OPERATION & MAINTENANCE MANUAL

HD 356B
LOAD HAUL DUMPER COAL MACHINE

SERIAL NUMBER
OLH00217-UP (MACHINE)
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TABLE OF CONTENTS OPERATORS/MAINTENANCE MANUAL

TABLE OF CONTENTS Operating Techniques .......................................... 36

Parking ............................................................... 38
INTRODUCTION
Transportation Information ................................... 40
Foreword ............................................................... 1
Towing Information ............................................... 42
SAFETY
MACHINE MAINTENANCE
Safety Signs and Labels ....................................... 4
Torque Specifications .......................................... 45
General Hazard Information ................................... 6
Tyre Inflation Information ...................................... 47
Crushing Prevention and Cutting Prevention .......... 8
Lubricant Viscosities and Refill Capacities .......... 48
Burn Prevention ..................................................... 9
Maintenance Locations ....................................... 52
Fire Prevention and Explosion Prevention .............. 9
Maintenance Interval Schedule ............................ 55
Fire Extinguisher Location ................................... 10

Tyre Information .................................................... 11

REFERENCE INFORMATION

Electrical Storm Injury Prevention ........................ 12 Reference Materials ........................................... 100

Mounting and Dismounting .................................. 12 SERVICE SHEETS

Before Starting Engine ......................................... 12 Every 10 Service Hours or Daily ......................... 102

Engine Starting .................................................... 13 Every 50 Service Hours or Weekly ..................... 104

Before Operation ................................................. 13 Every 250 Service Hours or Monthly ................... 105

Operation ............................................................ 13 Every 500 Service Hours or 3 Months .................107

Engine Stopping .................................................. 14 Every 1000 Service Hours or 6 Months ............... 108

Parking ............................................................... 14 Every 2000 Service Hours or 1 Year ................... 109

Equipment Lowering with Engine Stopped ........... 14 Every 3000 Service Hours or 2 Years .................. 110

Guards (Operator Protection) .............................. 14 Every 10000 Service Hours or 4 Years ................ 111

PRODUCT INFORMATION

General Information ............................................. 15

Model Views and Specification ............................ 15

Identification Information ...................................... 18

OPERATION

Operator Station Features ................................... 19

Machine Controls and Operation ......................... 24

Before Starting Engine ......................................... 29

Engine Starting .................................................... 32

Operation ............................................................ 34

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OPERATORS/MAINTENANCE MANUAL FORWORD

FOREWORD the items to be maintained at a specific service

interval. Items without specific intervals are listed
under the “When Required” service interval. The
Literature Information Maintenance Interval Schedule lists the page number
for the step-by-step instructions required to accom-
This manual should be stored in the operator’s plish the schedules maintenance. Use the Mainte-
compartment in the literature holder or seat back nance Interval Schedule as an index or “one safe
literature storage area. course” for all maintenance procedures.
This manual contains safety information, operation
instructions, transportation information, lubrication
Maintenance Intervals
information and maintenance information.
Use the service hour meter to determine servicing
Some illustrations in this publication may show intervals. Calendar intervals shown (daily, weekly,
details or attachments that may be different from your monthly, etc.) can be used instead of service hour
vehicle. Some illustrations show guards or covers meter intervals if they provide more convenient servic-
removed for clear illustration that need not be removed ing schedules and approximate the indicated service
for routine lubrication and maintenance. hour meter reading. Recommended service should
always be performed at the interval that occurs first.
Continuing improvement and advancement of product
design may have caused changes to your machine Under extremely severe, dusty or wet operating
which are not included in this publication. Read, study conditions, more frequent lubrication than is specified
and keep this manual with the machine. in the maintenance intervals chart might be neces-
sary.
Whenever a question arises regarding your vehicle, or
this publication, please consult Caterpillar dealer for Perform service on items at multiples of the original
the latest available information. requirement. For example, at every 500 service hours
or 3 months, also service those items listed under
every 250 service hours or monthly and every 10
Safety service hours or daily.
The safety section lists basic safety precautions. In
addition, this section identifies the text and locations
Certified Engine Maintenance
of warning signs and labels used on the machine.
Proper maintenance and repair is essential to keep
Read and understand the basic precautions listed in the engine and machine systems operating correctly.
the safety section before operating or performing As the heavy duty off-road diesel engine owner, you
lubrication, maintenance and repair on this machine. are responsible for the performance of the required
maintenance listed in the Owner Manual, Operation
and Maintenance Manual, and Service Manual.
Operation
It is prohibited for any person engaged in the business
The operation section is a reference for the new of repairing, servicing, selling, leasing or trading
operator and a refresher for the experienced operator. engines or machines to remove, alter, or render
This section includes a discussion of gauges, inoperative any emission related device or element of
switches, machine controls, attachment controls, design installed on or in an engine or machine that is
transportation and towing information. in compliance with the regulations (40 CFR Part 89).
Certain elements of the machine and engine such as
Photographs and illustrations guide the operator the exhaust system, fuel system, electrical system,
through correct procedures of checking, starting, intake air system and cooling system may be emis-
operating and stopping the machine. sion related and should not be altered unless ap-
proved by Caterpillar.
Operating techniques outlined in this publication are
basic. Skill and techniques develop as the operator
gains knowledge of the machine and its capabilities.
Machine Capacity

Additional attachments or modifications may exceed

machine design capacity which can adversely affect
Maintenance performance characteristics. Included would be
stability and system certifications such as brakes,
The maintenance section is a guide to equipment steering, and rollover protective structures (ROPS).
care. The Maintenance Interval Schedule (MIS) lists Contact your Caterpillar dealer for further information.

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SAFETY OPERATORS/MAINTENANCE MANUAL

IMPORTANT SAFETY INFORMATION

Most accidents involving product operation, maintenance and repair are caused by failure to observe basic
safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations
before an accident occurs. A person must be alert to potential hazards. This person should also have the
necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or other persons.

The hazards are identified by the ‘WARNING’ as shown below.

The meaning of this Safety Alert Symbol is as follows:

Attention! Become Alert! Your Safety is involved.

The message that appears under the warning, explaining the hazard, can be either written or pictorially
presented.

Operations that may cause product damage are identified the “NOTICE” labels on the product and in this
publication.

Barloworld cannot anticipate every possible circumstance that might involve a potential hazard. The
WARNINGS in this publication and on the product are therefore not all inclusive. If a tool, procedure,
work method or operating technique not specifically recommended by Barloworld is used, you must
satisfy yourself that it is safe for you and others. You should also ensure that the product will not be
damaged or made unsafe by the operation, lubrication, maintenance, or repair procedures you
choose.

The information, specifications, and illustrations in this publication are on the basis of information available
at the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations
and other items can change at any time. These changes can affect the service given to the product. Obtain
the complete and most current information before you start any job. Barloworld have the most current informa-
tion available.

When replacement parts are required for this product Barloworld recommends using Caterpillar
replacement parts or parts with equivalent specifications including, but not limited to, physical
dimensions, type, strength and material.

Failure to heed this warning can lead to premature failures, product damage, personal injury or
death.

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OPERATORS/MAINTENANCE MANUAL SAFETY

SAFETY
Safety Signs and Labels
Do not operate or work on this machine unless
There are several specific safety signs on this you have read and understood the instructions
machine. Their exact location of the hazards and and warnings in the Operation and
the description of the hazard are reviewed in this Maintenance guide. Failure to follow the
section. Please take time to familiarise with all instructions or heed the warnings could result
safety signs. in injury or death. Contact any Barloworld
Equipment dealer for replacement guides.
Make sure that all of the safety signs are legible. Proper care is your responsibility.
Clean the safety sign or replace the safety signs if
you cannot read the words. Replace the No Clearance
illustrations of the illustrations are not legible.
When you can clean the safety signs use a cloth,
water and soap. Do not use solvent, gasoline or
any other harsh chemicals to clean the safety
signs. Solvents, gasoline, or harsh chemicals could
loosen the adhesive that secures the safety sign.
Loose adhesive will allow the safety sign to fall.

Replace any safety sign that is damaged, or

missing. If a safety sign is attached to a part that is
replaced, install a safety sign on the replacement
part. Barloworld can provide new safety signs.

Do Not Operate

This safety label is located in the operator station.

This safety label is located on both sides of the

machine articulating hitch.

No clearance for a person in this area when

machine turns. Severe injury or death from
crushing could occur. Connect steering frame
lock between front and rear frames before
lifting, transporting, or servicing machine in
articulation area. Disconnect lock and secure
before resuming operation.

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Steering Frame Lock

No clearance for a person in operator’s station

access area when machine turns. Severe injury
or death from crushing could occur.

Engage transmission lock before leaving operator’s

station.

Bucket Control Group

This safety label is located on both sides of the lift

arm.

This safety label is located on the front mudguards of

the machine.

Operator Station Access

No clearance for a person in this area when

bucket control group lowers. Severe injury or
death from crushing could occur.

Install bucket control group safety pins before

servicing machine in this area.

This safety label is located on the inside of the Remove safety pins and secure before
operator station. resuming operation.

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High Pressure Cylinder (Brake General Hazard Information

Accumulator)

Attach a “Do Not Operate” warning tag or a similar

warning tag to the start switch or to the controls
This safety label is located near the brake before you service the equipment. These warning
accumulator. tags (Special Instruction, SEHS7332) are available
from Barloworld.

Know the width of the equipment in order to maintain

proper clearance when you operate the equipment
near fences or nearby boundary obstacles.

Be aware of high voltage power lines and power

cables that are buried. If the machine comes in
contact with these hazards, serious injury or death
may occur from electrocution.

High Pressure Cylinder!

Do not remove any valve, hydraulic fitting, or

valve core, nor disassemble any parts until
pressure has been relieved, or personal injury
may occur.

To relieve pressure:
Refer to the Service Manual for the correct
method of dissipating hydraulic system Wear a hard hat, protective glasses, and other
pressure. protective equipment, as required.

Charge the cylinder with dry nitrogen gas. Do not wear loose clothing or jewelry that can snag
on controls or on other parts of equipment.
See Barloworld for tools and detailed
information required for charging cylinders. Make sure that all protective guards and all covers
are secured in place on the equipment.

Keep the equipment free from foreign material.

Remove debris, oil, tools, and other items from the
deck, from walkways, and from steps.

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SAFETY OPERATORS/MAINTENANCE MANUAL

Secure all loose items such as lunch boxes, tools, Fluid Penetration
and other items that are not a part of the equipment.
Pressure can be trapped in the hydraulic circuit long
Know the appropriate work site hand signal sand the after the engine has been stopped. The pressure can
personnel that are authorized to give the hand cause hydraulic fluid or items such as pipe plugs to
signals. Accept the signals from one person only. escape rapidly if the pressure is nor relieved
Do not smoke when you service an air conditioner. correctly.
Also, do not smoke if refrigerant gas may be
present. Inhaling the fumes that are released from a Do not remove any hydraulic components or parts
flame that contacts air conditioner refrigerant can until pressure has been relieved or personal injury
cause bodily harm or death. Inhaling gas from air may occur. Do not disassemble any hydraulic
conditioner refrigerant through a lighted cigarette components or parts until pressure has been
can cause bodily harm or death. relieved or personal injury may occur. Refer to the
Service Manual for any procedures that are required
Never put maintenance fluids into glass containers. to relieve the hydraulic pressure.
Drain all liquids into a suitable container.

Obey all local regulations for the disposal of liquids.

Use all cleaning solutions with care. Report all

necessary repairs.

Do not allow unauthorized personnel on the

equipment.

Unless you are instructed otherwise, perform

maintenance with the equipment in the servicing
position. Refer to Operation and Maintenance
Manual for the procedure for placing the equipment
in the servicing position.

Pressure Air and Water Always use a board or cardboard when you check
for a leak. Leaking fluid that is under pressure can
Pressurized air and/or water can cause debris and/or penetrate body tissue. Fluid penetration can cause
hot water to be blown out. This could result in serious injury and possible death. A pin hole leak
personal injury. can cause severe injury. If fluid is injected into your
skin, you must get treatment immediately. Seek
When pressure air and/or pressure water is used for treatment from a doctor that is familiar with this type
cleaning, wear protective clothing, protective shoes, of injury.
and eye protection. Eye protection includes goggles
or a protective shield.
Containing Fluid Spillage
The maximum air pressure for cleaning purposes
Care must be taken in order to ensure that fluids are
must be below 205 kPa (30 psi). The maximum
contained during performance of inspection,
water pressure for cleaning purposes must be below
maintenance, testing, adjusting and repair of the
275 kPa (40 psi).
equipment. Prepare to collect the fluid with suitable
containers before opening any compartment or
Trapped Pressure disassembling any components containing fluids.

Pressure can be trapped in the hydraulic system. Refer to Special Publication, NENG2500, “Tools and
Releasing trapped pressure can cause sudden Shop Products Guide” for the following items:
machine movement or attachment movement. Use
caution if you disconnect hydraulic lines or fittings. z Tools that re suitable for collecting fluids and
High pressure oil that is released can cause a hose equipment that is suitable for collecting fluids.
to whip. High pressure oil that is released can cause
oil to spray. Fluid penetration can cause serious z Tools that are suitable for containing fluids and
injury and possible death. equipment that is suitable for containing fluids.

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Dispose of Waste Properly

Barloworld equipment and replacement parts that are

shipped from Barloworld are asbestos free. Barloworld
recommends the use of only genuine Barloworld Improperly disposing of waste can threaten the
replacement parts. Use the following guidelines when environment. Potentially harmful fluids should be
you handle any replacement parts that contain disposed of according to local regulations.
asbestos or when you handle asbestos debris.
Always use leakproof containers when you drain
Use caution. Avoid inhaling dust that might be fluids. Do not pour waste onto the ground, down a
generated when you handle components that contain drain, or into any source of water.
asbestos fibers. Inhaling this dust can be hazardous
to your health. The components that may contain
Crushing Prevention and Cutting
asbestos fibres are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The Prevention
asbestos that is used in these components is usually
bound in a resin or sealed in some way. Normal Support he equipment properly before you perform
handling is not hazardous unless airborne dust that any work or maintenance beneath that equipment.
contains asbestos is generated. Do not depend on the hydraulic cylinders to hold up
the equipment. Equipment can fall if a control is
If dust that may contain asbestos is present, there moved, or if a hydraulic line breaks.
are several guidelines that should be followed:
Do not work beneath the cab of the machine unless
z Never use compressed air cleaning. the cab is properly supported.
z Avoid brushing materials that contain asbestos.
z Avoid grinding materials that contain asbestos. Unless you are instructed otherwise, never attempt
z Use a wet method in order to clean up asbestos adjustments while the machine is moving or while
materials. the engine is running.
z A vacuum cleaner that is equipped with a high
efficiency particulate air filter (HEPA) can also be Never jump across the starter solenoid terminals in
used. order to start the engine. Unexpected machine
z Use exhaust ventilation on permanent machining movement may result.
jobs.
z Wear an approved respirator if there is no other Whenever there is equipment control linkages the
way to control the dust. clearance in the linkage area will change with the
z Comply with applicable rules and regulations for movement of the equipment or the machine. Stay
the work place. In the United States, use clear of areas that may have a sudden change is
Occupational Safety and Health Administration clearance with machine movement or equipment
(OSHA) requirements. These OSHA movement.
requirements can be found in “29 CFR
1910.1001”. Stay clear of all rotating and moving parts.
z Obey environmental regulations for the disposal
of asbestos. If it is necessary to remove guards in order to
z Stay away from areas that might have asbestos perform maintenance, always install the guards after
particles in the air. the maintenance is performed.

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Keep objects away from moving fan blades. The fan Remove the hydraulic tank filler cap only after the
blade will throw objects or cut objects. engine had been stopped. The filler cap must be
cool enough to touch with a bare hand. Follow the
Do not use a kinked wire cable or a frayed wire standard procedure in this manual in order to
cable. Wear gloves when you handle wire cable. remove the hydraulic tank filler cap.

When you strike a retainer pin with force, the Batteries

retainer pin can fly out. The loose retainer pin can
injure personnel. Make sure that the area is clear of Electrolyte is an acid. Electrolyte can cause personal
people when you strike a retainer pin. To avoid injury injury. Do not allow electrolyte to contact the skin or
to your eyes, wear protective glasses when you the eyes. Always wear protective glasses for
strike a retainer pin. servicing batteries. Wash hands after touching the
batteries or connectors. Use of gloves is
Chips or other debris can fly off an object when you recommended.
strike the object. Make sure that no one can be
injured by flying debris before striking any object. Fire Prevention and Explosion
Prevention
Burn Prevention

Do not touch any part of an operating engine. Allow

the engine to cool before any maintenance is
performed on the engine. Relieve all pressure in the
air system, in the oil system, in the lubrication
system, in the fuel system, or in the cooling system
before any lines, fittings or related items are
disconnected.

Coolant

When the engine is at operating temperature, the

engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.
All fuels, most lubricants, and some coolant
Any contact with hot coolant or with steam can
mixtures are flammable.
cause severe burns. Allow cooling system
components to cool before the cooling system is
Flammable fluids that are leaking or spilled onto hot
drained.
surfaces or onto electrical components can cause a
fire. Fire may cause personal injury and property
Check the coolant level only after the engine has
damage.
been stopped.
Remove all flammable materials such as fuel, oil,
Ensure that the filler cap is cool before removing the
and debris from the machine. Do not allow any
filler cap. The filler cap must be cool enough to
flammable materials to accumulate on the machine.
touch with a bare hand. Remove the filler cap slowly
in order to relieve pressure.
Store fuels and lubricants in properly marked
containers away from unauthorized persons. Store
Cooling system conditioner contains alkali. Alkali
oily rags and any flammable materials in protective
can cause personal injury, Do not allow alkali to
containers. Do not smoke in areas that are used for
contact the skin, the eyes, or the mouth.
storing flammable materials.
Oils Do not operate the machine near any flame.

