may adversely affect its protection in case of machine rollover.

9. Visually check the screw joints, particularly:

♦ Drive axle to frame mounting,
♦ Driveshaft connecting,
♦ Center articulation pivot mounting,
♦ Wheel mounting,
♦ Cab to frame mounting.

5.3. MAINTENACE AND SERVICE CHART

IMPORTANT: The points of service are individually explained in more details in the following text.
Always use clean lubricators and containers. Wipe the dirt from the fittings before fresh grease is
added. Use the hourmeter to determine service intervals. Do not use the warning lights to
determine the service intervals.

IMPORTANT: The intervals of time between services are based on the average operating
conditions. In severe conditions of operation reduce the interval of time between the services.

OM560C99/1E DRESSTA

Chart 1.

MAINTENANCE SECTION 5

Page 7

MAINTENACE AND SERVICE CHART

Service
Interval

Every

10 Hours

Every

50 Hours

Every

100 Hours

Every

250 Hours

Ref.No Point of Service

1

7
13
15

17

8

9

5

5
10
12

3

6

6

6

6

6
13

Hydraulic Reservoir Oil Level
Radiator Coolant Level
Transmission Oil Level
Fuel Tank

Engine Crankcase Oil Level
Bucket Pivots

Bucket Link Pins

Transfer Drive
Steering Cylinder Pivots
Center Drive Shaft
Bolster Pivots

Loader Linkage Pivots
Engine Oil Filters
Fuel Filters – all
Engine Crankcase Breather
Coolant for DCA-4, Filter
Engine Crankcase Oil
Torque Converter and Transmission
Breather

Service

Points

1
1
1
1

1
2

2

1
4
3
2

10

1
2
1
1
1
1

Lubricant Service

HDTF

-

HDTF

-

EO1

MPG
MPG

MPG
MPG
MPG
MPG

MPG

-

-

-

-

-

EO1

Check
Check
Check
Drain
Sediment
Check

Lube
Lube

Lube
Lube
Lube
Lube

Lube
Change
Replace
Clean
Add, change
Change
Clean

Every

500 Hours

Every

1000 Hours

Periodic or

at Least

Once a

Year

Every 6000

hours or

every 2

years

4
19
14
14
20

1

1

1

4
11
13
13
13
18

2
15

21 Radiator Coolant 1 - Change

Drive Axle Oil
Steering Gear Oil
Transmission Filters
Brake System Filters
Tracking System linkage

Hydraulic System Oil
Hydraulic Oil Filters
Hydraulic Reservoir Breather
Drive Axles Oil
Center Articulation Pivots
Transmission Strainer
Transmission Oil
Transmission Breather
Drive Shafts

Air Filter Elements
Fuel Tank Strainer

-

Cab Hinges and Side Doors,
Pedals, Levers

2
1
2
1
4

1
2
2
2
1
2
1
1

12

1
1

MPL
MPL

-

-

MPG

HDTF/EO2

-

-

MPL

-

MPG

HDTF

-

MPG

-

-

MPG

Check
Check
Replace
Replace
Lube

Change
Replace
Clean
Change
Clean
Lube
Change
Clean
Lube

Clean
Clean
Lube

DRESSTA OM560C99/1E

SECTION 5 MAINTENANCE

Page 8

MAINTENACE AND SERVICE CHART

DESCRIPTION:
E01 – Engine Oil

E02 – Multigrade Engine Oil
MPG – Muli-Purpose Grease
HDTF – Hydraulic Transmission Fluid
MPL - Multigrade Transmission Oil

5.3.1. SERVICE POINTS

Fig. 5.1. Service Points

Service point description is given in Chart 1.

