DRESSTA 560C Operator's Manual
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DRESSTA 560C Operator's Manual

Serial numbers 15001 and up
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OM560C99/1E
OPERATOR'S MANUAL
560C
SERIAL NUMBERS
15001 AND UP

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  • Page 1 OM560C99/1E OPERATOR’S MANUAL 560C SERIAL NUMBERS 15001 AND UP...
  • Page 2 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.

  • Page 4: Table Of Contents

    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...

  • Page 6: Introduction

    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.
  • Page 8 SECTION CONTENTS INTRODUCTION 1.1. Introduction ..........................3 1.2. Serial Numbers ........................4 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.
  • Page 9 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.

  • Page 10: Introduction

    SECTION 1 INTRODUCTION...
  • Page 11 INTRODUCTION SECTION 1 SECTION CONTENTS 1.1. Introduction ..........................3 1.2. Serial Numbers ........................4 DRESSTA OM560C99/1E...

  • Page 13: Introduction

    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...
  • Page 14 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...

  • Page 15: Serial Numbers

    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...

  • Page 16: Safety Precautions

    SECTION 2 SAFETY PRECAUTIONS...
  • Page 17 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...

  • Page 19: General

    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...

  • Page 20: Before Starting The Engine

    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...

  • Page 21: Operating 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...
  • Page 22 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...

  • Page 23: General Maintenance Precautions

    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...
  • Page 24 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...
  • Page 25 − 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...

  • Page 26: When Parking

    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...

  • Page 27: Safety Graphics Location

    SAFETY PRECAUTIONS SECTION 2 Page 11 2.6.SAFETY GRAPHICS LOCATION Fig. 2.1. Safety Graphics Location L, R – Graphics attached on left hand side or right hand side of the machine DRESSTA OM560C99/1E...
  • Page 28 SAFETY PRECAUTIONS SECTION 2 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...
  • Page 29 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...
  • Page 30 SAFETY PRECAUTIONS SECTION 2 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...
  • Page 31 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...

  • Page 32: Machine Transport And Storage

    SECTION 3 MACHINE TRANSPORT AND STORAGE...
  • Page 33 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...
  • Page 35 ATTENTION ! When transporting this machine on a high speed carrier or railaway car, seal the exhaust pipe openining to prevent turbocharger damage. 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...

  • Page 36: Machine Transport

    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...

  • Page 37: Lifting On Slings

    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...

  • Page 38: Moving A Disabled Machine

    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...
  • Page 39 0° to +21 °C . Be sure the batteries are fully charged. DRESSTA OM560C99/1E...
  • Page 40 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...
  • Page 41 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...

  • Page 42: Operating

    SECTION 4 OPERATING...

  • Page 44: General

    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 Machine ..................44 DRESSTA OM560C99/1E...

  • Page 46: General

    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...
  • Page 47 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...

  • Page 48: Universal Symbols For Instruments And Controls

    OPERATING SECTION 4 Page 5 UNIVERSAL SYMBOLS FOR INSTRUMENTS AND CONTROLS Fig. 4.1. Universal Symbols for Instruments and Controls DRESSTA OM560C99/1E...
  • Page 49 OPERATING SECTION 4 Page 6 UNIVERSAL SYMBOLS FOR INSTRUMENTS AND CONTROLS OM560C99/1E DRESSTA...
  • Page 50 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 DRESSTA OM560C99/1E...
  • Page 51 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...

  • Page 52: 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...
  • Page 53 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...
  • Page 54 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. DRESSTA OM560C99/1E...
  • Page 55 (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. OM560C99/1E DRESSTA...
  • Page 56 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). DRESSTA OM560C99/1E...
  • Page 57 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. OM560C99/1E DRESSTA...
  • Page 58 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. DRESSTA OM560C99/1E...
  • Page 59 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...
  • Page 60 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. DRESSTA OM560C99/1E...
  • Page 61 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...

  • Page 62: Seat Belt

    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. DRESSTA OM560C99/1E...

  • Page 63: Suspension Seal

    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). OM560C99/1E DRESSTA...
  • Page 64 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...

