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

INTRODUCTION SECTION 1
DRESSTA OM515C520C99/1E
SECTION CONTENTS
1.1. Introduction ............................................................................................................................. 3
1.2. Serial Numbers ....................................................................................................................... 5

INTRODUCTION SECTION 1
Page 3
DRESSTA OM515C520C99/1E
1.1. INTRODUCTION
Fig. 1.1. 515 Series C Wheel Loader
a - Right Hand Side of the Machine
b - Left Hand Side of the Machine c - Front of the Machine d - Rear of the Machine
Fig. 1.2. 520 Series C Wheel Loader
a - Right Hand Side of the Machine
b - Left Hand Side of the Machine c - Front of the Machine d - Rear of the Machine

SECTION 1 INTRODUCTION
Page 4
OM515C520C99/1E DRESSTA
INTRODUCTION
GENERAL
Throughout this manual there will be two types of cross references. One type - numerical - refers to
a heading within the same section. The other type - numerical followed by the section
title - refers to a heading in another section. Refer to the section contents page at the beginning of
the individual sections for specific page numbers.
Throughout this manual the use of the terms "left", "right", "front", and "rear" must be understood to
avoid confusion when following the instructions. "Left" and "right" indicate the left and right sides of
the machine when facing forward in the operator's seat. The „front” is in front of the operator, the
„rear” - behind his back. See Fig. 1.1, 1.2.
Some illustrations are of general application of this model and may not show your machine
accurately in all details.
The loaders are available in 2 different versions:
1. standard version equipped with a mechanical feedback steering and a hydraulic system
controlled with either 2 or 3 levers mechanically connected with a 2 or 3-spool control valve
respectively.
2. upgraded version: equipped with a hydraulic feedback steering and a hydraulic system controlled
with 1 or 2 levers hydraulically connected with a 2 or 3-spool control valve respectively. In this
version it can be configured as CE version according to EC directives.
WARNING!: This symbol and text in bold letters is used throughout this manual
to call your attention to instructions concerning personal safety. Observe and
follow these instructions. Be certain anyone operating and servicing this
machine is aware of these rules. Failure to follow these rules may result in injury
or death.
IMPORTANT: This sign and text in italics is used throughout this manual to call your attention to
key problems for machine operation. Failure to follow such instructions may result in damage of the
machine and heavy material losses.
NOTE: This sign and text in italics is used throughout this manual to call your attention to important
function having influence on the right functioning of the machine or for informational purposes.

INTRODUCTION SECTION 1
Page 5
DRESSTA OM515C520C99/1E
1.2. SERIAL NUMBERS
Fig.1.3. Location of Machine Serial Number plates
1. The machine serial number plate is located at the bottom of the left hand side of the cab. It is
also stamped on the left rear corner of the rear frame.
Fig.1.4. Location of stamped machine serial number
Fig.1.5. Engine Serial Number Plate

SECTION 1 INTRODUCTION
Page 6
OM515C520C99/1E DRESSTA
SERIAL NUMBERS
2. The engine serial number plate is located on the left hand side of the engine in the space
designated “Engine serial number” (Fig. 1.5).
Fig.1.6. Cab Serial Number Plate
3. The cab serial number plate is located inside the cab in the right front corner near the floor board
(Fig. 1.6).
All other main components having serial numbers are each equipped with a separate serial number
plate or the number is stamped on the component body.
Use respective serial numbers when requesting information or ordering parts and proper numbers
from Parts Catalogue.

SECTION 2
SAFETY PRECAUTIONS

SAFETY PRECAUTIONS SECTION 2
DRESSTA OM515C520C99/1E
SECTION CONTENTS
2.1. General .............................................................................................................................. 3
2.2. Before Starting the Engine ................................................................................................ 4
2.3. Operating the Machine ...................................................................................................... 4
2.4. General Maintenance Precautions .................................................................................... 6
2.5. When Parking .................................................................................................................. 10
2.6. Safety Graphics Location ................................................................................................ 11
2.6.1. Safety Graphics ..................................................................................................... 12
2.6.2. Safety Graphics (Version CE) ................................................................................ 16

SAFETY PRECAUTIONS SECTION 2
Page 3
DRESSTA OM515C520C99/1E
2.1. GENERAL
WORK SAFELY - FOLLOW THESE RULES
WARNING!: This symbol and text with bold letters is used throughout this manual
to call your attention to instructions concerning personal safety. Observe and
follow these instructions. Be certain anyone operating and servicing this
machine is aware of these rules. Failure to follow these rules may result in injury
or death.
Recommendations and information given in this Section do not cover all subjects to be acquired for
safe operating of the machine. Detailed information respecting safe operating of the machine are
specified in the following Sections. Observe and follow these rules.
Operating and servicing this machine can be hazardous if performed improperly. Personnel must have
necessary skill information and use proper procedures and recommendations included in this manual.
Only trained and authorized personnel should be allowed to operate and service this machine.
Do not rush. Hurrying can lead to accidents. Haste, carelessness and lack of training are the primary
causes of equipment-related injuries.
The machine must be equipped with a fully charged fire extinguisher recharged immediately after use
and first-aid kit. The fire extinguisher is fixed on the floor at the left band side of the operator’s seat.
Operator’s seat must be equipped with safety belt. Also, the machine must be equipped with
a safety triangle.
If the machine is equipped with outside ventilation check the engine exhaust system periodically for
leaks. Exhaust gases are dangerous to the operator. On machines equipped with a cab without
outside ventilation, keep sliding windows open to outside air.
The operator must not wear loose fitting or hanging clothing, belts or jewelry and must wear shoes with
non-slipping soles as well as a hard hat insulated during cold weather.
Do not jump on or off the machine. Keep two hands and one foot, or two feet and one hand in contact
with the steps and handholds at all times. Always face the machine when climbing on or off to reduce
the chances of slipping and injury.
Follow all machine-mounted safety signs before starting, operating, maintaining or servicing the
machine.
The operator must be alert, physically fit and free from the influences of alcohol, drugs or
medications that might affect his eyesight, hearing, reactions or judgment.
Do not use controls or hoses as hand holds when climbing on or off the machine. The hoses and
controls can move and do not provide solid support. Movement of the controls may cause
inadvertent and unexpected movement of the machine or its equipment.
Be sure the area of the operator's compartment, all mounting steps and grab handles are free of
oil, grease, loose objects, ice and mud to lessen the possibility of slipping. All damaged steps or
grab handles should be repaired immediately. Remove or secure all maintenance and personal
items so they will not interfere with the operator or jam the controls.