OM560C99/1E DRESSTA

MAINTENANCE SECTION 5

Page 9

5.4. LUBRICATION

5.4.1. WHEN SHIPPED

This Wheel Loader has been lubricated at the factory for operation in an air temperature range of
+21°C to -23°C. If this machine is to be operated above or below this range, change to the correct
lubricants. Unless an exception is shown below, all lubricants can be used (within above
temperature range) until regular scheduled (normal) change intervals occur. Refer to "SERVICE
CHART" for the scheduled (normal) change intervals and to "REFILL SPECIFICATIONS AND
CAPACITIES" for the proper oil grades for ambient temperatures.

5.4.2. WHEN SERVICED

The life and performance of a wheel loader and its equipment depends on the service that it is
given. Proper lubrication is an important part of the maintenance service.
Thorough lubrication service performed at the specified intervals will aid in prolonging the life of the
loader and its equipment and in reducing operating expense. The type of work being done, load,
ground and weather conditions are all factors to consider in frequency of lubrication.

The scheduled intervals between the lubrication periods shown on the "SERVICE CHART" are
approximate, based on average operating conditions. It may be necessary to lubricate after shorter
working periods under severe operating conditions such as extreme dust, low engine temperatures,
intermittent operation, excessively heavy loads with high oil temperatures, or when diesel fuel with a
high sulfur content is used. However, the time intervals between lubrication periods must never
exceed those indicated in this manual.

5.4.3. LUBRICANT SELECTION

The selection of the proper type (specification) and the grade (weight or viscosity) of lubricant is
important.

Many tests have been made to determine the correct lubricants for this wheel loader and its
equipment.

5.4.4. VISCOSITIES

During cold weather, base the selection of a crankcase lubricating oil viscosity on the lowest
anticipated temperature for the day to make starting easier. For hot weather operation, base the
selection on the highest anticipated temperature. Refer to the "REFILL SPECIFICATIONS AND
CAPACITIES" chart.

DRESSTA OM560C99/1E

SECTION 5 MAINTENANCE

Page 10

LUBRICATION

5.4.5. REFILL SPECIFICATIONS AND CAPACITIES

Chart 2.

Lubrication

point

Crankcase 57 EO1 Engine oil per B21-0002 CE, CF-4 or CD

Hydraulic

System

Transmission

and Converter

System

Drive Axles

(each)

Steering Gear

Housing

Capacity [l] Grade

382 HDTF

LUB
EO2

144 HDTF Hydraulic & Transmission Fluid

80

0.33

MPL Transmission oil per HMS B22-0003

Temp.

+49°° to –7 °°C

SAE 15W/40 | SAE 5W/30

| SAE 5W/40

NOTE: Refer to Operating and Maintenance

Instruction of Cummins Engine

Hydraulic & Transmission Fluid

Per HMS B21-0006 passing Test C-4/TO-4*)

Engine oil per HMS B21-0003

or CD MIL-L-2104C SAE 10W

Per HMS B21-0006 passing Test C-4/TO-4*)

or GL-5, MIL-L-2105C

SAE 85W/140 | SAE 80W/90 | SAE 80W/90

Temp.

+21°° to –23 °°C

per API

SAE 10W

Or

SAE 10W

| SAE 85W/140 |

Temp.

-12°° to –34 °°C

Temp.

-12°° to –54 °°C

Arctic grease

Per HMS B21-0001

Arctic grease

Grade 75

Per HMS B22-0003

All Lube

Fittings

Cooling

System

Fuel Tank 625 Diesel oil per HMS B32-0001 or ASTM D975

*) oil should not include viscosity improving additives

OM560C99/1E DRESSTA

As required MPG Mylti-purpose grease per HMS B27-0002

Or

Lithium Grease NLG12 with 3% MoS

101 Antifreeze per HMS B21-0001

50% antifreeze concentrate

50% water

1D
2D

Arctic grease

Per HMS B27-0003

62% antifreeze

concentrate

35% water

DFA

MAINTENANCE SECTION 5

LUBRICATION

5.4.6. LUBRICANT, COOLANT AND FUEL EQUIVALENTS

Chart 3

RECOMMENDED EQIVALENT LUBRICANT TYPE

LUBRICANT

Engine oil per HMS
B21-0002 or API CE, CF-4,
or MIL-L2104C
with sulfated ash of 1.65%