Hot oil and hot components can cause personal Exhaust shields (of equipped) protect hot exhaust
injury. Do not allow hot oil to contact the skin. Also, components from oil spray or fuel spray in case of a
do not allow hot components to contact the skin. break in a line, in a hose, or in a seal. Exhaust
shields must be installed correctly.

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Do not weld on lines or on tanks that contain

flammable fluids. Do not flame cut lines or tanks that
contain flammable fluid. Clean any such lines or
tanks thoroughly with a nonflammable solvent prior
to welding or flame cutting.

Check all electrical wires daily. Repair any wires that

are loose or frayed before you operate the machine.
Clean all electrical connections and tighten all
electrical connections.

Dust that is generated from repairing nonmetallic

hoods or nonmetallic fenders can be flammable and/
or explosive. Repair such components in a well
ventilated area away from open flames or sparks.

Inspect all lines and hoses for wear or for

deterioration. The hoses must be properly routed.
The lines and the hoses must have adequate
support and secure clamps. Tighten all connections
to the recommended torque. Leaks can cause fires.

Gases from a battery can explode. Keep any open

flames or sparks away from the top of a battery. Do
not smoke in battery charging areas.

Never check a battery charge by placing a metal

object across the terminal posts. Use a voltmeter or
a hydrometer.

Improper jumper cable connections can cause an

explosion that can result in injury. Refer to the
Operation Section of this manual for specific
instructions.

Do not charge a frozen battery. This may cause an

explosion.

Fire Extinguisher

Make sure that the fire extinguisher is available. Be

familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
Use caution when you are refueling a machine. Do on the instruction plate.
not smoke while you are refueling a machine. Do not
refuel a machine near open flames or sparks. Ether
Always stop the engine before refueling. Fill the fuel
tank outdoors. Ether is flammable and poisonous.

Use ether in well ventilated areas. Do not smoke

while you are replacing an ether cylinder or while
you are using an ether spray.

Do not install ether cylinders in living areas or in the

operator compartment of a machine. Do not store
ether cylinders in direct sunlight or in temperatures
above 49oC (120 oF). Keep ether cylinders away
from open flames or sparks.

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SAFETY OPERATORS/MAINTENANCE MANUAL

Dispose of used ether cylinders properly. Do not

puncture an ether cylinder. Keep ether cylinders
away from unauthorized personnel.

Do not spray ether onto an engine if the machine is

equipped with a thermal starting aid for cold weather
starting.

Lines, Tubes and Hoses

Do not bend high pressure lines. Do not strike high

pressure lines. Do not install any lines that are bent
or damaged.

Repair any lines that are loose or damaged. Leaks

can cause fires. Consult Barloworld for repair or for
replacement parts.
The fire extinguishers should be mounted on the left
Check lines, tubes and hoses carefully. Do not use and right side of the front fender. This is the
your bare hand to check for leaks. Use a board or recommended location. Do not weld the ROPS in
cardboard to check for leaks. Tighten all connections order to install the fire extinguisher. Also, do not drill
to the recommended torque. holes in the ROPS in order to mount the fire
extinguisher.
Replace the parts if any of the following conditions
are present: Tyre Information

z End fittings are damaged or leaking. Explosions of air inflated tyres have resulted from
z Outer coverings are chafed or cut. heat-induced gas combustion inside the tyres.
z Wires are exposed. Explosion can be caused by heat that is generated
z Outer coverings are ballooning. by welding, by heating rim components, by external
z Flexible part of the hoses are kinked. fire, or by excessive use of brakes.
z Outer covers have embedded armoring.
z End fittings are displaced. A tyre explosion is much more violent than a
blowout. The explosion can propel the tyre, the rim
Make sure that all clamps, guards, and heat shields components, and the axle components as far as
are installed correctly. During machine operation, 500m (1500 ft) or more from the machine. Both the
this will help to prevent vibration, rubbing against force of the explosion and the flying debris can
other parts, and excessive heat. cause property damage, personal injury or death.

Fire Extinguisher Location

Make sure that the fire extinguisher is available. Be

familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.

If equipped, know how to use the machine fire

suppression system.

(A) At least 15 m (50 ft)

(B) At least 500 m (1500 ft)

Do not approach a warm tyre. Maintain a minimum

distance, as shown. Stay outside the shaded area in
the above Illustration.

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Do not use water or calcium as a ballast for the tyres. Mount the machine and dismount the machine only at
Dry nitrogen gas is recommended for inflation of tyres. locations that have steps and/or handholds. Before
If the tyres were originally inflated with air, nitrogen is you mount the machine, clean the steps and the
still preferred for adjusting the pressure. Nitrogen handholds. Inspect the steps and handholds. Make
mixes properly with air. any necessary repairs.

Nitrogen inflated tyres reduce the potential of a tyre Face the machine whenever you mount the machine
explosion because nitrogen does not aid and whenever you dismount the machine.
combustion. Nitrogen helps to prevent oxidation of
the rubber, deterioration or rubber, and corrosion of Maintain a three-point contact with the steps and
rim components. with the handholds.

To avoid over inflation, proper nitrogen inflation Note: Three-point contact can be two feet and one
equipment and training in the usage of the hand. Three-point contact can also be one foot and
equipment are necessary. A tyre blowout or a rim two hands.
failure can result from improper equipment or from
misused equipment. Never mount a moving machine. Never dismount a
moving machine. Never jump off the machine.
When you inflate a tyre, stand behind the thread and
use a self-attaching chuck. Do not carry tools or supplies when you mount the
machine or when you dismount the machine. Use a
Servicing tyres and rims can be dangerous. Only hand line to raise and lower tools or supplies.
trained personnel that use proper tools and proper
procedures should perform this maintenance. If Do not use any controls as handholds when you
correct procedures are not used for servicing tyres enter the operator compartment or when you exit the
and rims, the assemblies could burst with explosive operator compartment.
force. This explosive force can cause serious
personal injury or death. Carefully obey the specific Before Starting Engine
instructions from your tyre dealer.

Electrical Storm Injury Prevention

When lighting is striking in the vicinity of the

machine, the operator should never attempt the
following procedures:

z Mount the machine

z Dismount the machine

If you are in the operator’s station during an

electrical storm, stay in the operator’s station. If you
are on the ground during an electrical storm, stay
away from the vicinity of the machine.

Mounting and Dismounting

Make sure the steering frame lock is stored in the
unlocked position as shown. The steering frame lock
must be removed to steer the machine.

Note: Start the engine only from the operator’s

station. Never short across the starter terminals or
across the batteries. Shorting could bypass the
engine neutral start system. Shorting could also
damage the electrical system.

Before you mount the machine, perform a walk

around inspection. Look for any damaged
components and leaks. Report discrepancies and
make any necessary repairs before operating the
machine.

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Reference: For more information, refer to the Diesel engine exhaust contains products of
Operation and Maintenance Manual, “Walk Around combustion which can be harmful to your health.
Inspection” for the machine that is being serviced. Always operate the engine in a well ventilated area.
If you are in a enclosed area, vent the exhaust to the
When you enter the operator station, inspect the outside.
condition of the seat belt and the condition of the
mounting hardware. Replace any damaged parts Before Operation
and any worn parts. Regardless of appearance,
replace the seat belt after three years of use. Do not Make sure that there are no personnel on the
use a seat belt extension on a retractable seat belt. machine or in the area around the machine.

Adjust the seat so that full pedal travel can be Clear all obstacles from the path of the machine.
achieved when the operator’s back is against the Beware of hazards such as wires, ditches, etc.
back of the seat.
Secure the door in the closed position.
Make sure that the machine is equipped with a Make sure that the horn, the backup alarm, the
lighting system that is adequate for the job action alarm and all other warning devices are
conditions. Make sure that all lights are working working properly.
properly.
Operation
Before you start the engine or before you move the
machine, make sure that no one is on the machine, Only operate the machine while you are sitting in a
underneath the machine, or around the machine. seat. The seat belt must be fastened while you
Make sure that there are no personnel in the area. operate the machine. Only operate the controls
while the engine is running.
Engine Starting
While you operate the machine slowly in an open
area, check for proper operation of all controls and
all protective devices.

Before you move the machine, make sure that no

one will be endangered.

Do not allow riders on the machine unless the

machine has the following equipment:

z Additional seat.
z Additional seat belt.
z Falling Object Protective Structure (FOPS).

Note any needed repairs during machine operation.

Report any needed repairs.
If a warning tag is attached to the engine start switch
or to the machine controls, do not start the engine. Carry work on tools at approximately 400mm (15
Also, do not move any machine controls. inches) above ground level.

Move all hydraulic controls to the HOLD position Do not go too close to the edge of a cliff, an
before you start the engine. excavation, or an overhang.

Move the transmission control to the NEUTRAL Avoid operating the machine across the slope.
position. When possible, operate the machine up the slopes
and down the slopes. If the machine begins to
Move the transmission lock control to the LOCKED sideslip on a downgrade, immediately remove load
position. and turn the machine downhill.

Engage the parking brake. Avoid any conditions that can lead to tipping the
machine. The machine can tip when you work on
hills, on banks and on slopes. Also, the machine can
tip when you cross ditches, ridges or other
unexpected obstructions.

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OPERATORS/MAINTENANCE MANUAL SAFETY

Maintain control of the machine. Do not overload the Equipment Lowering with Engine
machine beyond the machine capacity. Stopped
Make sure that the hitches and the towing devices Before lowering any equipment with the engine
are adequate. Only connect trailing equipment to a stopped, clear the area around the equipment of all
drawbar or to a hitch. personnel. The procedure to use will vary with the
type of equipment lowered. Keep in mind most
Never straddle a wire cable. Never allow other systems use a high pressure fluid or air to raise of
personnel to straddle a wire cable. lower equipment. The procedure will cause high
pressure air, hydraulic, or some other media to be
Before you maneuver the machine, make sure that released in order to lower the equipment. Wear
no personnel are between the machine and the appropriate personal protective equipment and
trailing equipment. Block up the hitch of the trailing follow the established procedure in the Operating
equipment in order to align the hitch with the and Maintenance Manual, “Equipment Lowering with
drawbar. Maneuver the machine. Connect the Engine Stopped” in the Operation Section of the
machine to the trailing equipment. manual.
Know the maximum dimensions of your machine.
Guards
Always keep the Rollover Protective Structure
(ROPS) or the Falling Protective Structure (FOPS) There are different types of guards that are used to
installed during machine operation. protect the operator. The machine and the machine
application determines the type of guard that should
Always anticipate the grade and select the proper be used.
gear range for the grade.
A daily inspection of the guards is required in order
Obey all road signs. to check for structures that are bent, cracked or
loose. Never operate a machine with a damaged
A signalman should be present, when you move the structure.
machine in a building or out of a building.
The operator becomes exposed to a hazardous
situation of the machine is used improperly or if poor
Engine Stopping operating techniques are used. This situation can
occur even though a machine is equipped with an
Do not stop the engine immediately after the appropriate protective guard. Follow the established
machine has been operated under load. This can operating procedures that are recommended for
cause overheating and accelerated wear of engine your machine.
components.

After the machine is parked and the parking brake is

engaged, allow the engine to run for five minutes
before shutdown. This allows hot areas of the engine
to cool gradually.

Parking

Park the machine on a level surface. If you must

park on a grade, block the machine’s wheels.

Apply the service brake in order to stop the

machine. Move the transmission control to the
NEUTRAL position.

Engage the parking brake.

Lower all work tools the ground. Activate any control

locks.

Stop the engine.

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GENERAL INFORMATION OPERATORS/MAINTENANCE MANUAL

PRODUCT INFORMATION Model Views and Specifications

SECTION
General Information 1 2 3
4
Welding on Machine and Engines with
Electronic Controls

Proper welding procedures are necessary in order to

avoid damage to the electronic controls and to the
bearings. The following steps should be followed in 5
order to weld on a machine or an engine with
electronic controls

1. Turn off the engine. Place the engine start switch 1. Engine compartment
in the OFF position. 2. Transmission compartment.
3. Bucket control group safety pin
4. Lift Arm
5. Fuel tank

6 9
Do not use electrical components (ECM or ECM
10
sensors) or electronic component grounding points
for grounding the welder.

2. Clamp the ground cable from the welder to the

component that will be welded. Place the clamp
as close as possible to the weld. Make sure that
7 8
the electrical path from the ground cable to the
component does not go through any bearing. Use
this procedure in order to reduce the possibility or
damage to the following components:
6. Engine air cleaner.
· Bearings of the drive train. 7. Hydraulic tank
8. Steering frame lock.
· Hydraulic components. 9. Tilt cylinder
10.Bucket.
· Electrical components.

· Other components of the machine. 11

3. Protect any wiring harnesses from the debris

which is created from welding. Protect any wiring
harnesses from the splatter which is generated
from welding.

4. Use standard welding procedures in order to weld

the materials together. 12

11.Operator station
12.Final drives

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OPERATORS/MAINTENANCE MANUAL GENERAL INFORMATION

13

13. Radiator

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GENERAL INFORMATION OPERATORS/MAINTENANCE MANUAL

SPECIFICATIONS AND MODEL VIEWS

HD356
Operating weight - 20,1 tonne.

1 3.8m3 Coal Ejector Bucket

2 Shortened 966 Tilt cylinder
3 Shortened 966 Lift cylinder
4 966 Based Oscillating Axle
5 Operators Station
6 936 based Hydraulic Oil Tank
7 613/950 Transmission
8 613 Torque Converter
9 3306 NA Flameproof Engine
10 Fuel Tank
11 Modular Core Radiator
12 966 Articulation
13 17.5 x 25 L5-20 Ply Tyres
14 966 Based Steering Cylinder
15 Spring Applied - Hydraulically Released Brakes

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OPERATORS/MAINTENANCE MANUAL GENERAL INFORMATION

Bucket Rated Load Product Identification Number

Failure to comply to the related load can cause

possible personal injury or property damage.
Review the rated load of a particular work tool
before performing any operation. Make
adjustments to the rated load a necessary for
non-standard configurations.

Note: Rated loads should be used as a guide. Work

tools, uneven ground conditions, or poor ground
conditions have effects on rates loads. The operator
is responsible for being aware of these effects.

Rated loads are based upon a standard machine

with the following conditions: Machine PIN _______________________________

z Proper lubricants Serial Number Plates (SN)

z Full fuel tank

z ROPS

z 75kg (165 lb) operator

z 17.5 x 25 20PR L-5 tyres or equivalent for the

HD356 Load Haul Dumper.

Rated loads will vary for different work tools. Consult

Barloworld about the rated load for specific work tools.

The rated operating load is defined by the ISO 5998

(1986) standard as 50 percent of the full turn static
tipping load.

Identification Information
Engine Serial Number________________________
For quick reference, record the identification
numbers in the spaces that are provided below the
illustration.

Transmission Serial Number___________________

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Operator Station Features Air Charge Valve Closed (2) - Turn the lever to the
CLOSE position when the specified pressure is
reached. Disconnect the outside air source.
Air Reservoir Valve
Engine Shutdown Valve

1
2

The air reservoir shut off valve and the charge valve
are located on the right rear side of the machine Engine shutdown valve is located inside the operator
station.
Shut Off Valve Open (1) - To activate the air system
the shut off valve must be in the OPEN position before Engine Shutdown Valve - Use engine shutdown
you start the engine. valve in order to stop engine. Pull the shutdown
lever back. This will stop the engine.
Shut Off Valve Closed (2) - To deactivate the air
system, turn the valve lever to the CLOSED position.
Engine Start Button
The entire air system is disabled when you close off
the shut off valve. Turn the shut off valve to the
CLOSED position if you do not operate the machine
for an extended period of a month or more. This will
prevent drainage of the air from the reservoir.

The engine start button is used to start the

engine. Push the button in to start the engine.
When the engine starts release the button.

The air reservoir can be charged from an outside air

source.

Air Charge Valve Open (1) - To allow air into the

reservoir open the valve. Minimum air pressure to start
machine is 280 kPa.

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OPERATORS/MAINTENANCE MANUAL MACHINE OPERATION

Engine Start / Shutdown Valve

Engine Oil Pressure (1) - Indicates the engine

Start Valve - Push the lever and link forward and oil pressure. If the pressure drops below 50
hold. Minimum oil pressure to keep levers in position kPa the engine will shutdown and the
is 0.5 Bar (50 kPa). emergency brake will be engaged. Investigate the
cause of the fault.

Engine Coolant Temperature (2) - Indicates

the engine coolant temperature. If the gauge
needle is in the red range, the engine will
Ensure that the operators station door is closed shutdown and the emergency brake will be engaged.
before an attempt is made to start the engine. Do not operate the machine and investigate the
cause of the fault.
Engine Shutdown (Emergency)
Air Pressure (3) - Indicates the system air
The Wright engine shutdown system will act under pressure. If the air pressure drops below 180
the following conditions: kPa (25 PSI) the engine will shut down and
the emergency brake will be engaged. Investigate
z Engine oil pressure drop to 50 kPa. the cause of the fault.

z Exhaust gas temperature above 90oC.

z Engine water temperature above 96oC.

z Low engine water level.

z Low air pressure.

z Low exhaust scrubber tank water level.