  • Page 65: Seat Belt

    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...

  • Page 66: Cab Heating And Ventilation

    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...

  • Page 67: Dome Lights 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...

  • Page 68: Cab Door Latch

    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...
  • Page 69 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...

  • Page 70: Starting And Stopping The Engine

    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...
  • Page 71 1. Perform the steps 1 thru 5 of NORMAL START. 2. Disconnect the electrical wire from the fuel pump solenoid valve. OM560C99/1E DRESSTA...
  • Page 72 3 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...

  • Page 73: Driving The Machine

    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...
  • Page 74 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. DRESSTA OM560C99/1E...

  • Page 75: Shifting Gears

    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 OM560C99/1E DRESSTA...

  • Page 76: Stopping The Machine

    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...

  • Page 77: Parking The Machine

    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") OM560C99/1E DRESSTA...

  • Page 78: Loader Operations

    "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. DRESSTA OM560C99/1E...
  • Page 79 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. OM560C99/1E DRESSTA...
  • Page 80 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...

  • Page 81: Loader Techniques

    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...
  • Page 82 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...
  • Page 83 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. OM560C99/1E DRESSTA...
  • Page 84 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...
  • Page 85 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...
  • Page 86 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. DRESSTA OM560C99/1E...

  • Page 87: Economical Operation Of The Machine

    (at high torque converter efficiency), − take care to fill the bucket correctly during operation, use 1 and 2 gear, avoid maximum speed of the engine, − avoid stopping machine due stall of the engine. OM560C99/1E DRESSTA...

  • Page 88: Maintenance

    SECTION 5 MAINTENANCE...
  • Page 89 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...
  • Page 90 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...

  • Page 91: General Precautions

    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...
  • Page 92 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...

  • Page 93: Scheduled Maintenance Guide

    − 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...
  • Page 94 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...

  • Page 95: Maintenance And Service Chart

    Transmission Breather Clean Drive Shafts Lube Air Filter Elements Clean Fuel Tank Strainer Clean Cab Hinges and Side Doors, Lube Periodic or Pedals, Levers at Least Once a Year Radiator Coolant Change Every 6000 hours or every 2 years DRESSTA OM560C99/1E...
  • Page 96 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...
  • Page 97 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...

  • Page 98: Lubrication

    Lithium Grease NLG12 with 3% MoS Cooling Antifreeze per HMS B21-0001 System 62% antifreeze 50% antifreeze concentrate concentrate 50% water 35% water Fuel Tank Diesel oil per HMS B32-0001 or ASTM D975 *) oil should not include viscosity improving additives OM560C99/1E DRESSTA...
  • Page 99 HMS B27-0003 or Grease 2816 manufactured by EMERY Ind. ARCTIC MIL-L-10924D Diesel Fuel Diesel fuel per Polish Standard PN-C-96051:1992 DL above 0°C HMS B32-0001 DP above –12°C DZ above -20°C IZ-40 above –30°C For temperatures below -30°C add depersator DRESSTA OM560C99/1E...
  • Page 100 L, R- fittings are located on the left (L) hand side and right (R) hand side of the machine frame. 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...
  • Page 101 MAINTENANCE SECTION 5 Page 13 LUBRICATION Fig. 5.4. Boom Cylinders Pivot Fittings Fig. 5.5. Bellcrank Fittings Fittings are arranged symetrically on both sides of the bellcrank. Fig. 5.6. Boom Pivots Fittings DRESSTA OM560C99/1E...
  • Page 102 Gas-fired forced air heaters may also be obtained to heat the transmission and final drives. If a loader is to be used in low temperatures it is best to order a machine designed for operation in low temperatures, which is equipped with necessary heaters. OM560C99/1E DRESSTA...

  • Page 103: Seasonal Preparations

    IMPORTANT: Never operate the engine unless a filter element is installed. Never start the engine unless air cleaner elements are in place and the covers are tight. DRESSTA OM560C99/1E...

