DRESSTA 515C User manual

OM515C520C99/1E
OPERATOR`S MANUAL
515C - 520C
SERIAL NUMBER 7001
AND UP
9001 AND UP FOR 515CH
SERIAL NUMBER 11001
AND UP
13001 AND UP FOR 520CH
DRESSTACo. Ltd.
A JOINT VENTURE OF KOMATSU AMERICA INTERNATIONAL CO. AND HUTA STALOWA WOLA S.A.

DRESSTA OM515C520C99/1E
FOREWORD
Welcome to the growing group of value-conscious people who operate DRESSTA machines
This manual covers the instructions for safe operation, lubrications, adjustments and maintenance
for normal daily care. These instructions are divided into six sections to simplify your reference to
the information most important to you. Refer to the contents page at the beginning of the section for
a complete list of the subjects covered except for Section 2, which should be read entirely.
This manual has been prepared to help you operate and maintain your machine with utmost
efficiency and safety. Read this manual thoroughly and learn your machine before you attempt to
operate it.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve
the right to make changes or add improvements at any time without incurring any obligation to
install such changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be made to
this publication. It is recommended that customers contact their distributor for information on the
latest revision.
We hope you will be able to use our machines safety and to the best advantage.
DRESSTA Co. Ltd.
This material is proprietary to DRESSTA Co. Ltd. and is not to be reproduced, used or disclosed
except in accordance with written authorization from DRESSTA Co. Ltd.

OM515C520C99/1E DRESSTA

DRESSTA OM515C520C99/1E
SECTION INDEX
Section 1 Introduction.......................................................................................................................1.1
Section 2 Safety Precautions...........................................................................................................2.1
Section 3 Storage and Shipping.......................................................................................................3.1
Section 4 Operating..........................................................................................................................4.1
Section 5 Maintenance.....................................................................................................................5.1
Section 6 Specifications...................................................................................................................6.1

DRESSTA OM515C520C99/1E
SECTION CONTENTS
SECTION 1 - INTRODUCTION
This section discusses the use of this manual and serial number locations.
SECTION 2 - SAFETY PRECAUTIONS
This section lists safety rules concerning personal safety. Read this section carefully and observe
safety precautions specified herein.
SECTION 3 - STORAGE AND SHIPPING
This section discusses how to ship or store this machine.
SECTION 4 - OPERATING
The front portion of this section provides you with instructions for trouble free operation of the
machine. A universal symbol chart for instruments and controls designation is provided. The
instruments and controls area is designed to tell you "where it is, what it does and how to use it".
Read this area carefully. The remaining portion of this section outlines and illustrates the step-by-
step procedures for starting, operating and stopping the machine and discusses a few operating
suggestions and techniques and simple ideas to help ease the work and lengthen the useful life of
your machine.
SECTION 5 - MAINTENANCE
The beginning of this section outlines a complete scheduled maintenance program, which helps to
reduce down-time and expense, and increase the profit and work from your machine. Read and
use this area. Following the maintenance program are the lubrication recommendations and
requirements for the machine. The remainder of the section is devoted to clearly explaining the
"how to" of the many maintenance and adjustment procedures listed in the maintenance program.
SECTION 6 - SPECIFICATIONS
This section covers the general dimensions schematics, forces and weights, refill capacities,
ground speeds and the standard and special torque values.