The emergency brake is automatically engaged

when any of the above conditions occur, and
the transmission will shift to neutral.
Engine Coolant Level. If the coolant level
Personal injury could result from the sudden drops below the bottom of the sight gauge
stop of the machine. the engine will shutdown and the emergency
brake will be engaged. Investigate the cause of the
Be prepared for a sudden stop. Correct the fault.
reason for the emergency engine shutdown.

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MACHINE OPERATION OPERATORS/MAINTENANCE MANUAL

Gauges

2
1

5
3

4
6

Scrubber Auxiliary Tank Level - If the water level

drops below the inlet of the exhaust scrubber the Hydraulic Oil Temperature (1) - Indicates the
engine will shut down and the emergency brake will temperature of the hydraulic oil. The normal
engage. Investigate the cause of the fault. operating range is the green range. The
gauge needle will indicate in the red range if the
hydraulic oil temperature exceeds 104oC (219oF).

Engine Coolant Temperature (2) - Indicates

the temperature of the engine coolant. The
normal operating range is the green range.
The gauge needle will indicate in the red range if the
engine coolant temperature exceeds 103oC (217oF).

Transmission Oil Temperature (3) - Indicates

the temperature of the torque converter/
transmission oil. The normal operating range
is the green range. The gauge needle will indicate in
the red range if the transmission oil temperature
exceeds 129oC (264oF).

Brake Accumulator Oil Pressure (4) -

Exhaust Gas Temperature Thermal Valve - If the Indicates the brake accumulator oil pressure.
exhaust temperature rises above 90oC the engine will The normal operating range is the green
shut down and the emergency brake will engage. range. If the pressure drops below 8,5 Mpa the
Investigate the cause of the fault. parking/emergency brake will automatically engage.

Engine Oil Pressure (5) - Indicates the engine

oil pressure. The minimum pressure
permissible is 0,5 Bar with the engine idling
at normal operating temperature.

Air Pressure (6) - Indicates the system air

pressure. Minimum pressure to start the
engine is 280 kPa (40 PSI).

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OPERATORS/MAINTENANCE MANUAL MACHINE OPERATION

Horn

Brake Oil Pressure - Shows the hydraulic

pressure in the braking circuit when the brakes Horn - Push the horn button in order to sound
are fully released. The normal operating range the horn. Use the horn button for alerting
is the green range (10 - 15 Mpa). personnel or for signaling personnel.

Service Hour Meter - Located at the left rear of

Fuel Level - Indicates the amount of fuel the machine - Indicates the total operating
remaining in the fuel tank. hours of the engine. It should be used to
determine service intervals.

Running out of fuel can cause engine damage. Do not

continue to operate the machine when critically low on
fuel.

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MACHINE OPERATION OPERATORS/MAINTENANCE MANUAL

Seat

Adjust the seat in order to allow full travel of the

pedals. Make the seat adjustments when the
operator is sitting against the back of the seat.

Seat Angle Lever (4) - Pull up the seat angle

2 lever. Adjust the seat cushion to the desired
angle. Release the lever to lock the seat
cushion.
Seat Back rest (1) - Pull the back rest up and move
to the desired position. Lower the back rest to lock in Seat Belt
position.

Seat Height Lever (2). Hold down the seat height

1 2
lever to release the seat height lock. Push the seat
to the desired height. Release the lever to lock the
seat in position.

Place the seat belt across the operator’s lap. Fasten

the seat belt catch (1) into buckle (2). To release the
seat belt, push in release button (3) on the buckle.
5

6 The automatic locking retractor will adjust the length

3 of the seat belt. The seat belt is also equipped with a
comfort ride sleeve which allows limited movement
by the operator. The seat belt should fit snugly
across the operator’s lap.

Note: Extension for seat belts and longer seat belts

Fore and Aft Lever (3) - Pull up fore and aft are available from Barloworld. Use one of these seat
lever. Hold the lever upward and slide the seat belts when the seat belt is too short for the operator.
forward or backward to the desired position.
Release the lever in order to lock the seat into
position.

Weight Adjusting Knob (5) - Turn weight

adjusting knob in order to adjust the seat
suspension for different operator weights. Turn
weight adjusting knob (5) until the yellow rod in the
indicator (6) is just visible.

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OPERATORS/MAINTENANCE MANUAL MACHINE OPERATION

Machine Controls and Operation Standard Pull-to-Engage Type Parking

Brake Control
Braking

Parking Brake

This machine is equipped with spring applied

parking brakes. The spring force engages the brakes
on all four wheels. Hydraulic pressure is used to
disengage the brakes. If the hydraulic pressure is
unavailable, the brake will remain engaged.

If hydraulic pressure is unavailable and the machine

must be towed, use the mounted Hydraulic Pump in
order to release the parking brake.

Reference: For further information on towing an

inoperable machine, consult Barloworld or refer to
Operation and Maintenance Manual, “Towing
Information” for the machine that is being services. Use the parking brake control to engage the parking
brake when you park the machine. The parking
brake control is a push-pull type switch.

Parking Brake Control - Push parking brake

control knob inward to the OFF position in
Personal injury could result from the sudden order to disengage the parking brake. Pull the
stop of the machine. The parking brake is parking brake control knob outward to the ON
automatically engaged when oil pressure drops position in order to engage the parking brake.
below an adequate operating pressure.

If the brake system oil pressure drops below

Service Brake
normal operating pressure, the transmission will
shift to neutral. 1 2

Be prepared for a sudden stop. Correct the

reason for the loss of brake oil pressure. Do not
move the machine without normal brake oil
pressure.

The standard brake control is a pull-to-engage type. Service Brake/Transmission Lock Pedal (1) - Use the
When the knob is pulled OUT, the parking brake will left brake pedal to lock the transmission and to slow
be engaged. down the machine’s ground speed. This permits
higher engine speed for better hydraulic response.
Before operating the machine, ensure you are
familiar with the operation of the parking brake APPLY - Depress the left brake pedal when
control. truck loading, positioning or when raising the
bucket to increase hydraulic speed and reduce
unnecessary torque converter stalling. It can also be
used to give additional hydraulic power in difficult or
particularly tight digging (mucking) conditions.

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MACHINE OPERATION OPERATORS/MAINTENANCE MANUAL

RELEASE - Release the pedal to unlock the Transmission Control

transmission and to release the brake.
Direction Selection
Service Brake Pedal (2) - The right brake pedal slows
down the machine ground speed for normal braking.

APPLY - Depress the right brake pedal for

normal machine braking.

RELEASE - Release the right brake pedal in

order to release the brake.

Transmission Lock Control

No clearance for person in operator’s station

access area when machine turns. Severe injury
or death from crushing could occur. FORWARD (1) - Shift the transmission lever
counter clockwise, the machine will move
Engage transmission control lever lock before forward.
leaving the operator’s station.
NEUTRAL (2) The machine should not move
when the transmission lever is in neutral.

REVERSE (3) - Shift the transmission lever

clockwise, the machine will move in reverse.

Speed Selection

Locked - Push the knob in to lock the

transmission in neutral.

Unlocked - Pull the knob out to unlock the

transmission. The transmission control lever
can be moved to the forward or reverse
position.
Transmission Upshift - Turn the transmission
speed selection clockwise to shift the
transmission into the next higher gear speed.

Transmission Downshift - Turn the

transmission speed selection
counterclockwise to shift the transmission into
the next lower gear speed.

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OPERATORS/MAINTENANCE MANUAL MACHINE OPERATION

The transmission has four speeds:

1 - First Speed.

2 - Second Speed. Never use the FLOAT position to lower a loaded

bucket.
3 - Third Speed.
Machine damage can result from a bucket that falls
4 - Fourth Speed. too fast.

LOWER (2) - Push the lever forward to lower

Throttle Control the bucket. The lever will return to the HOLD
position when released.

RAISE (3) - Push the lever back to raise the

bucket. The lever will return to the HOLD
position when released.

HOLD (4) - The lever will return to the HOLD

position when released. The bucket will remain
in the selected position when in the HOLD
position.

Throttle Pedal - The throttle pedal is located on the

1
floor of the operator station.
3

Depressing the Throttle Control - Depress the

throttle pedal in order to increase the engine
speed. 2

Releasing the Throttle Control - Release the

throttle pedal in order to decrease the engine
speed.

Implement Controls

2 1
4
DUMP (1) - Push the lever forward to dump the
bucket. The lever will return to the HOLD
3 position when released.

TILT BACK (2) - Pull the lever back to tilt the

bucket back. The lever will return to the HOLD
position when released.

HOLD (3) - The lever will return to the HOLD

position automatically when released. The
bucket will remain in the selected position
when in the HOLD position.

FLOAT (1) - Push and hold the lever all the

way forward for the FLOAT position. The
bucket will lower to the ground and move up
and down following the ground contour. Pull the lever
back to the HOLD position.

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MACHINE OPERATION OPERATORS/MAINTENANCE MANUAL

Steering Frame Lock

1
3

No clearance for person in this area when

2
machine turns. Severe injury or death from
crushing could occur.

Note: To install the steering frame lock the

machine must be in the straight ahead position.

The steering frame lock is located at the

articulating hitch in the centre of the machine.

EJECT EJECTOR BUCKET (1) - Push the

lever forward. This will cause the ejector to
eject the load. The lever will return to the
HOLD position when released. 1

RETRACT EJECTOR BUCKET (2) - Pull the

lever back. This will cause the ejector plate to
retract into the ejector bucket. The lever will
return to the HOLD position automatically when
released. The ejector will remain in the selected
position when in the HOLD position.

HOLD (3) - The lever will return to the HOLD

position automatically when released. The
ejector will remain in the selected position
when in the HOLD position. Install the steering frame lock when the machine is
being lifted and when the machine is being
transported. Also install the steering frame lock if
you are performing service work near the articulating
hitch. Connect the steering frame lock between the
front and rear frame.

Remove the steering frame lock before the machine

is operated. Remove pin (1) from the bores of the
front frame and install the pin and lock in the stored
position as shown.

Bucket Control Group Safety Pins

No clearance for a person in this area when

bucket control group lowers. Severe injury or
death from crushing could occur. Be sure that
the bucket control group safety pins are
installed before working under or near the
bucket control group.

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OPERATORS/MAINTENANCE MANUAL MACHINE OPERATION

5. Lower the lift arm until the safety pins contact the
front frame tower.

6. Move the bucket to the fully dumped position.

Before operating the machine, be sure the bucket
control group safety pins are removed and put in the Note: The following steps are for the removal of the
stored position. Damage to the front frame and to the bucket control group safety pins.
lift arm can result if the machine is operated with
bucket control group safety pins installed in the lift arm. 7. Raise the lift arm (1) until the safety pins are
above both sides of the front frame tower.
The bucket control group safety pins are located on
both sides of the lift arm. Install the bucket control
group safety pins before performing service work in
the bucket control group area of the machine.

1. Park the machine on a flat, level surface in a

straight ahead position.

2. Engage the parking brake.

8. Remove safety pin from the lift arm on each side

of the machine. Install the pins in the stored
position bore, as shown. The bores for storing the
pins are located on each side of the front frame.

9. Lower the bucket onto the ground.

3. Raise lift arm (1) until the safety pin bore can be
aligned with the front frame tower.

4. Remove the safety pins from the stored position.

Fully insert each safety pin (2) into the bores of
the lift arm on each side of the machine.

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MACHINE OPERATION OPERATORS/MAINTENANCE MANUAL

BEFORE STARTING THE ENGINE Note: If the machine has not been operated for more
than 48 hours, qualified personnel should complete
a service inspection before you operate the
Walk-Around Inspection machine.
For maximum service life of the machine, make a Reference: Refer to the Operation and Maintenance
thorough walk-around inspection before you mount Manual, Service Inspection” for further information.
the machine.
Inspection points for the walk-around inspection
Look around the machine and under the machine.
Inspect the condition of all major components. (A) Frame (K) Air cleaner
Check all grease fittings. Look for the following (B) Left front tyre (L) Engine
discrepancies: (C) Front lights (M) Fuel tank
(D) Bucket and linkage (N) Air reservoir
z loose bolts (E) Right front tyre (O) Radiator
(F) Steering cylinders (P) Rear lights
z trash build up (G) Auxiliary water tank (Q) Power train
(H) Hydraulic tank (R) Left rear tyre
z oil, coolant, or fuel leaks (I) Steering frame lock (S) Operator station
(J) Right rear tyre
z broken parts or worn parts

z cracks in the frames

Remove any trash and debris. Report any

abnormalities to the shop. Make any necessary
repairs before you operate the machine.

E H G J N M
K
I

O
D L
C

Q P
D A F S R
B
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OPERATORS/MAINTENANCE MANUAL MACHINE OPERATION

2
G. Inspect the auxiliary water tank. Check the water
level. Inspect for leaks.

H. Inspect the hydraulic tank. Check the oil level in

the hydraulic tank in sight gauge. Inspect the
tank for leaks or for damage. Make sure that filler
cap is installed.
A. Inspect front frame (1) and rear frame (2). Check
for cracks or damage.

B. Inspect the left front tyre. Check the tyre inflation.

Make sure that you check the inside of the tyre
for damage or for wear. Inspect the tyre treads for
damage. Remove large rocks from the treads.
Check the wheel for nuts and washers that are
loose or missing.

Note: Rust behind a nut may indicate that the nut is

loose. Shiny metal areas around a nut may indicate
that the nut is loose.

C. Inspect the front operating lights for damage.

D. Inspect the bucket and linkage for damage or for

excessive wear.
I. Check that the steering frame lock is not
installed. The machine will not steer if the
E. Repeat paragraph 2 for the right front tyre.
steering frame lock is installed.
F. Inspect the steering cylinder. Look for leaks,
J. Repeat paragraph 2 for the right rear tyre.
cracking, or marks on the chrome. Inspect the
articulating hitch.
K. Inspect the air cleaner. Remove debris that may
obstruct the air cleaner.

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MACHINE OPERATION OPERATORS/MAINTENANCE MANUAL

S. Inspect the operator station for cleanness.

Inspect the instrument panel for broken and
inoperative gauges.

Refer to the Operation and Maintenance Manual,

“Service Inspection” for further information.

Mounting and Dismounting

L. Inspect the engine. Use dipstick to check the oil

in the sump of the engine. Check for oil leaks
and coolant levels.

M. Inspect the fuel tank, Make sure that the filler cap
is installed correctly. Look for any leaks or
damage to the fuel tank.
N. Inspect air reservoir for leaks and damage. Make
sure that the reservoir air shut off valve is in the
OPEN position.

O. Check the coolant level in the radiator sight

gauge. Inspect the radiator. Check for leaks.
Remove any debris that could block the air flow.
Get on the machine only at locations that have steps
P. Inspect the rear lights for damage. and/or handholds. Get off the machine only at
locations that have steps and/or handholds. Before
you get on the machine, clean the steps and the
handholds. Inspect the steps and handholds. Make
any necessary repairs.

Q. Inspect the power train. Use dipstick to check

the transmission oil level when the engine is
running at low idle at working temperature. Check Face the machine whenever you get on the machine
for leaks from the torque converter and from the and whenever you get off the machine.
transmission.
Maintain a three-point contact with the steps and
R. Repeat paragraph B for the left rear tyre. with the handholds.

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OPERATORS/MAINTENANCE MANUAL MACHINE OPERATION

Note: Three-point contact can be two feet and one Engine Starting
hand. Three-point contact can also be one foot and
two hands.

Do not get on a moving machine. Never jump off the

machine. Do not try to get on the machine when you
carry tools or supplies. Use a hand line to pull the Diesel engine exhaust contains products of
equipment onto the platform. Do not use any combustion which may cause personal injury.
controls as handholds when you enter the operator
station or when you exit the operator station. Always start and operate the engine in a well
ventilated area, and, if in an enclosed area, vent
Seat Adjustment and Seat Belt the exhaust to the outside.
Inspection 1. Make sure that no one is on the machine,
underneath the machine or around the machine.
Make sure that there no personnel in the area.

2. Close the operator station door.

3. Adjust the operator’s seat.

4. Fasten the seat belt.

Note: Adjust the seat at the beginning of each shift

or adjust the seat when there is a change of
operators.

When the operator is seated against the back of the 5. Move the transmission direction control to the
seat, adjust the seat in order to allow full pedal NEUTRAL position.
travel. The operator may adjust the seat forward or
backward.

Inspect the belt mounting hardware. If the hardware is

damaged or worn, replace the hardware. Keep the
mounting bolts tight.

Fasten seat belt before you start the engine.

Reference: For further information on the seat and

the seat belt, refer to Operation and Maintenance
Manual, “Seat, Seat Belt” for the machine that is
being serviced.

6. Push the knob in to lock the transmission in

neutral.

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The hydraulic oil will warm up faster if the control

7. Pull the parking brake control knob outward to lever is held in the full TILT BACK position for
the ON position in order to engage the parking short periods of ten seconds or less. This will
brake. allow the hydraulic oil to reach relief pressure,
which causes the hydraulic oil to warm more
8. Sound the horn. rapidly.

Cycle all hydraulic controls in order to allow

warm hydraulic oil to circulate through all
hydraulic cylinders and through all hydraulic
lines.