SAE 10W/40

SAE 10W/30 MYRINA TX 10W/30 URSA TDX 10W/30
SAE 5W/40
Engine oil per
HMS B21-0003 or

CD MIL-L2104C
SAE 10W SUPEROL CD SAE 10W ROTELLA TX 10W URSA SUPER LA 10W
SAE 30 SUPEROL CD SAE 30 ROTELLA TX 30 URSA SUPER LA 30
Transmission Fluid HDTF

per HMS B21-0006 passing
formula C-4 and TO-4

LOTS DIESEL CE/SF
SAE 15W/40
SUPEROL FALCO CD
15W/40

POLISH SHELL TEXACO

MYRINA TX 15W/40
RIMULA X 15W/40

URSA SUPER LA
15W/40

Page 11

E01

E02

HDTF

SAE 10W GERAX TKD 10W DONAX TC 10 TEXTRAN HD 10W
SAE 30 GERAX TKD 30 DONAX TC 30 TEXTRAN HD 30
Gear Lube per HMS

B22-0003 or API GL-5
or MIL-L-2105C

SAE 85W/140 HIPOL 85W/140 SPIRAX HD

85W/140

SAE 80W/90 HIPOL 80W/90 SPIRAX HD 80W/90 GEARTEX EP-C

Multi-purpose grease per
HMS B27-0002 or NLGI
grade #2
Multi-purpose lithium
grease with 3% minimum
molybdenum disulfide
(MoS2)

Anti-freeze, ethylene glycol
base per HMS B01-0001

Arctic oil, synthetic
75W per HMS B22-0003
Arctic oil, synthetic per HMS
B21-0001 OR
MIL L-46167

Arctic grease per
HMS B27-0003 or
MIL-L-10924D

Diesel Fuel
Per
HMS B32-0001

LITMOS EP-23 RETINAX EPX2 MOLYTEX EP-2 MPG

ERGOFRYZ GLYCOSHELL

DILUTED

Cheveron subzero fluid OW-30 or Frigid-go
Code 2809A by Emery Industries

SRI grease manufactured by CONOCO
Grease 2816 manufactured by EMERY Ind.

Diesel fuel per Polish Standard PN-C-96051:1992
DL above 0°C
DP above –12°C
DZ above -20°C
IZ-40 above –30°C
For temperatures below -30°C add depersator

GEARTEX EP-C
85W/140

80W/90

ANTIFREEZE
ETX 6042

SYN-STAR 75W
CODE 2080

MPL

MPL

ARCTIC

EO

Arctic

MPG

ARCTIC

DRESSTA OM560C99/1E

SECTION 5 MAINTENANCE

Page 12

LUBRICATION

5.4.7. LUBRICATING FITTINGS

WARNING! Never run the engine when cleaning or lubricating the machine
because serious injury could result from contacting moving parts. Before
servicing the machine, be sure the engine is off, the bucket is lowered, the
transmission range gear lever locked in neutral position, the parking brake
applied and the electrical master switch is off and the key is removed.

The lubricating fittings (see Fig. 5.1.) are to be greased at the intervals indicated in the service
chart. Always use a clean lubricator. Wipe all accumulated dirt from fittings before applying fresh
grease. Apply grease at each fitting until fresh grease appears. If grease fails to go through the
fitting, determine the cause and correct it.

Fig. 5.2. Lubricating Fittings

1 - Transfer Drive
2 - Lower Articulation Pivot

L, R- fittings are located on the left (L) hand side and right (R) hand side of the machine frame.

3 - Steering Cylinders
4 - Upper Articulation Pivot

Lubricating fittings of other service points are shown in Fig. 5.3. to 5.8. Easier access to service
points may be gained by proper positioning of loader linkage.

Fig. 5.3. Bucket Cylinder Pivot Fittings

OM560C99/1E DRESSTA