DRESSTA 560C User 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-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.

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
DRESSTA OM560C99/1E
SECTION CONTENTS
1.1. Introduction ............................................................................................................................. 3
1.2. Serial Numbers ....................................................................................................................... 4

INTRODUCTION SECTION 1
Page 3
DRESSTA OM560C99/1E
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.

SECTION 1 INTRODUCTION
Page 4
OM560C99/1E DRESSTA
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

INTRODUCTION SECTION 1
Page 5
DRESSTA OM560C99/1E
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.

SECTION 2
SAFETY PRECAUTIONS

SAFETY PRECAUTIONS SECTION 2
DRESSTA OM560C99/1E
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

SAFETY PRECAUTIONS SECTION 2
Page 3
DRESSTA OM560C99/1E
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 non-
slipping 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.

SECTION 2 SAFETY PRECAUTIONS
Page 4
OM560C99/1E DRESSTA
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.