2. Look at the gauges frequently during operation.

When you idle the engine to warm up the

engine, observe the following
recommendations:

z Allow the engine to warm up for

approximately 15 minutes when the
temperature is higher than 0oC (32oF).
z Allow the engine to warm up for
approximately 30 minutes when the
temperature is below 0oC (32oF).
9. Push the lever of the start valve forward and z More time may be required if the
hold. Minimum oil pressure to keep lever in temperature is less than -18oC (0oF). More
position is 0.5 Bar (50 kPa). time may also be required if the hydraulic
functions are sluggish.

Preparing to Operate the Machine

1. Do not attempt to move the machine without

normal brake oil pressure.

2. In order to prevent injury, make sure that no one

is working on the machine or near the machine.
Keep the machine under control at all times in
order to prevent injury.

3. Know the maximum height of the machine.

Know the maximum width of the machine.
Maintain proper clearance.

4. With the engine at low idle and with the oil at

10. Push the start button in to start the engine. normal operating temperature, check the oil
Release the button when the engine starts. level of the transmission.

Note: For starting below -18oC use of additional cold Reference: Refer to the Operation and Maintenance
weather starting aids is recommended. Manual, “Transmission Oil Level - Check” for the
machine that is being serviced.
Engine and Machine Warm-Up
5. Before machine operates at high speed, check
1. Allow a cold engine to warm up at low idle for at the operation of the braking system and of the
least five minutes. To help the hydraulic steering system. These systems should be
components to warm up faster, engage and checked while the machine maintains a low
disengage the hydraulic controls to help speed speed.
warm up of the hydraulic oil and components.
Note: Every 10 service hours or daily, test the
operation of the braking system. For the correct
procedure, refer to the Operation and Maintenance

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OPERATORS/MAINTENANCE MANUAL MACHINE OPERATION

Manual, “Braking System - Test” for the machine that Operation

is being serviced.
Follow these basic instructions whenever you are
Reference: For further operating information, refer to operating the machine:
the Operation and Maintenance Manual, “Operating
Technique Information, Loading, Hauling and z To prevent injury, make sure that no one is
Dumping, and Bucket Loading Hauling Units” for the working on the machine or near the machine.
machine that is being serviced. Always maintain control of the machine.

z Raise the bucket or the work tool enough to

negotiate any obstacles.

z Before you disengage the parking brake, depress

the service brake pedal in order to keep the
machine from moving.

z Reduce the engine speed when you maneuver in

tight quarters and when you are going over a hill.

z When you drive downhill, use the same gear

range that is used for driving uphill. Do not
change gears while you travel downhill.

z Do not allow the engine to over speed while you

travel downhill. Apply the service brake in order
to reduce the engine speed.

1. Frequently observe gauges. All gauges should

be at normal operating range.

2. Adjust the operator’s seat.

3. Fasten the seat belt.

4. Raise the bucket approximately 400mm (15 inch)

above the ground.

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MACHINE OPERATION OPERATORS/MAINTENANCE MANUAL

Use the service brakes for stopping the machine.

Using the service brakes in order to control the
travel speed of the machine or using the service
brakes for stopping from high speeds can cause the
axle oil to overheat. This will result in significant
wear and/or damage to the service brakes and the
axle components.

Changing Direction and Speed

Speed changes at full engine speed and directional

changes at full engine speed are possible. However,
5. Depress the brake pedal. deceleration and/or braking is recommended when
you change direction. This will maximize operator
6. Move parking brake control knob to the OFF comfort and the service life of the power train
position to disengage the parking brake. components.

1. Decrease the engine speed by releasing the

throttle pedal.

2. Push the brake pedal downward in order to slow

down the machine. If you are shifting from
FORWARD to REVERSE or vice versa, stop
the machine completely.

3. Shift the transmission to the desired speed and/

or to the desired direction.

4. Release the brake pedal.

5. Increase the engine speed by depressing the

throttle pedal.

7. Move transmission direction control lever to the

desired travel direction. Turn the transmission
speed selector to the desired speed.

8. Release brake pedal.

9. Depress throttle pedal to the desired engine and

machine speed.

Downhill Operation

Maintain a ground speed that is slow enough for the

conditions. Before you operate the machine down a
hill, select the proper gear before you start down a
grade. The proper gear should allow the machine to
maintain the appropriate speed on the down grade.
The throttle control should be at high idle and the
engine should not over speed. In most situations, the
proper gear will be the same gear that is required to
drive up the grade.

If the machine builds up excessive speed, the engine

can over speed. This can result in damage to the
engine. Use the service brake in order to slow the
machine until a lower gear can be selected. Select a
lower gear and proceed with the throttle control at high
idle.
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OPERATORS/MAINTENANCE MANUAL MACHINE OPERATION

Parking Brake For good operator vision and machine stability, carry
the loaded bucket low, approximately 400mm (15
inch) above the ground.

Travel in reverse when you carry a load down a

steep incline. Travel forward when you go uphill.
Personal injury could result from sudden stop of
the machine. The parking brake is automatically Clean the work area during waiting periods and level
engaged when brake oil pressure drops below the work area during waiting periods.
an adequate operating pressure.
Maintain traction by avoiding excessive downward
pressure on the bucket.

Make sure that the bucket that is being used is

appropriate for the work that is being performed.
Exceeding the machine limits will reduce the service
life of the machine.

Loading, Hauling and Dumping

Note: Use the left brake pedal to permit higher engine

speed for better hydraulic response.

Anticipate a sudden stop. Correct the cause of the

loss of oil pressure. Do not operate the machine
without normal brake oil pressure.

Moving the machine with the parking brake engaged

or the service brake pedal locked can cause
excessive wear or damage to the brake. If
necessary, have the brake repaired before operating
the machine.
1. Position the bucket parallel to the ground. The
Operating Technique Information bucket should barely skim the ground. Drive the
bucket straight into the pile.

400mm

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MACHINE OPERATION OPERATORS/MAINTENANCE MANUAL

2. Move the lift control lever to the RAISE position 7. When you reach the dump area, move the lift
as forward movement slows. Return the lever to control lever to the RAISE position.
the HOLD position for additional tilt back power.
8. When at the correct height, move the tilt control
3. To fill the bucket, work the bucket control lever lever to the DUMP position.
back and forth from the TILT BACK position to
the HOLD position. Continue to use RAISE as
required to reduce wheel slip.

9. Move the ejector control lever to the eject position

to empty the bucket. Move the ejector control
lever to the retract position.
4. When the bucket is loaded, move the tilt control
lever to the TILT BACK position.

5. Raise the bucket high enough to clear the

material being loaded. Tilt the bucket back until
the bucket contacts the stops. Always carry a Striking the stops unnecessarily and repetitively can
load with the bucket in the fully tilted back result in accelerated wear and high maintenance
position to avoid material spillage and minimize cost of the loader linkage.
loader linkage wear.

6. Move the transmission direction and speed

control to the REVERSE position. Carry the
loaded bucket approximately 400 mm (15 inch)
above the ground level.

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OPERATORS/MAINTENANCE MANUAL MACHINE OPERATION

Bucket Loading Hauling Units

1. To reduce the loader turning and the travel

distance, position the hauling unit at an angle to
the material that is being loaded (if possible).

2. The optimum travel distance should be long

enough so that the bucket can reach the lift
height without slowing the movement of the
loader. This may vary due to specific
underground loading areas.

3. Position the loader in order to dump the load in

the centre of the hauling unit body. If the hauling
unit body is two bucket widths or more in length,
load the material into the hauling unit body from
the front to rear.
6. Move the tilt control lever to the TILT BACK
position.

7. Before lowering the bucket, make sure that the

hauling unit is not under the bucket.

8. Lower the bucket while positioning the loader for

the next load.

Parking

Stopping the Machine

Personal injury or death could result from not

4. Move the tilt control lever to the DUMP position. engaging the parking brake.

5. Use the ejector to dump the load from the If the parking brake is not engaged the machine
bucket. Shake the bucket in order to loosen may roll while personnel are on or near the
sticky material. machine.

Always engage the parking brake before leaving

the machine.

Striking the stops unnecessarily and repetitively can

result in accelerated wear and high maintenance
cost of the loader linkage.
No clearance for person in this area when
machine turns. Severe injury or death from
crushing could occur.

Engage transmission control lever lock before

leaving the operator’s station.

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Do not engage the parking brake while the machine

is moving unless the service brakes fail. The use of
the parking brake as a service brake in regular
operation will cause severe damage to the parking
brake.

1. Park the machine on a level surface. If it is

necessary to park on a grade, block the wheels.

1
2

4. Move parking brake control knob to the ON

position in order to engage the parking brake.

5. Lower the bucket to the ground and apply a

slight downward pressure.

2. Release throttle pedal (2). Depress service brake Stopping the Engine
pedal (1) in order to stop the machine.
1. Park the machine on level ground.

Stopping the engine immediately after it has been

working under load can result in overheating and
accelerated wear of the engine components.

If the engine has been operating at high rpm and/or

high loads, run a low idle for at least three minutes
to reduce and stabilize internal engine temperature
before stopping the engine.

2. In order to allow the engine to gradually cool,

operate the engine at low idle for three minutes.
3. Move transmission direction control lever to the
NEUTRAL position. Push the knob in to lock the
transmission in neutral.

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OPERATORS/MAINTENANCE MANUAL MACHINE OPERATION

Transportation Information
3. Pull the shutdown lever back in order to stop the
engine. Shipping the Machine
4. If the machine is parked, block the wheels. Consult Barloworld for shipping instructions for your
machine.

Investigate the travel route for overpass clearances.

Make sure that there is adequate clearance for the
machine that is being transported.

Remove ice, snow, or other slippery material from

the loading dock and from the transport machine
before you load the machine. This will also help to
prevent a shift while the machine is moving in
transit.

Obey all state and local laws governing the weight,

width and length of a load.
5. Drain the moisture from the bottom of the air
reservoir by opening and closing the drain cock. Make sure the cooling system has proper antifreeze
of moving machine to a colder climate.
Leaving the Machine
Observe all regulations governing wide loads.

1. Use the steps and handholds when you get off

the machine. Make sure the steps are clear of
debris before dismounting. Face the machine
and maintain a three-point contact with the
steps and with and handholds. 1. Block the trailer wheels or rail car wheels before
you load the machine (trailer shown).
Note: Three-point contact can be two feet and one
hand. Three-point contact can also be one foot and 2. After the machine is positioned, install the
two hands. steering frame lock in order to hold the front
frame and the rear frame in place.
2. Inspect the engine compartment for debris.
Clean out any debris and paper in order to avoid 3. Lower the bucket or the attachment to the floor
a fire. of the transport vehicle. Move the transmission
direction and speed control to the NEUTRAL
position.

4. Engage the parking brake.

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MACHINE OPERATION OPERATORS/MAINTENANCE MANUAL

5. Move the transmission lock control lever to the Lifting and Tying Down the Machine
LOCKED position.

6. Pull the shutdown lever to stop the engine.

7. Lock the door and the access covers. Attach any

vandalism protection. Improper lifting or tie-downs can allow the load to shift
and cause injury or damage. Install steering frame
8. Secure the machine, any equipment and any lock link before lifting.
tools with adequate tie-downs in order to
prevent movement during shipping.

Roading the Machine

Before you road the machine, consult your tyre

dealer for recommended tyre pressures and for
speed limitations.

Limitations for TON-kilometer per hour (TON-mile

per hour) must be obeyed. Consult your tyre dealer
for the speed limit of the tyres that are used.
Reference: Refer to the Operation and Maintenance
When you travel for long distances, schedule stops Manual, “Model views and Specifications” for the
in order to allow the tyres and the components to dimensions of the machines.
cool. Stop for 30 minutes after every 40 km (25
miles) or after every hour. Use proper rated cables and proper rated slings for
lifting the machine. Position the crane in order to lift
Perform a Walk-Around Inspection and measure the the machine in a level plane.
fluid levels in each of the compartments.
The spreader bar widths must be sufficient in order
Bring the engine coolant, the crankcase oil, and the to prevent contact with the machine.
transmission oil up to the correct levels.
Install tie-downs at several locations. Place blocks in
Inflate the tyres to the correct pressure. front of the wheels and behind the wheels.

Use a self-attaching inflation chuck in order to inflate Obey the appropriate laws that govern the
the tyre. Stand behind the tyre tread while you inflate dimensions of the load (weight, width, and length).
the tyres.
Consult Barloworld for shipping instructions of your
Reference: For information on tyre inflation, refer to machine.
the Operation and Maintenance Manual, “Tyre
Inflation Information” for the machine that is being
serviced.

Check with the proper officials in order to obtain the

required licenses and other similar items.

Travel at a moderate speed. Observe all speed

limitations when you road the machine.

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OPERATORS/MAINTENANCE MANUAL MACHINE OPERATION

Towing Information Do not use a chain for pulling. A chain link may break.
This can cause personal injury. Use a wire rope cable
with cable loops or end rings. Position an observer at
Towing the Machine a safe location. The observer should stop the pulling
procedure if the cable starts to break or the cable
starts to unravel. If the towing machine moves without
the pulled machine, stop the pulling procedure.

Personal injury or death could result when Keep the tow line angle to a minimum. Do not
towing a disabled machine incorrectly. exceed a 30 degrees angle from the straight ahead
position.
Block the machine to prevent movement before
releasing the brakes. The machine can roll free if Quick machine movement could overload the tow
it is not blocked. line or tow bar. This could cause the tow line or the
tow bar to break. Gradual, smooth machine
In order to properly perform the towing procedure, movement will be more effective.
use the following recommendations.
Normally, the towing machine should be as large as
This machine is equipped with spring applied the disabled machine. The towing machine must
parking brakes that are released by oil pressure. If have enough brake capacity, enough weight, and
the engine is inoperable or if the brake oil system is enough power for the grade that is involved and for
inoperable, the parking brakes are engaged. The the distance that is involved.
machine cannot be moved.
It may be necessary to connect a larger machine or
The parking brake can be disengaged manually in additional machines to the disabled machine in order
the event of insufficient oil pressure in the system. to provide sufficient control and sufficient braking.
This will prevent the disabled machine from rolling
Reference: For additional information, refer to the away out of control on a downgrade.
Operation and Maintenance Manual, “Parking Brake
Manual Release” for the machine that is being The requirements for all different situations cannot
serviced. be specified. Minimal towing machine capacity is
required on smooth, level surfaces. Maximum
Use these towing instructions for moving a disabled towing machine capacity is required in inclines or on
machine over a short distance. Do not move the poor surface conditions.
machine faster than 2 km/h (1.2 mph). Move the
machine to a convenient location for repair. Use If possible, dump the load before attempting to tow
these instructions for emergency situations only. the machine. Any towed machine with a load must
Always haul the machine in long distance moving is be equipped with a braking system that can be
required. operated from the operator’s station.

Shielding must be provided on both machines in Consult Barloworld for additional details about towing
order to protect the operator in case the low line a disabled machine.
breaks or the tow bar breaks.
Towing with an Operable Engine
Do not allow riders on a machine that is being towed
unless the operator can control the steering and/or If the engine is running, the machine can be towed
the braking. for a short distance under certain conditions. The
power train and steering system must be operable.
Before you tow the machine, inspect the condition of Tow the machine for a short distance only. For
the tow line or of the tow bar. Make sure that the tow example, pull the machine out of mud or pull the
line or tow bar is sturdy enough to tow the disabled machine to the side of the road.
machine. The tow line or the tow bar must have a
strength that is equal to 1.5 times the gross weight The operator on the towed machine must steer the
of the machine that is being towed. Use a tow bar machine in the direction of the low line.
with this strength or a tow line with this strength to
tow a disabled machine that is struck in the mud. Carefully obey all of the instructions that are outlined
Also, use a tow bar with this strength or a tow line in this topic.
with this strength to tow a disabled machine up a
grade.

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Towing an Inoperable Engine

Perform the following steps before you tow the

machine. Personal injury or death can occur from a brake
malfunction.
1. Block the wheels.
Make sure all necessary repairs and adjustments
2. If failure of the internal transmission or of the have been made before a machine that has been
drive line is suspected, remove the sun gears towed to a service area is put back into
from the axle shafts. operation.
Reference: For information on removing the sun
gear refer to the Power Train, Disassembly and
Parking Brake Manual Release
Assembly, “Sun Gear Removal” for the machine
being serviced.

Personal injury or death can result from a brake

malfunction. Do not operate the machine if the
When the sun gears are removed, the machine brake was applied due a malfunction of the oil
has no service or parking brakes. The machine system or brake.
can roll and cause personal injury or death.
Correct any problem before attempting to
Block the wheels securely so that the machine operate the machine.
cannot move.

The towing connection must be ridgid, or towing

must be done by two machines of the same size
or larger than the towed machine. Connect the Care must be taken to ensure that fluids are
machine on each end of the towed machine. contained during performance of inspection,
maintenance, testing, adjusting and repair of the
3. If possible, dump the bucket load. product. Be prepared to collect the fluid with suitable
containers before opening any compartment or
4. Fasten the tow bar. disassembling any component containing fluids.

5. Manually release the parking brake. Refer to Special Precaution, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and
Reference: For information about the manual supplies suitable to collect and contain fluids on
release of the parking brake, refer to the Operation Barloworld products.
and Maintenance Manual, “Parking Brake Manual
Release” for the machine that is being serviced. Dispose of fluids according to local regulations and
mandates.

Release the parking brake to prevent excessive

wear and damage to the parking brake system when
towing the machine.