  • Page 104: Air Cleaning System

    Fig. 5.9. Air Cleaner Assembly Filter Assembly Wing Nut Wing Nut 10. Body 13. O-Ring Cover Washer Cotter Key 11. Clamp Cover Gasket Outer Element Inner Element 12. Precleaner Hood OM560C99/1E DRESSTA...
  • Page 105 2. Install gasket 3 (replace if damaged), cover 2 and secure the cover to the body with the three locking clamps . 3. Inspect and tighten all air cleaner connections before resuming operation. IMPORTANT: After servicing the filter element press reset button 1, Fig. 5.10. to reset the air cleaner service indicator. DRESSTA OM560C99/1E...
  • Page 106 Service indicator orifice fitting is installed on the air cleaner elbow close to the service indicator. If the indicator or its tubing becomes damaged, the orifice fitting will prevent unfiltered air from entering the engine. If a leak occurs, this orifice will, with continued operation, plug up. This will be OM560C99/1E DRESSTA...

  • Page 107: Service Brake System

    These circuits can operate independently securing safe operation of a wheel loader. The service brake is actuated with the brake pedal from the operator’s cab. Increasing gradually pressure exerted on the brake pedal the required braking effect is obtained. The more the pedal is depressed the stronger the braking effect. DRESSTA OM560C99/1E...

  • Page 108: Cooling System

    Fig. 5.12. When the gasket contacts the head torque the filter to 40 to 50 Nm. The filter replacement should be made when replacing the transmission and torque converter system filters. OM560C99/1E DRESSTA...
  • Page 109 3. Loosen hose fitting 2 of hose 1, Fig. 5.14. on the transmission at the transmission disconnecting valve by app. 1 turn. 4. Depress slightly the brake pedal. Observe the outflow of air and oil at loosened hose connection. 5. Tighten the connection when clear oil without air bubbles starts to flow. DRESSTA OM560C99/1E...

  • Page 110: Parking Brake

    If an adjustment is necessary consult service personnel. WARNING! If the parking brake does not hold the machine stationary correct the cause. Until the cause is corrected, park the machine on level ground and block the tires to prevent it from moving. OM560C99/1E DRESSTA...
  • Page 111 “A” as shown in Fig. 5.15. after placing the brake head in the utmost position in the direction shown by the arrow, Fig. 5.15. NOTE: No not exceed specified values as jamming of the brake shoes may occur and accelerated wear of brake linings. DRESSTA OM560C99/1E...

  • Page 112: Cooling System

    Antifreeze may retain its freeze protection for more than one season but coolant conditioners must be added to maintain corrosion protection. Antifreeze formulated with metoxy propanol, or propylene glycol is not recommended for this system. OM560C99/1E DRESSTA...

  • Page 113: Inhibitors/Conditioners

    - ON position. NOTE: Mixing of DCA4 and other supplemental coolant additives is not recommended because there is currently no test kit available to measure concentration levels with mixed chemical solutions. DRESSTA OM560C99/1E...

  • Page 114: Radiator Cap

    2. Add coolant if it must be added; remove the radiator cap as outlined above. 3. Add coolant until the level in sight gauge in reached. 4. After adding coolant, check and replenish DCA4 concentration. 5. Reinstall the radiator cap. Fig. 5.18. Radiator Sight Gauge OM560C99/1E DRESSTA...

  • Page 115: Draining The System

    The coolant filter is a spin-on type filter. This filter cannot be cleaned and should not be disturbed except when it becomes necessary to replace it. The proper coolant filter to be applied depends upon the total capacity of the cooling system and operating conditions of the engine, refer to Engine Operation and Maintenance Manual. DRESSTA OM560C99/1E...
  • Page 116 1. Open the engine side access door on the left side of the machine. 2. Open the radiator cap. Close shut-off valve (1) located on the left side of the engine, by placing it in OFF position. Fig. 5.22. Cleaning Coolant Filter Head OM560C99/1E DRESSTA...

  • Page 117: Filling The System

    3. Start the engine and run it idle until the normal operating temperature is reached. Add coolant as needed to keep the level to the neck of the radiator. 4. After all air is removed and level remains fixed, install the radiator cap and check the system for leaks. DRESSTA OM560C99/1E...