DRESSTA OM515C520C99/1E
SECTION CONTENTS
1. INTRODUCTION
1.1. Introduction ............................................................................................................................. 3
1.2. Serial Numbers ....................................................................................................................... 5
2. SAFETY PRECAUTIONS
2.1. General ................................................................................................................................... 3
2.2. Before Starting the Engine ...................................................................................................... 4
2.3. Operating the Machine ............................................................................................................ 4
2.4. General Maintenance Precautions ......................................................................................... 6
2.5. When Parking ....................................................................................................................... 10
2.6. Safety Graphics Location ..................................................................................................... 11
3. MACHINE TRANSPORT AND STORAGE
3.1. Machine Transport ...................................................................................................................3
3.2. Lifting on Slings ........................................................................................................................5
3.3. Moving a Disabled Machine .....................................................................................................6
3.4. Machine Storage ......................................................................................................................7
4. OPERATING
4.1. General ................................................................................................................................... 3
4.2. Universal Symbols for Instruments and Controls ................................................................... 4
4.3. Instruments and Controls ....................................................................................................... 8
4.4. Cab Door and Windows ....................................................................................................... 20
4.5. Operator’s Seat .................................................................................................................... 21
4.6. Seat Belt ............................................................................................................................... 24
4.7. Cab Heating and Ventilation .................................................................................................. 25
4.8. Air Cleaner Service Indicator .................................................................................................27
4.9. Electrical Master Switch ....................................................................................................... 27
4.10. Dome Lights with Switches .................................................................................................. 28
4.11. Starting and Stopping the Engine ......................................................................................... 28
4.12. Driving the Machine .............................................................................................................. 30
4.13. Shifting Gears ....................................................................................................................... 32
4.14. Steering ................................................................................................................................. 32
4.15. Stopping the Machine ........................................................................................................... 33
4.16. Parking the Machine ............................................................................................................. 34
4.17. Loader Operations ................................................................................................................ 34
4.18. Loader Techniques ............................................................................................................... 41
4.19. Economical Operation of the Machine ................................................................................. 54
4.20. Quickcoupling ........................................................................................................................54
4.21. Ride Stabilizing Mechanism ..................................................................................................56
4.22. High-Dump Bucket ............................................................................................................... 57

OM515C520C99/1E DRESSTA
5.MAINTENANCE
5.1. General Precautions ............................................................................................................... 3
5.2. Scheduled Maintenance Guide ............................................................................................... 4
5.3. Maintenance and Service Chart .............................................................................................. 6
5.4. Lubrication ............................................................................................................................... 9
5.5. Seasonal Preparations .......................................................................................................... 14
5.6. Air Cleaning System .............................................................................................................. 15
5.7. Brakes ................................................................................................................................... 19
5.8. Cooling System ..................................................................................................................... 22
5.9. Drive Axles ............................................................................................................................ 27
5.10. Electrical System .................................................................................................................. 29
5.11. Engine ................................................................................................................................... 31
5.12. Ether Injector ......................................................................................................................... 37
5.13. Fuel System .......................................................................................................................... 38
5.14. Hydraulic System .................................................................................................................. 42
5.15. Seat Belt ................................................................................................................................ 47
5.16. Steering Gear ........................................................................................................................ 47
5.17. Tires and Rims ...................................................................................................................... 47
5.18. Transmission System ........................................................................................................... 48
5.19. ROPS Cab and ROPS Canopy .............................................................................................53
5.20. Hood Assembly and Radiator Grill ........................................................................................ 54
5.21. Loader Equipment ................................................................................................................. 55
5.22. Air Conditioner or Heater ....................................................................................................... 56
6.SPECIFICATIONS
6.1. Application ............................................................................................................................... 3
6.2. Technical Description ............................................................................................................. 3
6.3. Schematic of 515C and 520C Wheel Loader Drive Train ...................................................... 4
6.4. Schematic of Transmission Hydraulic System ...................................................................... 5
6.5. Loader Equipment and Steering Hydraulic System Schematic ............................................. 6
6.6. Wiring Diagram...................................................................................................................... 14
6.7. Brake Hydraulic System Schematic...................................................................................... 25
6.8. Specifications ........................................................................................................................ 26
6.9. 515C and 520C Loader Equipment ...................................................................................... 32
6.10. Torque Values for Standard Metric Fasteners ...................................................................... 35
6.11. Torque Values for Standard English Fasteners.................................................................... 35
6.12. Torque Values for Split Flange Connections ........................................................................ 36
6.13. Torque Values for Hydraulic Tubes and Fittings ................................................................... 37
6.14. Torque Values for Hose Clamps ........................................................................................... 37
6.15. Torque Values for Air Conditioning Tubes and Fittings ......................................................... 38
6.16. Torque Values for Air Conditioning O-Ring Connections ..................................................... 38
6.17. Special Torques .................................................................................................................... 39
6.18. Service Tools ........................................................................................................................ 40

SECTION 1
INTRODUCTION