Remove the wheel block. Tow the machine slowly.

Do not exceed 2 km/h (1.2 mph).

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1. Hydraulic Pressure Release. Move the lever to 4. Remove handle from storing place. Install handle
position (A) to release the hydraulic pressure in in hand pump pumping mechanism. Move the
the brake system. Observe the hydraulic mechanism through the pumping movement in
pressure gauge on the dash panel in the order to pressurise the braking system.
operators compartment. The gauge should drop
to zero.

Do not remove any valve, hydraulic fitting, or

valve core, nor disassemble any parts until
pressure has been relieved, or personal injury
may occur.

3
1
5. Observe the pressure on the pressure gauge,
when the braking system has full oil pressure.

Note: The service brake can be used to stop the

machine when the machine has brake oil pressure.
Use the service brake to control the machine when
the machine is being towed. Using the service brake
will cause the braking system oil pressure to
decrease. Ensure that the braking system pressure is
maintained for the duration of the towing by operating
the hand pump.
2. Remove dust cap (1) from elbow (2) on juction
block. To change the brake system to normal operation use
steps 5 through 1.
3. Remove hose (3) from pilot valve. Fit hose (3) on
elbow (2) at junction block. Fit dust cap on elbow
at pilot valve.

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MAINTENANCE OPERATORS/MAINTENANCE MANUAL

Maintenance Section Standard Torque for Worn Drive Band

Hose Clamps
Torque Specifications

General Torque Information

Mismatched or incorrect fasteners can result in

damage or malfunction, or personal injury. Width of C lamp
Initial Installation Torque
o n N ew H o se
Take care to avoid mixing metric dimensioned 7.9mm (0.31 i nch) 0.9 + 0.2 Nm (8 + 2 lb i n)
fasteners and inch dimensioned fasteners.
13.5mm (0.53 i nch) 4.5 + 0.5 Nm (40 + 4 lb i n)

Exceptions to these torques are given in the Service 15.9mm (0.63 i nch) 7.5 + 0.5 Nm (65 + 4 lb i n)
Manual, if necessary. R eassembly or
Width of C lamp
R etightening Torque
Prior to installation of any hardware, ensure that
7.9mm (0.31 i nch) 0.7 + 0.2 Nm (6 + 2 lb i n)
components are in near new condition. Bolts and
threads must not be worn or damaged. Threads 13.5mm (0.53 i nch) 3.0 + 0.5 Nm (27 + 4 lb i n)
must not have burrs or nicks. Hardware must be free 15.9mm (0.63 i nch) 4.5 + 0.5 Nm (40 + 4 lb i n)
of rust and corrosion. Clean the hardware with a
non-corrosive cleaner. Do not lubricate the fastener
threads except for the rust preventive. The rust Standard Torque for Constant Torque
preventive should be applied by the supplier of that Hose Clamps
components for purposes of shipping and storage.
Other applications for lubricating components may Use a constant torque hose clamp in place of any
also be specified in the Service Manual. standard hose clamp. Ensure that the constant
torque hose clamp is the same size as the standard
Torques for Ground Engaging Tool Bolts hose clamp. Due to extreme temperature changes,
the hose will heat set. Heat setting can cause hose
B olt Siz e R ecommended Torque (1) clamps to loosen. Loose hose clamps can result in
Inch leaks. There have been reports of component
Nm lb ft
failures that have been caused by hose clamps that
5/8 270 + 40 200 + 30 have loosened. The constant torque hose clamp will
3/4 475 + 60 350 + 45 help prevent these failures.

7/8 750 + 90 550 + 65

1 1150 + 150 850 + 110

1 1/4 2300 + 300 1700 + 220

These values are only for Caterpillar bolts for

(1)

cutting edges.

Use a torque wrench for proper installation of the

constant torque hose clamps. The constant torque
hose clamp is installed correctly under the following
conditions:

z Screw tip (1) extends 6.35mm (0.25 inch) (X)

beyond the housing.

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z The Belleville washers are collapsed nearly flat Standard Torque for Metric Fasteners
after screw (2) is tightened to a torque of 11 +
1Nm (98 + 9 lb in). Metric N uts and B olts

Thread Siz e
Standard Torque
Standard Torque for Inch Fasteners Metric

M6 12 + 3 Nm (9 + 2 lb ft)
Inch N uts and B olts
M8 28 + 7 Nm (21 + 5 lb ft)
Thread Siz e
Standard Torque
Inch M10 55 + 10 Nm (41 + 7 lb ft)

1/4 12 + 3 Nm (9 + 2 lb ft) M12 100 + 20 Nm (75 + 15 lb ft)

5/16 26 + 6 Nm (18 + 4 lb ft) M14 160 + 30 Nm (120 + 22 lb ft)

3/8 47 + 9 Nm (35 + 7 lb ft) M16 240 + 40 Nm (175 + 30 lb ft)

7/16 70 + 15 Nm (50 + 11 lb ft) M20 460 + 60 Nm (340 + 44 lb ft)

1/2 105 + 20 Nm (75 + 15 lb ft) M24 800 + 100 Nm (590 + 75 lb ft)

9/16 160 + 30 Nm (120 + 22 lb ft) M30 1600 + 200 Nm (1180 + 150 lb ft)

5/8 215 + 40 Nm (160 + 30 lb ft) M36 2700 + 300 Nm (2000 + 220 lb ft)

3/4 370 + 50 Nm (275 + 37 lb ft)

7/8 620 + 80 Nm (460 + 60 lb ft) Metric Taperlock Studs

1 900 + 100 Nm (660 + 75 lb ft) Thread Siz e

Standard Torque
Metric
1 1/8 1300 + 150 Nm (960 + 110 lb ft)
M6 8 + 3 Nm (6 + 2 lb ft)
1 1/4 1800 + 200 Nm (1320 + 150 lb ft)
M8 17 + 5 Nm (13 + 4 lb ft)
1 3/8 2400 + 300 Nm (1780 + 220 lb ft)
M10 35 + 5 Nm (26 + 4 lb ft)
1 1/2 3100 + 350 Nm (2280 + 260 lb ft)
M12 65 + 10 Nm (48 + 7 lb ft)

Inch Taperlock Studs M16 110 + 20 Nm (80 + 15 lb ft)

Thread Siz e M20 170 + 30 Nm (125 + 22 lb ft)

Standard Torque
Inch M24 400 + 60 Nm (300 + 44 lb ft)
1/4 8 + 3 Nm (6 + 2 lb ft) M30 750 + 80 Nm (550 + 60 lb ft)
5/16 17 + 5 Nm (13 + 4 lb ft) M36 1200 + 150 Nm (880 + 110 lb ft)
3/8 35 + 5 Nm (26 + 4 lb ft)

7/16 45 + 10 Nm (33 + 7 lb ft)

1/2 65 + 10 Nm (48 + 7 lb ft)

5/8 110 + 20 Nm (80 + 15 lb ft)

3/4 170 + 30 Nm (125 + 22 lb ft)

7/8 260 + 40 Nm (190 + 30 lb ft)

1 400 + 60 Nm (300 + 44 lb ft)

1 1/8 525 + 60 Nm (390 + 44 lb ft)

1 1/4 740 + 80 Nm (550 + 60 lb ft)

1 3/8 950 + 125 Nm (700 + 90 lb ft)

1 1/2 1200 + 150 Nm (880 + 110 lb ft)

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Tyre Inflation Information Tyre Shipping Pressure

Tyre Inflation with Nitrogen The following table contains the cold tyre shipping
pressures.
Barloworld recommends the use of dry nitrogen gas
for tyre inflation and for tyre pressure adjustments. HD356 Load Haul Dumper
This includes all machines with rubber tyres. Nitrogen
is an inert gas that will not aid combustion inside the Ply Rating Shipping Pressure
tyre. Tyre Siz e or Strength
Index Front R ear

6 9 0 kP a 5 8 5 kP a
17.5-25 20
(100 psi) 85 (psi)

6 9 0 kP a 5 8 5 kP a
17.5-R25 Two Star
Proper nitrogen inflation equipment, and (100 psi) 85 (psi)
training is using the equipment, are necessary
to avoid over inflation. A tyre blowout or rim Note: The “R” in the tyre size signifies radial
failure can result from improper or misused construction.
equipment and personal injury or death can
occur. The tyre inflation pressure is based on the weight of
a ready-to-work machine without attachments, at
A tyre blowout and/or rim failure can occur if the rated payload, and in average operating conditions.
inflation equipment is not used correctly, due to The tyre pressures for each application may vary.
the fact that a fully charged nitrogen cylinder’s Always obtain the proper pressures from your tyre
pressure is approximately 15000 kPa (2200 psi). supplier.

There are other benefits of using nitrogen in addition Tyre Inflation Pressure Adjustment
to reducing the risk of an explosion. The use of
nitrogen for tyre inflation lessens the slow oxidation The tyre pressure in a warm shop area 18o to 21oC
of the rubber. Use of nitrogen also slows gradual tire (65oF to 70oF) will significantly change when you
deterioration. This is especially important for tyres move the machine into freezing temperatures. If you
that are expected to have a long service life of at inflate the tyre to the correct pressure in a warm
least four years. Nitrogen reduces the corrosion of shop, the tyre will be under inflated in freezing
rim components. Nitrogen also reduces problems temperatures. Low pressure shortens the life of a
that result from disassembly. tyre.

Reference: When you operate the machine in

freezing temperatures, refer to Operation and
Maintenance Manual, SEBU5898, “Cold Weather
A tyre blowout or a rim failure can cause Recommendations” in order to adjust tyre pressures.
personal injury.
Lubricant Viscosities and Refill
Use a self-attaching inflation chuck and stand Capacities
behind the tread when inflating a tyre, to prevent
personal injury. The oil viscosities shown in bold type in the following
table are the standard oils used in Wright HD356
Note: Do not set the tyre inflation equipment machines. If the ambient temperatures you operate
regulator higher than 140 kPa (20 psi) over the in do not fall within the standard oil temperature
recommended tyre pressure. range, choose an oil that meets the required
ambient temperature range.
Use 6V-4040 Inflation Group or an equivalent
inflation group to inflate tyres with a nitrogen gas
cylinder. Refer to Special Instruction, SMHS7867 for
tyre inflation instructions.

For nitrogen inflation, use the same tyre pressures

that are used for air inflation. Consult your tyre
dealer for operating pressures.

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Lubricant Viscosities for Ambient Temperatures (1)

C ompartment or
o
C o
F
Oil Type and C lassification Oil Viscosities
System Min Max Min Max

SAE 0W20 -40 +10 -40 +50

SAE 0W30 -40 +30 -40 +86

C aterpillar Multigrade D EO SAE 0W40 -40 +40 -40 +104

API Multigrade C H -4 SAE 0W30 -30 +30 -22 +86
Engi ne C rankcase API Multigrade C G-4
API Multigrade C F-4 SAE 0W40 -30 +40 -22 +104
Global D H D -1 Multigrade
SAE 10W30 -20 +40 -4 +104

SAE 10W40 -20 +50 -4 +122

SAE 15W40 -15 +50 +5 +122

SAE 0W20(2) -40 +10 -40 +50

SAE 0W30(2) -40 +20 -40 +68

SAE 5W30(2) -30 +20 -22 +68

C aterpillar TD TO
Power Shi ft
C ommercial TO-4 S A E 10W -20 +10 -4 +50
Transmi ssi on
C aterpillar TD TO-TMS
SAE 30 -0 +35 +32 +95

S A E 50 +10 +50 +50 +122

TD TO-TMS(3) -10 +43 +14 +110

SAE 0W20(2) -40 +40 -40 +104

C aterpillar B iodegradable SAE 0W30(2) -40 +40 -40 +104
H ydraulic Oil (H EES)
C aterpillar H YD O SAE 5W30(2) -30 +40 -22 +104
C aterpillar D EO
SAE 5W40 -30 +40 -22 +104
C aterpillar TD TO
C aterpillar MTO SAE 10W -20 +40 -4 +104
API C G-4
S A E 30 +10 +50 +50 +122
Hydrauli c Systems API C F-4
API C F SAE 10W30 -20 +40 -4 +104
C ommercial TO-4
SAE 15W40 -15 +50 +5- +122
C aterpillar TO-4M
C aterpillar TD TO-TMS C aterpi llar MTO -25 +40 -13 +104
API C H -4 C at Bi odegradable
C ommercial B F-1(4) Hydrauli c Oi l (HEES) -40 +43 -40 +110
Global D H D -1 (4)
TD TO-TMS(3) -20 +50 -4 +122

S A E 30 -20 +20 -4 +68

C aterpillar TD TO SAE 50 -10 +43 +14 +110
D ri ve Axles C ommercial TO-4
C aterpillar TD TO-TMS S A E 60 -5 +50 +23 +122

TD TO-TMS(3) -25 +22 -13 +72

(1)
When you are operating the machine in temperatures below -20oC (-4oF), refer to Operation and Maintenance
Manual, SEBU5898, “Cold Weather Recommendations”. This is available from Barloworld.
(2)
First Choice: Oils of full synthetic base stock without viscosity index improvers that meet the performance
requirements of the TO-4 specification for the SAE 30 viscosity grade. Typical lubricant viscosity grades are
SAE 0W-20, SAE 0W-30, and SAE 5W-30. Second Choice: Oils that contain a TO-4 additive package and a lubricant
viscosity grade of SAE 0W-20, SAE 0W-30, or SAE 5W-30.
(3)
TDTO-TMS Transmission Multi-Season (exceeds the TO-4/TO-4M Multigrade specification requirements).
(4)
Commercial Biodegradable Hydraulic Oil (HEES) must meet the Caterpillar BF-1 specification. The listed ambient
temperature range is for the current Caterpillar Biodegradable Hydraulic Oil (HEES), not for commercial BF-1 oil.

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Capacities (Refill)

Approximate R efill C apacities

C ompartment or
Litres
System

Engi ne C rankcase 22

Transmi ssi on 39

Hydrauli c Tank 72

C ooli ng System 40

Front D i fferenti al and Fi nal D ri ves 38

Rear D i fferenti al and Fi nal D ri ves 38

Fuel Tank 205

Exhaust Scrubber Water Reservoi r 280

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Recommended Oils
VISCOSITY
BP CF4 BP VANELLUS C3 1 5W40 MULTIGRADE 105.5
TO4 BP ENERGOL CAT TO 430 = (SAE 30) (0 to 35oC) 105
TO 440 = (SAE 40) (5 to 45oC) 149
FORD M2C/134D BP TRACTRAN 9 62.3
GL5 BP HYPOGEAR GL5 - EP SAE 90 OR SAE 85W140 178, 402
10W BP VANELLUS C3 10W 36.0
GREASE BP ENERGREASE L21M GREASE
SHELL CF4 SHELL MYRINA M 15W40 103
CERA SHELL RIMULA X 15W40 103
HONEYLUBE TO4 SHELL DONAX, SAE 30 94.9
GL5 SHELL SPIREX HD 80W90, 85W140 149,460
FORD M2C/134D SHELL TRANSMISSION ON OIL TU EXTRA.B 90 60.8
10W SHELL RIMULA X 10W 38.1
GREASE RETINAX AM
ENGEN CF4 ENGEN DIESELUBE 300 SUPER 15W40 116
TREK TO4 ENGEN TRANSFLUID TO4 SAE40 146
CONDOR 10W ENGEN DIESELUBE 310 40
GREASE ENGEN GENFLEX EP 42 MT
CALTEX CF4 CALTEX DELO 500 MULTIGRADE 15W40 113.1
TO4 CALTEX TORQUE FLUID 434 = (SAE 30) 92.0
10W DELO 350 SAE 10W 41.9
GREASE MOLYTEX EP2 (3% MOLYBDINUM)
SASOL CF4 SASOL ONYX 15W40 95.0
TO4 SASOL BERIL 100 = (SAE 30) 100
10W SASOL RUBIS 32 31
GREASE BECHEM LITHOMOL EP2
CASTROL CF4 RX SUPER PLUS 15W40 109.5
TFC 450 FOR SAE 30
10W RX SUPER MONO GRADE SAE 10W 32.54
GREASE SPHEEROL LMM 3% MOLY
TOTAL CF4 TOTAL RUBIA XT 15W40 API CF4 SG/CE 108
TO4 TOTAL TRANSMISSION AC 3 108
10W RUBIA S 10W 36.2
GREASE TOTAL MULTIS MS2
CHEMICO CF4 HP MULTIFLEET 15W40 115
TO4 OTA TO4 SAE40 150
10W MS10W 38
GREASE LM62
DIMOL CF4 DIMOL SUPER 15W40 110
TO4 NIL
10W DIMOL SERIES 3 MOTOR OIL SAE 10W 38
GREASE DIMOL LITHIUM/MOLYBDENUM DISULPHIDE GREASES
ZENEX CF4 ZENEX SUPER ZX 15W40 118.9
TO4 ZENEX TRANS 4 SAE 30 102.5
10W ZENEX SINGLE GRADE MOTOR OIL 10W 40
GREASE ZENEX LITHIUM MOLLY 2 GREASE
FUCHS CF4 FUCHS TITAN TRUCK 15W40 130
LUB’S WM PENN SUPERB HD TURBO 15W40 105
VALVOLINE ALL FLEET EXTRA 15W40 105
FUCHS C 30 100
40 160
WM PENN C 30 100
40 160
GREASE WM PENN MOLLY HT2 EP (3% MOLY)

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COOLING SYSTEM Coolant Information

Coolant Specifications

Use a mixture of fill water, anti-freeze and Cooling

System Conditioner. Never add coolant to an overheated engine; allow
the engine to cool first.
Fill Water
Check the specific gravity of the anti-freeze solution
Always add conditioner to water. Never use plain frequently in the cold weather to ensure adequate
water only. protection. A minimum of 30% anti-freeze is
recommended.
Acceptable water for use in the ethylene glycol-type
anti-freeze and water mixture is shown on the chart If the machine is to be stored in, or shipped to an area
below. with below freezing temperatures; the cooling system
must be protected against freezing to the lowest
expected ambient temperature.
Acceptable Water
All water is corrosive at engine operating
Water 50% Without
temperature. The cooling system should be
Content Anti-freez e Anti-freez e protected with a 3% to 6% concentration of cooling
Chlorides 100 ppm or less 50 ppm or less system conditioner at all times regardless of the
concentration of the antifreeze. Coolant should be
Sulphur 100 ppm or less 50 ppm or less
drained and replaced “Every 2 000 Service Hours or
Hardness 200 ppm or less 100 ppm or less
1 Year”. However, when Cooling System Conditioner
as C A C O 3
additions are made every 250 Service Hours as
Dissolved 500 ppm or less 250 ppm or less recommended, the drain period can be extended to
Solids “4 000 Service Hours or 2 Years”.
pH 6.5 or higher 6.5 or higher
ppm = parts per million A 3% to 6% concentration of Cooling System
Conditioner can be maintained by adding conditioner
as follows:
Anti-freeze
Cooling System Conditioner
Use ethylene glycol-type anti-freeze protection to
the lowest expected outside temperature. A When filling complete
2 Litres
minimum of 30% antifreeze is recommended. system

Every 250 Service Hours 1/2 Litre

Conditioner
Pre-mix anti-freeze solution to provide protection to
Use Barloworld Equipment Cooling System the lowest expected ambient temperature. System
Conditioner or Equivalent. Follow the instructions on capacity is 34 litres.
the container.
Use clean water that is low in scale forming mineral.
Cooling System Conditioner Do not use softened water.
Siz e Part No. Filling at over 20 litres per minute can cause air
pockets in the cooling system.
1/2 Pint 0.24 litre 6V 3542
1 Quart 0.95 litre 3P 2044 After draining and refilling the cooling system, run
55 Gallon 208 litre 5P 2907 the engine with the filler cap off until the coolant
level stabilises. Add coolant as necessary to fill the
system to the correct level.