  • Page 118: Cleaning The Radiator

    1. Position the machine on level ground. Move the machine until the planetary plug (as shown in Fig. 5.28) is on the horizontal center line of the axle. 2. Apply the parking brake. Let the machine sit long enough for the oil in the axle and planetary to level out. OM560C99/1E DRESSTA...

  • Page 119: Changing The Oil

    Install all plugs. Fill the other axle in the same manner. Refer to REFILL SPECIFICATIONS AND CAPACITIES CHART. 4. Operate the machine for a couple of minutes to distribute the lubricant throughout the axle and planetaries. 5. Recheck each axle level as outlined above. DRESSTA OM560C99/1E...

  • Page 120: Electrical System

    1. Remove the screws mounting the gauge cluster to the instrument panel 2. Lift and shift the gauge cluster to the side. 3. Remove the socket, remove the burnt bulb install a new bulb and press in the socket home. 4. Re-install gauge cluster. OM560C99/1E DRESSTA...

  • Page 121: Batteries

    The sparks could cause a battery explosion. Use a voltmeter or hydrometer to measure the charge. WARNING! Be sure the electrical system disconnect switch is off when connecting or disconnecting batteries to minimize the chance of sparks and explosion. DRESSTA OM560C99/1E...

  • Page 122: Engine

    Prior to starting up a machine that has been idle, always make a visual inspection of the battery and take an open circuit voltage test. A reading of 1.23 g/cm (75% of full charge) or less indicates a state of discharge. OM560C99/1E DRESSTA...

  • Page 123: Engine

    Drain valve will be opened automatically as the hose nut is thread in. Drain the oil completely to a container. WARNING! Avoid direct contact of hot oil with your skin. Hot oil can cause personal injury. DRESSTA OM560C99/1E...

  • Page 124: Changing The Lubricating Oil Filters

    3. After refilling the engine with oil and before starting the engine, perform the procedure outlined under 4.12.3. STARTING AFTER OIL CHANGE OR LONGER STORAGE. This procedure insures that the engine receives proper lubricating oil flow. Lack of lubrication will damage the engine. OM560C99/1E DRESSTA...

  • Page 125: Fan

    Inspect visually the drive belts. Replace badly worn, greasy or severely cracked belts immediately. These conditions prevent proper function. Adjust the tension of the belts that have glossy surface mating the pulley. This indicates belt slippage. If the belts are properly installed and tensioned, the belt and pulley will wear evenly. DRESSTA OM560C99/1E...
  • Page 126 Fig. 5.37. Deflection under a force of 110 N should nor exceed belt thickness at a 30 cm distance between the pulleys. Adjust the belt if deflection exceeds the above value. New belts loose their tension during operation. OM560C99/1E DRESSTA...

  • Page 127: Ether Injector

    2. Reconnect the nozzle to the tube. 3. Direct the nozzle away from the engine and actuate the ether injector. 4. Dribbling or no spray indicates a blocked spray nozzle or tube. If necessary, clean or replace nozzle and/or tube. DRESSTA OM560C99/1E...

  • Page 128: Fuel System

    5.13.1. CHANGING THE FUEL FILTERS GENERAL The fuel fitters are spin-on type fifters. These filters cannot be cleaned and should not be disturbed except when it becomes necessary to replace them. OM560C99/1E DRESSTA...
  • Page 129 6. Install the filters on the filter header until the filter seal contacts the seal surface on the filter header and then turn the filter an additional 1/2 to 3/4 turn by hand (Fig. 5.43). Do not overtighten the filter or damage may result to the filter seal or threads. Use genuine filters only. DRESSTA OM560C99/1E...

  • Page 130: Fuel Tank

    Sight gauge (2, Fig. 5.45.) is located on the right side of the fuel tank. If the fuel level is not visible in the gauge, fill the tank. To prevent moisture due to condensation, the fuel tank should be refilled at the end of each day’s operation. OM560C99/1E DRESSTA...