The engine cooling system is protected to -28 oC

with permanent type anti-freeze, when shipped from
the factory.

Operate with thermostat in the cooling system year-

round. Cooling system problems can arise without a
thermostat.

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Maintenance Locations

Filter and Screen Locations

1 9 3 2 5 4 6
8
7

10 11 12

(1) Front axle breather (7) Engine crankcase breather

(2) Hydraulic system oil filler screen (8) Rear axle breather
(3) Hydraulic system oil filter (9) Transmission magnetic screen
(4) Engine air filters (10) Transmission oil filter
(5) Fuel tank filler screen (11) Primary fuel filter
(6) Engine oil filter (12) Secondary fuel filter

Sampling Interval and Location of

Sampling Ports

Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting and repair of the
product. Be prepared to collect the fluid with suitable
containers before opening any compartment or
disassembling any component containing fluids.

Refer to Special Publication, NENG2500,

“Caterpillar Tools and Shop Products Guide”, for
tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations

and mandates.

Take the oil samples as close as possible to the

standard intervals. To receive the full value from the
S.O.S oil analysis, you must establish a consistent
trend of data. To establish a pertinent history of data,
perform consistent oil samplings at set intervals.

Operate the machine for a few minutes before you

obtain the oil sample. This will thoroughly mix the oil
for a more accurate sample.

Reference: Refer to Special Publication, PEHP6001,

“How to Take a Good Oil Sample: for more
information about obtaining an oil sample.

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Obtaining a sample of the hydraulic system oil will

require a vacuum pump or an equivalent. Withdraw
C h an g e Sampling the oil through the filler opening.
Type of Fluid
Interval Interval

Engine Oil 250 Hours 250 Hours

Transmission Oil 1000 Hours 500 Hours

Hydraulic Oil 2000 Hours 500 Hours

Differential and
1000 Hours 500 Hours
Final Drive Oil

Coolant 6000 Hours 500 Hours

Consult Barloworld for complete information and for

assistance in establishing a S.O.S program for your
equipment.

Location of Sampling Sampling port for the final drive oil.

The sampling for the engine oil is located on the left Sampling port for the front differential oil.
side of the engine.

Sampling port for the rear differential oil.

The sampling for the transmission and torque
converter oil is located on the left side of the engine.

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Application

Studies have revealed that obtaining oil samples at

every 500 hours is too long a time interval in some
applications in order to predict potential failure modes.
A sampling interval at every 250 hours provides more
data between oil change intervals. More data
increases the chance for detecting a potential failure.

Determining Optimal Oil Change Intervals

Sampling the compartments at every 250 hours

provides information for oil condition and for oil
performance. This information is used to determine
the optimum usable life of a particular oil. Also,
more points of data will allow closer monitoring of
component wear rates. Close monitoring also allows
Obtaining a sample of the differential and final drive you to obtain the maximum use of the oil. For
oils will require a vacuum pump or an equivalent. detailed information about extending oil change
Withdraw the oil through the filler opening on each intervals, please consult Barloworld.
axle and final drive.
Optimizing Component Life Cycle

An increase in the number of oil samples provides a

better definition of the trends in data between oil
change intervals. More oil samples will allow you to
closely monitor wear patterns of components. This
action will ensure that the full life of the components
are achieved.

The standard interval that is used between S.O.S oil

samples is 250 hours for all Caterpillar engine.
While 500 hour oil sample intervals remain
acceptable for non-engine compartment, these
intervals are not necessarily optimum. If the
machine is operated under high load and/or high
temperature condition, sample all compartments at
Obtaining a sample of the coolant will require a the 250 hour interval.
vacuum pump or an equivalent. Slowly remove the
cooling system pressure cap on top of the radiator
and withdraw the coolant through the filler opening.

More frequent S.O.S Sampling Improves

Life Cycle Management

Traditionally, the suggested S.O.S sampling

intervals have been at each oil change (250 hours
for engines and every 500 hours for all other
compartments). However, more frequent oil
sampling is recommended in severe applications. If
the machine is operated under a high load and/or in
high temperature conditions, sample all
compartments at every 250 hour interval.

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Maintenance Interval Schedule Every 250 Service Hours or Monthly

Note: All safety information, warning and instructions Articulated Hitch Bearings - Inspect ..................... 80
must be read and understood before you perform Collet Pin Bolt Torque - Check .............................. 80
any operation of any maintenance procedure. Coolant Conditioner Element - Change ................. 79
Cooling System Coolant Additive (DEAC) - Add .... 79
Note: Before each consecutive interval is performed, Differential Final Drive Oil Level - Check ................ 77
all of the maintenance requirements from the Drive Shaft Universal Joints, Splines and Bearings -
previous intervals must be performed. Inspect/Lubricate .................................................. 78
Engine Oil and Filter - Change .............................. 75
When Required Engine Air Intake System (Flametrap) -
Inspect/Clean ....................................................... 82
Engine Air Filter Secondary - Replace .................. 57 Flameproof Exhaust System - Inspect ................. 82
Engine Air Pre-cleaner - Clean .............................. 58 Fuel System Primary Filter - Clean/Replace ......... 76
Fuel System - Prime ............................................ 56 Hydraulic Tank Filler - Clean ................................. 82
Oil Filter - Inspect ................................................. 56 Steering Stop - Check .......................................... 81
Radiator Core - Clean ........................................... 57 Rear Axle Trunnion Bearings - Inspect .................. 82

Every 10 Service Hours or Daily Every 500 Service Hours or 3 Months

Articulated Hitch Bearings - Lubricate .................. 66 Engine Crankcase Breather - Clean ..................... 86
Air Reservoir - Drain ............................................. 63 Fuel Tank Cap and Strainer - Clean ...................... 83
Auxiliary Water Tank - Scrubber - Check .............. 63 Fuel System Secondary Filter - Replace .............. 85
Belts - Inspect/Adjust/Replace ............................. 70 Hydraulic System Oil Filter - Replace ................... 83
Braking System - Test .......................................... 65 Transmission Oil Filter - Replace .......................... 84
Bucket Pivot Bearings - Lubricate ........................ 67
Cooling System Level - Check .............................. 62 Every 1000 Service Hours or 6 Months
Engine Air Filter Primary Element - Clean/Replace .. 72
Engine Oil Level - Check ...................................... 61 Brake Accumulator - Check .................................. 87
Ejector Cylinder Bearings - Lubricate ................... 69 Differential and Final Drive Oil - Change ................ 87
Ejector Pivot Bearings - Lubricate ........................ 69 Rollover Protective Structure (ROPS) - Inspect ..... 91
Fuel Tank Water and Sediment - Drain ................. 66 Transmission Oil - Change ................................... 89
Gauges - Test ...................................................... 71
Hydraulic System Oil Level - Check ..................... 64 Every 2000 Service Hours or 1 Year
Lift Arm and Cylinder Bearings - Lubricate ............ 67
Rear Axle Trunnion Bearings - Lubricate ............... 70 Brake Discs - Check ............................................ 91
Seat Belt - Inspect ............................................... 64 Crankshaft Vibration Damper - Inspect ................. 91
Service Inspection ................................................ 59 Engine Mounts - Inspect ...................................... 92
Steering Cylinder Bearings - Lubricate .................. 68 Engine Valve Lash - Check/Adjust ........................ 92
Tilt Cylinder and Tilt Lever Bearings - Lubricate .... 68 Engine Valve Rotators - Inspect ............................ 92
Tilt Linkage Bearings - Lubricate .......................... 69 Hydraulic System Oil - Change ............................ 93
Transmission Oil Level - Check ............................ 64
Every 3000 Service Hours or 2 Years
Every 50 Service Hours or Weekly
Cooling System Coolant (DEAC) - Change ........... 94
Bonnet Hinges - Lubricate .................................... 75 Cooling System Coolant Extender (ELC) - Add ..... 95
Engine Shut Down System .................................. 74 Cooling System Pressure Cap - Clean/Replace .... 96
Exhaust Scrubber Tank - Inspect/Clean ................ 74
Fan Drive Bearing - Lubricate ............................... 73 Every 3 Years
Jockey Pulley Drive Bearing - Lubricate ................ 74
Operators Door Hinge - Lubricate ......................... 74 Seat Belt - Replace .............................................. 96
Tyre Inflation - Check ............................................ 75
Wheel Nuts - Torque ............................................. 74 Every 6000 Service Hours or 4 Years
Initial 250 Service Hours - or at first oil Cooling System Coolant Extender (ELC) - Change .... 96
change) Cooling System Water Temperature Regulator -
Replace ................................................................ 98
Engine Valve Lash - Check/Adjust ........................ 92 Engine Water Pump - Inspect .............................. 99

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WHEN REQUIRED
Fuel System - Prime

After changing the fuel filters or if the engine fuel

system is run dry, prime (purge) the fuel system to 2
fill filters and remove air bubbles from the system.

Do not loosen the fuel lines at the fuel manifold. The

engine components may be damaged.

Do not remove the fitting in the fuel filter base in

order to release air from the fuel system while 1. Remove plug (1). Unlock and operate priming
priming the engine. Periodic removal of the fitting pump plunger (2) until clear fuel appears. Use a
will result in increased water of the threads in the cloth or container to catch excess fuel. A
fuel filter base and will lead to fuel leakage. considerable amount of pump strokes may be
required to fill the fuel lines and filters.
Do not allow dirt to enter the fuel system.
Thoroughly clean the area around any fuel system 2. Install plug (1). Push priming pump plunger (2)
component that will be disconnected. Fit a suitable in and lock in position.
cover over any disconnected fuel system component
in order to protect it from dirt and debris. 3. Crank the engine promptly after priming the fuel
system. The engine should start within 15
seconds.

4. If the engine will not start, allow the starter

motor two minutes to cool. Repeat steps 1
Care must be taken to ensure that fluids are through 3.
contained during performance of inspection,
maintenance, testing, adjusting and repair of the 5. If the engine starts, but runs rough, or once
product. Be prepared to collect the fluid with suitable started continues to misfire or smoke, further
containers before opening any compartment or priming is necessary to help purge fuel lines of
disassembling any component containing fluids. air. Continue to run the engine at low idle until
fuel flows free without pocket of air in the fuel
Refer to Special Publication, NENG2500, lines and engine runs smoothly.
“Caterpillar Tools and Shop Products Guide” for tools
and supplies suitable to collect and contain fluids on Oil Filter - Inspect
Caterpillar products.
Inspect a Used Filter for Debris
Dispose of all fluids according to local regulations
and mandates.

The element is shown with debris

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Use a 4C-5084 Filter Cutter to cut the filter element

open. Spread apart the pleats and inspect the element
for metal and for other debris. An excessive amount of
debris in the filter element can indicate a possible
failure.

If metals are found in the filter element, a magnet

can be used to differentiate between ferrous and on
cast iron parts.

Ferrous meals can indicate wear on the aluminium

parts of the engine, such as main bearings, rod
bearings or turbocharger bearings.

Small amounts of debris may be found in the filter

element. This could be caused by friction and by 2. You can use compressed air, high pressure
normal wear. Consult Barloworld to arrange for further water or steam to remove dust and other debris
analysis if an excessive amount of debris is found. from the radiator core. However, the use of
compressed air is preferred.
Using an oil filter element that is not recommended
by Barloworld can result in severe engine damage to Note: Care must be taken when you are using high
engine bearings, to the crankshaft, and to other parts. pressure water. High pressure water can cause
This can result in larger particles in unfiltered oil. The damage to the radiator. Using a water spray nozzle
particles could enter the lubricating system and the on the pressure washer which will disperse water
particles could cause damage. pressure is preferred.

Radiator Core - Clean 3. Close the grille.

To access the radiator for cleaning, perform the Engine Air Filter Secondary Element -
following procedure.
Replace

Service the air cleaner only with the engine stopped.

Engine damage could result.

Always replace the secondary element. Do not

attempt to reuse it by cleaning. Engine damage
could result.

Replace the engine air filter secondary element

1. Release latch (1) and open the grille at the rear of under the following conditions:
the machine.
z A clean primary element has been installed and
a warning for the air filter still occurs.

z The engine air filter primary element is serviced

for the third time.

z The exhaust smoke remains black and a clean

primary element has been installed.

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1. Remove the primary element. Engine Air Precleaner - Clean

Reference: For additional information, refer to the
Operation and Maintenance Manual, “Engine Air
Filter Primary Element - Clean/Replace” for the
machine that is being used.

1. Stop the engine.

2. Inspect the precleaner cup.

3. Empty the cup, when dirt reaches the indicator

2. Remove the secondary element. mark. See the topic “Engine Air Precleaner”
under “When Required” for detailed instructions.
3. Cover the air inlet opening. Clean the inside of
the air cleaner housing.

4. Uncover the air inlet opening. Install a new

secondary element.

5. Install the clean primary element and install the

cover on the air cleaner housing.

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Every 10 Service Hours or Daily

Remove any trash and any debris. As needed, adjust
Service Inspection (Walk Around) the tyre inflation. Make any necessary repairs. Make
sure that all loose connections and all parts are
For maximum service life of the machine, make a tightened to the specified torques. Replace any
thorough service inspection when you perform missing parts before starting the engine or before
lubrication and maintenance work. Look around the operating the machine.
machine and under the machine. Check all grease
fittings. Look for following discrepancies: Inspect the machine for leaks. If leaks are observed,
find the source of the leak and correct the leaks. If
z Loose bolts. leaks are suspected, check the fluid levels more
frequently than the recommended intervals.
z Trash buildup.

z Oil, coolant, or worm parts.

z Broken parts or worn parts.

z Cracks in the frame. F K I J

G H L
P
D C

D B B
A E

Inspection Points for Service Inspection (Walk Around)

(A) Frame (I) Engine air precleaner
(B) Tyres (J) Fuel tank
(C) Front lights (K) Auxiliary water tank
(D) Bucket and linkage (L) Scrubber box
(E) Steering hydraulic system (M) Cooling system
(F) Hydraulic system (N) Rear lights
(G) Handholds and steps (O) Power train
(H) Engine (P) Rollover Protective Structure (ROPS)

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(E) Inspect the steering hydraulic system for leaks,

worn hoses and damaged lines. If necessary
repair leaks, worn hoses and damages lines.
Inspect steering cylinder and the steering
cylinder mounts. Inspect the articulating hitch
for wear, damage, and loose or missing bolts. If
necessary, make repairs.
1
(F) Inspect the hydraulic system. Check for leaks,
worn hoses and damaged lines. Repair any
leaks, worn hoses and damaged lines.

Check the oil level in the hydraulic tank in sight

gauge. Make sure that the filler cap is installed.
Inspect the tank covers for damaged bolts, loose
bolts or missing bolts. Tighten loose bolts and
replace missing bolts. Check the welds and
mounting brackets for the hydraulic tank. Inspect the
2 tank for leaks or for damage. If necessary, make
repairs.

(G) Inspect the steps, the walkways and the

handholds. Remove any debris. Repair any
damage or replace and damaged parts.

(A) Inspect front frame (1) and rear frame (2). Check
for cracks or damage.

(B) Inspect tyre for cuts, gouges and proper

inflation. Remove large rocks from the treads.
Look for abnormal wear or uneven wear that
may indicate mechanical problems elsewhere.
Make sure that you check the inside of the tyre
for damage or for wear. Inspect the tyre treads for
damage. If necessary, repair the tyres.

Look for damaged rims. Replace any missing valve

caps. Check the wheels for nuts that are loose or
missing.

Note: Rust behind a nut may indicate that the nut is

loose. Shiny metal areas around a nut may indicate
that the nut is loose. (H) Inspect the engine for any obvious component
damage. Use dipstick to check the engine oil
Inspect the axles, the differentials, the wheel brakes level. Check for oil leaks, coolant leaks, and
and the final drives for leaks, Check for damaged exhaust leaks. Check the belts of the engine for
bolts, loose bolts or missing bolts. Tighten loose bolts proper tension and for good condition.
and replace missing bolts.
(C) Inspect the front lights for broken lamps, lenses (I) Check the engine air precleaner for
and proper operation. Replace broken lamps accumulated debris. If necessary, clean the
and lenses. engine air precleaner.

(D) Inspect the bucket and the linkages for wear and Reference: Refer to the Operation and Maintenance
for damage. Manual, “Engine Air Precleaner - Clean” for the
machine that is being serviced.

(J) Inspect the fuel tank. Make sure that the filler
cap in installed correctly. Look for any leaks or
damage to the fuel tank.

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(K) Inspect the auxiliary water tank for leaks, (O) Inspect the hydraulic systems for the torque
damage and damaged hoses. Make sure that the converter and for transmission. Use dipstick to
filler cap is installed. Check the water level. check the transmission oil level. Check for leaks
from the torque converter and from the
transmission. Check for worn hoses and for
damaged lines. Repair any leaks, worn hoses
and damaged lines.

(P) Inspect the Rollover Protective Structure (ROPS)

for cracks in welds, castings or any metal
section on the ROPS. Check the mounting bolts
and the mounting pads for damage. Consult
Barloworld for necessary repairs. Inspect the
operator station. Check the instrument panel for
broken and inoperative gauges.

Engine Oil Level - Check

(L) Inspect the exhaust scrubber tank for leaks and

damage. Do not underfill or overfill the engine crankcase with
oil. Either condition can cause engine damage.
(M) Check the coolant level in the cooling system.
Inspect the cooling system for leaks, worn
hoses and debris. Repair any leaks and
damaged hoses. Remove any debris that could
block the air flow through the radiator.

Reference: For more information about cleaning the

radiator core, refer to the Operation and
Maintenance Manual, “Radiator Core - Clean” for the
machine that is being serviced.
1 2
(N) Inspect the rear lights for broken lamps, lenses
and proper operation. Replace broken lamps
and lenses.

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Check the engine oil level with the machine level and Cooling System Level - Check
parking brake engaged.

The dipstick (2) is located on the left side of the

engine.

The level can be measured with the engine stopped or Pressurised system: Hot coolant can cause
the engine running and the oil at normal operating serious burn. To open cap, stop engine, wait
temperature. until radiator is cool. Loosen the cap slowly to
relieve the pressure.

Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting and repair of the
product. Be prepared to collect the fluid with suitable
containers before opening any compartment or
disassembling any component containing fluids.

1. With the engine stopped, the oil level should be Refer to Special Publication, NENG2500,
above the ADD OIL mark on the ENGINE “Caterpillar Tools and Shop Products Guide” for tools
STOPPED side of the dipstick. and supplies suitable to collect and contain fluids on
Barloworld products.

Dispose of all fluids according to local regulations

and mandates.

2. With the engine running, the oil level should be

between FULL and the ADD OIL mark on the
ENGINE IDLING side of the dipstick.

3. If necessary, remove the oil filler cap (1) and add

oil.

1. Maintain the coolant level in the sight gauge

located on the rear side of the machine. If it is
necessary to add coolant daily, check for leaks.

2. Inspect the radiator core for debris. Clean the

1 radiator core, if necessary.

Reference: For information on cleaning the radiator

core, refer to the Operation and Maintenance
Manual, “Radiator Core - Clean” for the machine
that is being serviced.

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Air Reservoirs - Drain

3. If coolant level is low, loosen the pressure cap

slowly to relieve pressure. Remove the pressure Drain the moisture from the bottom of the reservoir by
cap. Add coolant as required to within 13mm opening and closing the drain cock.
(0.50 inch) of the bottom of the filler pipe or to
the proper level in the sight gauge.

4. Inspect the pressure cap and cap seal for

damage, deposits or foreign material. Clean the
pressure cap with a clean cloth or replace the
cap if it is damaged.

5. Install the cooling system pressure cap.

Auxiliary Tank Level - Check

1. Check the Scrubber auxiliary water tank level,

ADD water to top of filler neck.

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Seat Belt - Inspect

1. Always check the condition of the seat belt and

mounting hardware before operating machine.

2. Inspect the seat belt for worn or frayed webbing. 1. When the engine is running at low idle, maintain
the oil level between the “LOW” and “FULL”
marks on the dipstick.

2. If necessary, remove the oil filler cap and add oil.

Reference: For information on lubricants and refill

capacities, refer to the Operation and Maintenance
Manual, “Lubricant Viscosities and Refill Capacities”
for the machine that is being serviced.

3. Clean the filler cap and install the filler cap.

Hydraulic System Oil Level - Check

3. Inspect the belt mounting hardware. Replace

any belt mounting hardware that is worn or
damaged. Keep the mounting bolts tight.

4. Regardless of the appearance, replace the seat

belt once during every three interval.

Transmission Oil Level - Check

1
Check the transmission oil level with the machine on
a level surface, the parking brake engaged, and the
oil at normal operating temperature.

The hydraulic oil tank is located on the right side of

the machine.

1. Maintain the oil level above the “ADD COLD”

mark in sight gauge (1) with the engine stopped
and the bucket level on the ground.

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To carry out the brake test, first start the engine and
let the brake oil pressure build up to the operating
range. The parking brake will stay engaged Until
operating oil pressure has been reached and the
parking brake control is moved to the OFF position
(parking brake disengaged). Once operating oil
pressure has been reached a test of the braking
system can be commenced.

Service Brake Holding Ability Test

1. Move the transmission direction and speed

control to the NEUTRAL position. Start the
engine. Raise the bucket slightly.

2. Open the hydraulic tank access cover located on

the upper right side of the machine.

3. Relieve the hydraulic tank pressure by operating

the hydraulic controls to help relieve the
pressure before removing the filler cap.

4. Remove the oil filler cap slowly to relieve any

remaining pressure. Add oil, if necessary, through
the filler tube.
2. Depress the service brake pedal.
5. Clean the oil filler cap and install the oil filler cap.

Braking System - Test

Personal injury can result if the machine moves

while testing.

If the machine begins to move during test,

reduce the engine speed immediately and
engage the parking brake.

Be sure the area around the machine is clear of

personnel and obstructions. Be sure the steering
frame lock is in the stored position.
3. Disengage the parking brake by moving the
parking brake control to the OFF position.
Test the brakes on a dry, level surface. Fasten the
seat belt before testing the brakes.
4. Move the transmission direction and speed
control to the SECOND SPEED FORWARD
The following test is to determine if the parking brake
position.
and service are functional. This test is not intended to
measure maximum holding effort. Brake holding effort
5. Gradually increase engine speed to high idle. The
required to hold a machine at a specific engine rpm
machine should not move,.
will vary from machine to machine due to differences
in engine setting, power train efficiency, etc., as well
6. Reduce the engine speed to low idle. Move the
as differences in brake holding ability.
transmission direction and speed control to the
NEUTRAL position. Engage the parking brake
Engine rpm at beginning of machine movement, with
and lower the bucket to the ground. Stop the
the brake applied, should be compared against the
engine.
engine rpm your specific machine was able to hold on
a prior test, as an indication of system deterioration.
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Fuel Tank Water and Sediment Articulated Hitch Bearing - Lubricate

Wipe off the fittings before any lubricant is applied.

Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting and repair of the
product. Be prepared to collect the fluid with suitable
containers before opening any compartment or
disassembling any component containing fluids.

Dispose of all fluids according to local regulations

and mandates.

1
Apply lubricant through one fitting for the upper hitch
bearing.
2

The drain valve is located on the right side of the

machine under the fuel tank.

1. Remove drain plug (2) from the drain opening.

2. Open (turn clockwise) drain valve (1) and allow

the water and sediment to drain out of opening
into a suitable container.
Apply lubricant through one fitting for the lower hitch
3. Close drain valve (1). bearing.

4. Install drain plug (2) into drain opening.

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Bucket Pivot Bearings - Lubricate

Wipe off the fittings before any lubricant is applied.

No clearance for a person in this area when
bucket control group lowers. Severe injury or
death from crushing could occur. Be sure that the
bucket control group safety pins are installed
before working under or near the bucket control
group.

1. Apply lubricant through one fitting on each side of

the machine for the rear lift arm bearing (2
points).

Apply lubricant through one fitting on each side of

the machine for the bucket pivot bearings.

Lift Arm and Cylinder Bearings -

Lubricate
2. Apply lubricant through one fitting for the
bearing at the head end of the left lift cylinder.

3. Apply lubricant through one fitting for the

bearing at the head end of the right lift cylinder.
Check that the lines attached to all the remote
grease fittings are undamaged. If the grease lines
are split, grease will not reach the components that
require lubricating. Machine damage will result.

Wipe off the fittings before any lubricant is applied.

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Tilt Cylinder and Tilt Lever Bearing -

Lubricate

Wipe off the fittings before any lubricant is applied.

4. Apply lubricant through one fitting on each side of

the machine for the bearing at the rod end of the
lift cylinder (2 points).
1. Apply lubricant through one fitting for the
Steering Cylinder Bearing - Lubricate bearing at the centre pivot of the tilt lever.

Wipe off the fittings before any lubricant is applied.

2. Apply lubricant through one fitting for the

bearing at the rod end of the tilt cylinder.

1. Apply lubricant through one fitting on each side

of the machine for the bearing at the rod end of
the steering cylinder.

2. Apply lubricant through one fitting on each side

of the machine for the bearing at the head end
of the steering cylinder.

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3. Apply lubricant through one fitting for the bearing Ejector Pivot Bearings - Lubricate
at the head end of the tilt cylinder.
Wipe off the fittings before any lubricant is applied.
Tilt Linkage Bearings - Lubricate

Wipe off the fittings before any lubricant is applied.

1. Apply lubricant through one fitting on each side of

the machine for the bucket ejector pivot bearings.

Ejector Cylinder Bearings - Lubricate

1. Apply lubricant through one fitting for each of

the bucket tilt linkage bearings (2 points). 1. Apply lubricant through one fitting on each side
of the machine for the bearing at the rod end of
the ejector cylinder.

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2. Apply lubricant through one fitting on each side 1. Apply lubricant through remote mounted fitting for
of the machine for the bearing at the head end front trunnion bearing.
of the ejector cylinder.

Rear Axle Trunnion Bearings - Inspect

1. Inspect the rear axle trunnion bearings for

excessive wear.

Reference: For information on the rear axle trunnion

bearings, refer to the Specifications, “Power Train”
for the machine that is being serviced.

2. Replace any parts that are worn or damaged.

Rear Axle Trunnion Bearings - Lubricate

2. Apply lubricant through remote mounted fitting

Check that the lines attached to all the remote for rear trunnion bearing.
grease fittings are undamaged. If the grease lines
are split, grease will not reach the components that Belts - Inspect/Adjust/Replace
require lubricating. Machine damage will result.
For maximum engine performance and utilization of
Wipe off the fittings before any lubricant is applied. your engine, inspect the belts for wear and for
cracking. Check and adjust the belt tension to
minimize belt slippage which will decrease belt life
and cause poor performance of the alternator and
any driven equipment.

1. Inspect the condition of the belts.

2. Inspect the tension of the fan belts and

alternator belt.

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Adjust the Alternator Belt

To check the belt tension, apply 110 N (125 lb) of

force midway between the pulleys. Correctly
adjusted belts will deflect 17 + 3mm (0.67 + 0.12
inch).

If new belt(s) are installed, check belt adjustment

again, after 30 minutes of operation. For multiple belt
drive applications, always replace belts in matched
sets.
1. Loosen mounting bolts (5) and (2).
If only one belt of a matched set is replaced, it will
carry more of a load than the belts not replaced 2. Loosen bracket bolt (4) and locknut (3).
since the older belts are stretched. The additional
lead on the new belt could cause it to break. 3. Turn adjusting nut (1) until the correct belt
tension is reached. Tighten the locknut to 150 +
Adjust the Fan Belts 20 Nm (110 + 15 lb ft).

4. Tighten bracket bolt (4), mounting bolts (5) and

(2).

5. Check the belt deflection. If the amount of

deflection is incorrect, repeat steps 1 to 3.

Indicators and Gauges - Test

1. Loosen the jockey pulley mounting bolts (5) and

(2).

2. Loosen the bracket bolt (4) and locknut (3).

3. Turn adjusting nut (1) until the correct belt

tension is reached. Tighten locknut (3) to 150 +
20 Nm (110 + 15 lb ft).
Before you operate the machine, perform the
4. Tighten bracket bolt (4), mounting bolts (5) and following checks and make necessary repairs:
(2).
z Look for broken lenses on the gauges. Also look
5. Check the belt deflection. If the amount of for broken indicator lights, broken switches and
deflection is incorrect, repeat steps 1 to 4. other broken components in the operator’s
station.

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z Make sure the parking brake is engaged.

z Check for oil leaks. Repair any oil leaks around

the covers of around the hoses.

z Look for inoperative gauges.

z Check for proper operation.

z Sound the horn.

z Stop the engine.

Engine Air Filter Primary Element -

Clean/Replace
1. Remove cover from the air cleaner housing.

Service the air cleaner daily or if the yellow piston in

filter element indicator moves into the red zone with
the engine running at high idle. Stop the engine. 2. Remove primary filter element from the air
cleaner housing.

3. Clean the inside of the air cleaner housing.

4. Inspect the primary element. If the pleats, the

Service the air cleaner only with the engine stopped. gaskets, or the seals are damaged, discard the
Engine damage could result of the air cleaner is primary element, Replace a damaged primary
serviced while the engine is running. element with a clean primary element.

This machine uses radial seal type air cleaners. To Do not clean the primary elements by bumping or
avoid engine damage, use only radial seal tapping them. Do not use primary elements with
replacement filters. Others will not seal. damaged pleats, gasket or seals. Engine damage
can result.
Radial seal filter gasket design and location are
critical to proper air cleaner operation. Use only Make sure the cleaned primary elements are
Caterpillar replacements. completely dry before installing them into the filter
housing. Water remaining in the elements can cause
false indications of contamination in S.O.S. Analysis
test results.

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Reference: For the correct procedure to replace the

5. If the primary element is not damaged, clean the secondary filter element, refer to the Operation and
primary element. The primary element can be Maintenance Manual, “Engine Air Filter Secondary
cleaned by using the following methods: Element - Replace” for the machine that is being
serviced.
z Pressure air.
EVERY 50 SERVICE HOURS OR
z Pressure water.
WEEKLY
z Detergent washing.
Fan Drive Bearing - Lubricate

Check that the lines attached to all the remote

grease fittings are undamaged. If the grease lines
are split, grease will not reach the components that
require lubricating. Machine damage will result.

Wipe off the fittings before any lubricant is applied.

6. When you clean the inside pleats and the

outside pleats, direct the air along the pleats or
direct the water along the pleats.

The primary element can be washed in a

solution that consists of warm water and of
nonsudsing household detergent. Fully rinse the
pleats. Allow the primary element to air dry
completely.

7. Inspect the primary element after you clean the

primary element. Do not use a primary element
if the pleats, the gaskets or the seals are
damaged.

8. Cover the clean primary element. Store the 1. Apply lubricant through the remote mounted
primary element in a clean, dry location. fitting for the fan drive bearing.

A primary element may be cleaned for a Note: To avoid seal damage do not over lubricate
maximum of six times. Also replace the primary the fan drive bearing.
element of the primary element has been in
service for one year.

9. Install a clean primary element. Clean the install

the cover.

Note: If the tallow piston in filter element indicator

moves into the red zone after starting the engine, or
the exhaust smoke is still black after installing a
clean primary element, install a new primary filter
element. If the piston remains in the red zone after
installing a new primary filter element, replace the
secondary filter element.

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Jockey Pulley Drive Bearings - Lubricate Operators Door - Hinges

Wipe off the fittings before any lubricant is applied. 1. Apply lubricant through two fittings for the door
hinge pins.

1. Apply lubricant through one fitting for the jockey

pulley drive bearings. Scrubber Tank - Inspect/Clean Exhaust

Wheel Nuts - Torque

1. Remove split pin and drain plug. Drain the

system.
1. Inspect for missing wheel nuts on each wheel.
Replace if necessary. Torque to 475 + 50 Nm.

Engine Shut Down System

Refer to the Flameproof System Operation testing and

adjusting for the correct procedures for the machine
that is being serviced.

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2. Remove the two covers and clean the inside of Bonnet Hinges
the scrubber tank with detergent, water and a
wire brush. 1. Apply lubricant through two fittings for the bonnet
hinge pins.
3. Install the drain plug and a new split pin.