  • Page 131: Hydraulic System

    1. Park the machine on level ground. Lower the bucket to the ground. 2. Stop the engine and apply the parking brake. 3. Check the oil level sight gauge. If the ball is not floating in the window, fluid must be added. DRESSTA OM560C99/1E...

  • Page 132: Changing The Hydraulic System Oil

    8. Raise the bucket completely, and roll the bucket all the way back. WARNING! NEVER work or walk under a raised bucket without proper blocking in raised position. 9. Remove reservoir covers 2, Fig. 5.49. OM560C99/1E DRESSTA...
  • Page 133 19. Lower the bucket to the ground and shut down the engine. Check the oil level as described in 5.14.1. IMPORTANT: The reservoir must be refilled in this manner until the proper level is maintained after the hydraulic system is operated at least five complete cycles. Fig. 5.50. Hydraulic Reservoir Drain Plug DRESSTA OM560C99/1E...

  • Page 134: Changing The Oil Filters

    4. Check seal rings 3 for wear or deterioration. Replace if necessary. 5. Reinstall filter 5 and cover 4. Secure with ring 2. 6. Tighten the reservoir filler cap. 7. Service the other breather in a similar manner. OM560C99/1E DRESSTA...

  • Page 135: Seat Belt

    Never vent built-up pressure in a tire, such as encountered on hot days. Pressure build- up on hot days actually protects the tires by avoiding excessive sidewall flexing and its overheating, which are detrimental to tire life. Venting tires will also result in underinflation when the tire cools. DRESSTA OM560C99/1E...

  • Page 136: Tires And Rims

    5. Check that oil can be seen in the top half of sight gauge 1, Fig. 5.53. in the cutout on the right side of the rear frame close to the transmission. The transmission oil level is correct when the ball is 10 mm above the middle of sight gauge with the engine running at low idle. OM560C99/1E DRESSTA...

  • Page 137: Transmission And Torque Converter

    Each element is changed in the same manner. 2. Loosen bolt 8, hold case 6, and unscrew the bolt completely. 3. Pull case 6 free out of base 1 together with element 3 and other parts. Fig. 5.55. Transmission and torque converter filters DRESSTA OM560C99/1E...
  • Page 138 Fig. 5.56. Transmission Oil Strainer Fig. 5.57. Transmission And T.C. Breather 1 - Tube 5 - Check Valve 2 - Split Flange 6 - Gasket 3 - Retainer 7 - Strainer 4 - Gasket 8 - Drain Plug OM560C99/1E DRESSTA...

  • Page 139: Servicing The Breather

    3 - Bolts Check periodically torque of ROPS cab mounting bolts. Refer to Section 6 SPECIAL TORQUES. 5.20. LOADER EQUIPMENT BUCKET INSTALLATION AND REMOVAL Fig. 5.59. Bucket Installation 1 - Bolt 3 - O-Ring 2 - Pin 4 - Shim DRESSTA OM560C99/1E...
  • Page 140 IMPORTANT: Allowable gap between bucket supports and boom arms is 1.5 mm. If gaps are bigger, fill symmetrically with shims. WARNING! When replacing the bucket take care. Disassembled heavy compo- nents of loader linkage system (boom arms, connector) must be securely protected against sudden movement. OM560C99/1E DRESSTA...

  • Page 141: Specifications

    SECTION 6 SPECIFICATIONS...
  • Page 142 6.8.12. Cycle Times ......................18 6.8.13. Fuel Consumption ....................18 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.

  • Page 144: Application

    Page 3 6.1. APPLICATION 560C Wheel Loader is a modern machine featuring the following foredesign criteria: optimization of performance, long service life, reliability, maximum unification of parts and assemblies, simplified maintenance and serviceability. This rugged loader is designed for continuous heavy reloading operations.

  • Page 145: Schematic Of Wheel Loader Drive Train

    SPECIFICATIONS SECTION 6 Page 4 6.3. SCHEMATIC OF WHEEL LOADER DRIVE TRAIN Fig. 6.1. Wheel Loader Drive Train Schematic OM560C99/1E DRESSTA...

  • Page 146: Schematic Of Torque Converter And Transmission Hydraulic System

    6.4. SCHEMATIC OF TORQUE CONVERTER AND TRANSMISSION HYDRAULIC SYSTEM Fig. 6.2. Schematic of Torque Converter and Transmission Hydraulic System 1. Pump 5. Regulating Valves 2. Torque Converter 6. Steering Valves 3. Transmission 7. Radiator 4. Pressure Filter 8. Filter Switch DRESSTA OM560C99/1E...

  • Page 147: Loader Equipment And Steering Hydraulic System Schematic

    SPECIFICATIONS SECTION 6 Page 6 6.5. LOADER EQUIPMENT AND STEERING HYDRAULIC SYSTEM SCHEMATIC Fig. 6.3. Loader Equipment and Steering Hydraulic System Schematic OM560C99/1E DRESSTA...
  • Page 148 10. Double Gear Pump with Diverter Valve 11. Steering Valve 12. Pilot Control Valve 13. Ground Driven Steering System 14. Ground Driven Steering Pump 15. Warning Light Switch 16. Boom Cylinders (2) 17. Bucket Cylinder 18. Steering Cylinders(2) 19. Check Valve DRESSTA OM560C99/1E...

  • Page 149: Brake Hydraulic System Schematic

    SPECIFICATIONS SECTION 6 Page 8 6.6. BRAKE HYDRAULIC SYSTEM SCHEMATIC Fig. 6.4. Brake Hydraulic System Schematic OM560C99/1E DRESSTA...
  • Page 150 11. Valve Block 12. Transmission Disconnect Solenoid Valve 13. Parking Brake Warning Light Switch 14. Suction Strainer 15. Wheel Brake Assembly 16. Wheel Brake Piston 17. Supply From Transmission System 18. Transmission Oil Reservoir Supply of Transmission Disconnect Valve DRESSTA OM560C99/1E...

  • Page 151: Wiring Diagram

    SPECIFICATIONS SECTION 6 Page 10 6.7. WIRING DIAGRAM Fig. 6.5. Wiring Diagram OM560C99/1E DRESSTA...

  • Page 152: Wiring Diagram

    53. Bulbs Check and Drive Disconnection Switch 54. Ether Start and Rear Work Lamps Switch 55. Low Level Lamps Switch (if equipped) 56. Front Work Lamps Switch (Parking and Passing, 560C CE) 57. Front Auxiliary Lamps Switch (if equipped) 58. Cab Work Lamp Connector...

  • Page 153: Specifications

    83. Cab Connectors 84. Front Parking Lamps 560C - CE 85. Passing Lamps 560C - CE 86. Directional And Emergency Light Switch 560C - CE 87. Rear Left Directional Lamp 560C - CE 88. Back-Up Lamp 560C - CE 89. Rear Right Directional Lamp 560C - CE 90.
  • Page 154 SPECIFICATIONS SECTION 6 Page 13 WIRING DIAGRAM Fig. 6.6. Wiring Diagram Of Cab DRESSTA OM560C99/1E...
  • Page 155 P. - pink W - white V - violet Y - yellow DB - dark blue B - black LB - light blue BR - dark gray DG - dark green G - gray LG - light green OM560C99/1E DRESSTA...
  • Page 156 6.8. SPECIFICATIONS 6.8.1. GENERAL SPECIFICATIONS OF THE LOADER (Refer to Fig. 6.7. and 6.8.) Below specified specifications are for standard configuration of 560C wheel loader equipped with ROPS-FOPS cab, standard bucket, counterweight and 29.5 x 29 tires. Rated bucket capacity........................ 5.73m Bucket width ..........................3645 mm...

  • Page 157: Capacities

    SPECIFICATIONS SECTION 6 Page 16 SPECIFICATIONS Fig. 6.8. Overall Dimensions - 560C LOGGER with Grapple GRAPPLE 90-108-119 HC-90-112 A Length of tines ..................... 2290 mm ..2290 mm B Maximum clamp opening ................4280 mm ..4060 mm C Minimum closure diameter................2290 mm ..2790 mm D Overall machine length, tines on ground ..........

  • Page 158: Engines

    7.1/7.1 gear 12.2/12.2. gear 32.5/32.5 6.8.6. TORQUE CONVERTER Type ......................single stage, single phase Diameter.........................409.5 mm (16.125”) Stall ratio............................2.72:1 6.8.7. DRIVE AXLES Standard Type....................differential with spiral bevel gear set, inboard mounted full – floating planetaries Differential..........................standard DRESSTA OM560C99/1E...

  • Page 159: Tires

    70 l/h. AVERAGE FUEL CONSUMPTION IN OPERATION Specified above fuel consumption is for short intensive operation of the machine. Practically, considering longer periods of operation, fuel consumption is much lower and for medium intensive operation is app. 50 l/h. OM560C99/1E DRESSTA...

  • Page 160: Loader Equipment

    SPECIFICATIONS SECTION 6 Page 19 6.9. 560C LOADER EQUIPMENT A- bucket w/teeth B- bucket w/o teeth Fig. 6.9. Spade Nose Buckets Bucket capacity 5.35 cu. m., 5.73 cu. m and 5.73 cu. m. Applications – quarry A- bucket w/teeth B- bucket w/o teeth Fig.

  • Page 161: Torque Values For Standard Metric Fasteners

    SPECIFICATIONS SECTION 6 Page 20 560C LOADER EQUIPMENT Fig. 6.11. Grapple Capacity app.18000 kg Dimensions - see Fig. 6.8. Grapples: 90-108-119 HC-90-112 LOGGER version is required for grapple application. 6.10. TORQUE VALUES FOR STANDARD METRIC FASTENERS Chart 1 provides tightening torque for general purpose applications using original equipment standard hardware.

  • Page 162: Torque Values For Standard English Fasteners

    (nuts with distorted threads or plastic inserts), phosphate coated bolts used with copper plated weld nuts. Markings on bolt heads or nuts indicate material grade ONLY and are NOT to be used to determine required torque. DRESSTA OM560C99/1E...

  • Page 163: Torque Values For Split Flange Connections

    Flange size in inches* Torque Value Nm 5/16 20÷24 30÷37 37÷47 1-1/4 7/16 47÷61 1- 1/2 1/ 2 62÷79 1/ 2 75÷88 2- 1/2 1/ 2 107÷123 187÷203 3- 1/2 159÷180 Outside diameter of hydraulic tube or hose fitting. OM560C99/1E DRESSTA...

  • Page 164: Torque Values For Hydraulic Tubes And Fittings

    6.2 ÷7.3 "T" Bolt (any diameter) 4.5 ÷5.6 Worm Drive - 1-3/4 in. 2.2÷ 3.3 Open Diameter & Under 4.5 ÷5.6 Worm Drive - Over 1-3/4 in. Open Diameter 10.7 ÷11.8 4.5 ÷5.6 Worm Drive - Al1 "Ultra-tite" DRESSTA OM560C99/1E...

  • Page 165: Torque Values For Air Conditioning Tubes And Fittings

    15 ÷ 25 7/16 – 20 27 ÷ 33 5/8 – 18 40 ÷ 48 3/4 – 16 47 ÷ 54 7/8 – 14 54 ÷ 61 1- 1/16 – 12 54 ÷ 61 1- 1/6 – 14 OM560C99/1E DRESSTA...

  • Page 166: Special Torques

    • bellcrank - link 1-1/8 • link - bucket ¾ • steering cylinders - frame ¾ • bolster - frame Transfer drive line mounting bolts Cab mounting bolts: • cab - floor • floor - frame Tightening torque tolerance ± 10%. DRESSTA OM560C99/1E...

  • Page 167: Service Tools

    Fuel tank sediment drain plug Cross screwdriver 2 mm Gauge cluster on instrument panel Cross screwdriver 3 mm Instrument panel screws Flat screwdriver 1 z 6.5 Primary filter clamp Filter wrench 110mm Fuel filters Oil filters Coolant filter OM560C99/1E DRESSTA...

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