4. Inspect the copper gaskets for damage and

wear. Replace if necessary.

5. Install the two covers. Tighten the capscrews.

6. Fill the system via the auxiliary tank filler neck

with water.

Tyres R
E
V
Y

250 SERVICE HOURS OR

MONTHLY
First perform the Previous Service Tasks

Engine Oil and Filter - Change

Note: Some commercial oils that meet API

specifications may require shorter oil change
intervals. The oil change intervals are determined by
1. Measure the tyre pressure on each tyre. Consult close monitoring of the oil condition and engine wear
your tyre dealer for correct load rating and metals. Barloworld prefers scheduled oil sampling as
operating pressures. the proper method of checking engine wear metals.

Consult Barloworld for the latest oil recommendations.

Use a self attaching air chuck and stand behind

the tyre tread while inflating the tyre.
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.

Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting and repair of the
product. Be prepared to collect the fluid with suitable
containers before opening any compartment or
disassembling any component containing fluids.

2. Inflate the tyres, if necessary. See “Tyre inflation

Information”.

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Refer to Special Publication, NENG2500, “Caterpillar filter element until the sealing surface contacts
Tools and Shop Products Guide”, for tools and the filter base. Tighten the filter element by an
supplies suitable to collect and contain fluids on additional 3/4 of a turn.
Caterpillar products.
Note: There are rotation index marks on the filter,
Dispose of all fluids according to local regulations that are spaced 90 degrees (1/4 turn) apart. Use
and mandates. these rotation marks as a guide when tightening the
filter.
The machine must be level and the parking brake
engaged. The oil must be warm and the engine
stopped.

7. Remove the engine oil filler cap. Fill the engine

crankcase with new oil. Clean the filler cap and
install the filler cap.
1. Remove the crankcase drain plug and drain the
oil into a suitable container. Reference: For information on lubricants and refill
capacities, refer to the Operation and Maintenance
2. Clean the drain plug and install the drain plug. Manual “Lubricant Viscosities and Refill Capacities”
for the machine that is being serviced.

8. Start the engine and run at low idle for five

minutes. Inspect the engine oil filter for leaks.
Stop the engine.

9. Maintain the oil level between the “ADD” and

“FULL” marks on dipstick. Add oil, of necessary.

Fuel System Primary Filter - Clean/

Replace

Clean the primary element when the engine has a

loss of power or when the exhaust smoke is black.

3. Remove used oil filter element (5) and discard the

used oil filter element. Personal injury or death can result if spilled fuel
ignites. Fuel leaked or spilled onto hot surfaces
4. Clean the filter housing base. Make sure that all or electrical components can cause a fire.
of the old seal is removed from the filter base.

5. Apply a thin film of clean engine oil to the new

filter element seal.

6. Install the oil filter element by hand. Tighten the

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7. Install the case and element on the base.

Tighten the retaining bolt.

8. Prime the fuel system.

Care must be taken to ensure that fluids are
contained during performance of inspection, Reference: For information on priming the fuel system,
maintenance, testing, adjusting and repair of the refer to the Operation and Maintenance Manual, “Fuel
product. Be prepared to collect the fluid with suitable System - Prime” for the machine that is being
containers before opening any compartment or serviced.
disassembling any component containing fluids.

Refer to Special Publication, NENG2500,

“Caterpillar Tools and Shop Products Guide”, for tools 9. Start the engine and inspect the filter for leaks.
and supplies suitable to collect and contain fluids on Make any necessary repairs. If the engine has a
Caterpillar products. loss of power of the exhaust smoke is still black,
replace the secondary filter.
Dispose of all fluids according to local regulations
and mandates. Reference: For the correct procedure to replace the
secondary filter, refer to the Operation and
Maintenance Manual, “Fuel System Secondary
Element - Replace” for the machine that is being
serviced.

Differential and Final Drive Oil Level -

Check

Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting and repair of the
product. Be prepared to collect the fluid with suitable
containers before opening any compartment or
1. Loosen the filter case retaining bolt. disassembling any component containing fluids.

2. Remove the case and the element from the filter Refer to Special Publication, NENG2500, “Caterpillar
base. Remove the seal from the filter base. Tools and Shop Products Guide”, for tools and
supplies suitable to collect and contain fluids on
3. Remove the filter element from the case. Caterpillar products.

Dispose of all fluids according to local regulations

and mandates.

Note: Before you measure the oil level, operate the

When using air pressure, wear protective face machine for a few minutes in order to equalize the
shield and protective clothing. The maximum air oil level.
pressure must be below 205 kPa (30 PSI) for
cleaning purposes. Wipe covers and surfaces around the openings
before checking or adding oil. Park on a level
4. Wash the element in a clean, non flammable surface.
solvent. Shake or blow it dry.
Note: Perform Steps 1 through 4 to the final drive on
5. Clean the case with a cloth, or a stiff fibre each wheel.
brush.
1. Park the machine on level ground. Engage the
6. Insert the element in the case. Install a new seal parking brake. Stop the engine.
in the groove of filter base.

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2. Position the wheels so that the final drive fill/ 6. Remove the rear differential fill/level plug from
drain plugs are even with the centre line of the the rear axle housing.
wheel. Stop the engine.
7. If the lubricant is below the fill plug opening, add
3. Remove the fill/drain plugs. The oil level should lubricant to bring the lubricant level to the
be at the bottom of the fill/drain plug openings. bottom of the plug opening and install the fill plug.
Add oil, if necessary.
8. Clean the fill/drain plugs and install the fill/drain
Reference: For information on lubricants, refer to the plugs.
Operation and Maintenance Manual, “Lubricant
Viscosities and Refill Capacities” for the machine Drive Shaft Universal Joints, Splines and
that is being serviced. Bearings - Inspect/Lubricate

Inspect the drive shaft universal joints for wear,

loose bolts, or missing bolts. Tighten loose bolts and
replace missing bolts. Inspect the drive shaft splines
and bearings for wear. Replace worn components.

Wipe off the fittings before any lubricant is applied.

4. Remove the fill/level plug from the front axle 1. Apply lubricant through seven fittings in
housing. universal joints.

5. If the lubricant is below the fill plug opening, add

lubricant to bring the lubricant level to the
bottom of the plug opening and install the fill
plug.

2. Apply lubricant through two fittings for the slip

joint splines.

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8. Clean the pressure cap and inspect the pressure

cap. Install the pressure cap.

9. Start the engine and check for leaks. Allow the

coolant level to stabilise.

10. If necessary, add premixed coolant in order to

bring the coolant to the proper level in the sight
gauge.

Cooling System Coolant Additive (DEAC)

- Add

3. Apply lubricant through one remote fitting for the Personal injury can result from hot coolant,
front drive shaft support bearings. steam and alkali.

Coolant Conditioner Element - Replace At operating temperature, engine coolant is hot

and under pressure. The radiator and all lines to
heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.

Remove cooling system pressure cap slowly to

relieve pressure only when engine is stopped
1 and cooling system pressure cap is cool enough
to touch with your bare hand.
2
Do not attempt to tighten hose connections
when the coolant is hot, the hose can come off
causing burns.

Cooling System Coolant Additive contains alkali.

3 Avoid contact with shin and eyes.

1. Loosen the pressure cap slowly to relieve

cooling system pressure. Remove the pressure
cap. Adding coolant to an overheated engine could result
in damage to the engine. Allow the engine to cool
2. Close element inlet valve (1) and outlet valve before adding coolant.
(2). Remove and discard element (3).
If the machine is to be stored in, or shipped to, an
3. Clean the element mounting base, Make sure area with freezing temperatures, the cooling system
all of the old seal is removed. must be protected to the lowest outside (ambient)
temperature.
4. Replace with a new maintenance element.
The engine cooling system is normally protected to
5. Coat the seal of a new element with a thin film a minimum of -29oC (-20oF) with Caterpillar
of engine oil. Antifreeze, when shipped from the factory unless
special requirements are defined.
6. Install and turn the element until the seal
contacts the base, then tighten 3/4 of a turn
more.

7. Open the inlet and outlet valves.

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1. Park the machine on a flat level surface in a

straight ahead position.

2. Engage the parking brake.

Care must be taken to ensure that fluids are
contained during performance of inspection, 3. Using the bucket and the lift arm, raise the front
maintenance, testing, adjusting and repair of the wheels of the machine slightly off the ground.
product. Be prepared to collect the fluid with suitable Then lower the front wheels onto the ground.
containers before opening any compartment or
disassembling any component containing fluids. 4. Have a second person, standing clear of the
machine and in view of the machine operator,
Refer to Special Publication, NENG2500, observe the upper and lower pivot bearings for
“Caterpillar Tools and Shop Products Guide”, for tools movement as Step 3 is performed repeatedly.
and supplies suitable to collect and contain fluids on
Caterpillar products. 5. Lower the front wheels to the ground.
Dispose of all fluids according to local regulations 6. If there is any noticeable movement, contact
and mandates. Barloworld for further information.

Articulated Hitch Bearings - Inspect Collet Pin Bolt Torque - Check

Before inspecting the articulated hitch bearings,
check the retaining bolt torque for the upper and
lower articulated hitch.

Reference: For the correct bolt torque, refer to the

Specifications, “Articulated Hitch” for the machine
that is being serviced.

No clearance for a man in this area when the

machine turns. Severe injury or death from
crushing could occur.

Install the steering frame lock pin into the locked

position before lifting the machine, transporting
Check the retaining bolt torque on bucket control
the machine on another vehicle, or performing
group collet retaining bolt.
service near the centre of the machine.
Retaining Bolt Torque = 1360 + 163 Nm.
Disengage the steering lock pin from articulation
joint and store in retainer before resuming
operation or the machine will not steer.

This test is a two person operation. There is no

clearance in the articulation area if the machine
turns. Severe injury or death from crushing
could occur. Stand clear of the machine while
observing the articulated hitch bearings.

Inspect the articulated hitch bearings for wear by

performing the following procedure:

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Steering Stop - Check Add Coolant Additive (If Required)

Check the clearance between the front frame and 1. Loosen the pressure cap slowly to relieve
the rear frame steering stops. cooling system pressure. Remove the pressure
cap.
Reference: For additional information about the
correct procedure, refer to Steering System, 2. It may be necessary to drain enough coolant
Systems Operation, Testing and Adjusting, from the radiator to allow for the addition of the
“Neutraliser Valve” for the machine that is being liquid supplemental coolant additive.
serviced.
Note: Make sure that the coolant is drained into a
suitable container.

3. Add liquid supplemental coolant additive

(conditioner) according to the requirements of
Excessive additive (greater than the recommended your cooling system determined by the coolant
6% initial fill) together with concentrations of additive concentration test.
antifreeze greater than 60% cause deposits to form
and can result in radiator tube blockage and 4. Clean the pressure cap and inspect the pressure
overheating. cap. Install the pressure cap.
Note: This procedure pertains only to Caterpillar 5. Start the engine and check for leaks. Allow the
Diesel Engine Antifreeze/Coolant (DEAC). This coolant level to stabilise.
procedure does not pertain to machines that are
shipped from the factory with Extended Life Coolant 6. If necessary, add premixed coolant in order to
(ELC) and machines that are maintained with bring the coolant to the proper level in the sight
Extended Life Coolant (ELC). gauge.
Reference: For all cooling system requirements,
refer to Caterpillar Machine Fluids
Recommendations, SEBU6250, “Cooling System
Specifications”.

Use the 8T - 5296 Test Kit in order to check the

concentration.

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Flameproof Exhaust System - Inspect 3. Clean the filler cap in clean non flammable
solvent. Shake the breather dry or use pressure
air.

4. Install the clean filler cap.

Engine Air Intake System (Flame Trap) -

Inspect/Clean

1. Remove the eight capscrews that hold the flame

trap and air cleaner to the engine.

2. Remove the flame trap and air cleaner from the

engine.

Examine the exhaust system from the cylinder head

to the scrubber tank and ensure that there are no Do not clean the flame trap by bumping or tapping it.
leaks in the system. Do not use the flame trap with damaged gaskets.
Engine damage can result.
Rear Axle Trunnion Bearings - Inspect
Make sure the cleaned flame trap is completely dry
Inspect the rear axle trunnion bearings for excessive before installing them.
wear.
3. The flame trap can be cleaned by using the
Reference: For information on the rear axle trunnion following methods:
bearings, refer to the Specifications, “Power Train”
for the machine that is being serviced. z Pressure air.

Replace any parts that are worn or damaged. z Pressure water.

Hydraulic Tank Filler Cap - Clean z Detergent washing.

When you use pressure air, the maximum air

pressure is 205 kPa (30 PSI). When you use
pressure water, the maximum water pressure is 280
kPa (40 PSI).

1. Relieve the system pressure by moving the

bucket controls before removing the oil filler
cap.

2. Remove the oil filler cap slowly to relieve any

remaining pressure. 4. Install the clean flame trap, copper gasket and
air cleaner.

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5. Install the eight capscrews. Tighten the 5. Install the fuel tank cap.
capscrews.
Hydraulic System Oil Filter - Replace
EVERY 500 SERVICE HOURS OR 3
MONTHS
Fuel Tank Cap and Strainer - Clean
Hot oil and components can cause injury. Do not
allow hot oil or components to contact the skin.

Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting and repair of the
product. Be prepared to collect the fluid with suitable
containers before opening any compartment or
disassembling any component containing fluids.

Refer to Special Publication, NENG2500,

“Caterpillar Tools and Shop Products Guide”, for
tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations

and mandates.
When using air pressure wear a protective face
shield and protective clothing. The maximum air
pressure must be below 205 kPa (30 PSI) for
cleaning purposes.

1. Remove oil filler cap slowly to relieve the

pressure.

1. Remove the four socket screws and the filler

neck complete with the fill screen.

2. Wash the strainer in clean, non-flammable

solvent. Shake or blow dry.

3. Install the strainer.

4. Replace the four socket screws.

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6. Remove and discard filter elements from filter

element cover.

7. Inspect the cover seal for damage. Replace the

cover seal, if necessary.

8. Install new filter elements to the filter element

cover. Tighten the locknuts to a torque of 10 +
1.5 Nm (7 + 1 lb ft).

9. Install filter element cover.

2.
10. Inspect the oil filler cap gasket. Replace the
gasket if it is damaged.

11. Maintain the hydraulic oil level above the “ADD

COLD” mark in sight gauge with the engine
stopped and the bucket level on the ground.
Remove hydraulic tank oil filler strainer. Wash the Add oil, if necessary through the filler tube.
strainer in clean, non flammable solvent.
12. Install oil filler cap.
3. Install filler strainer in the filler tube.
Transmission Oil Filter - Replace

The machine must be level, the parking brake

engaged and the engine stopped.

Hot oil and components can cause injury. Do not

allow hot oil or components to contact the skin.

Care must be taken to ensure that fluids are

contained during performance of inspection,
4. Remove the cover with the two filter elements. maintenance, testing, adjusting and repair of the
product. Be prepared to collect the fluid with suitable
containers before opening any compartment or
disassembling any component containing fluids.

Refer to Special Publication, NENG2500,

“Caterpillar Tools and Shop Products Guide”, for
tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations

and mandates.

5. Remove locknut retaining the filter elements.

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The transmission oil filter is located on the left side 13. Maintain the transmission oil level between the
of the machine in front of the engine. “LOW” and “FULL” marks on dipstick with the
engine running at low idle.
1. Remove the drain plug from the bottom of the
filter housing and allow the oil to drain into a 14. Remove the oil filler cap and add oil, if necessary.
suitable container.
Reference: For information on lubricants and refill
2. Use a wrench in order to remove the filter capacities, refer to the Operation and Maintenance
housing. Manual, “Lubricant Viscosities and Refill Capacities”
for the machine that is being serviced.
3. Remove the used filter element. Dispose of the
used filter element properly. 15. Clean and install oil filler cap.

4. Clean the filter housing with a clean, non 16. Stop the engine.
flammable solvent.
Fuel System Secondary Filter - Replace
5. Clean the housing base.

6. Inspect the filter housing seal. Replace the seal

if the seal is damaged.

7. Install a new filter element into the transmission Personal injury or death can result if spilled fuel
filter housing. ignites. Fuel leaked or spilled onto hot surfaces
or electrical components can cause a fire.
8. Clean the filter housing drain plug and install the
drain plug. Install the filter housing into the filter
housing base.

9. Start and run the engine at low idle. Apply the Care must be taken to ensure that fluids are
service brakes. contained during performance of inspection,
maintenance, testing, adjusting and repair of the
10. Disengage the parking brake. Slowly operate product. Be prepared to collect the fluid with suitable
the transmission controls in order to circulate containers before opening any compartment or
the transmission oil. disassembling any component containing fluids.
11. Move the transmission directional control to the Refer to Special Publication, NENG2500,
NEUTRAL position. Engage the parking brake. “Caterpillar Tools and Shop Products Guide”, for
tools and supplies suitable to collect and contain
12. Inspect the transmission oil filter for leaks. fluids on Caterpillar products.

Dispose of all fluids according to local regulations

and mandates.

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Engine Crankcase Breather - Clean

The engine crankcase breather is located on top of

the engine valve cover.
Do not fill fuel filters before installing them. The fuel
will not be filtered and could be contaminated.
Contaminated fuel will cause accelerated wear to
fuel system parts. The fuel system should be primed 2
prior to starting the engine. 1

1. Loosen the hose clamp (1) and remove the

outlet hose from breather assembly (3).

2. Remove bolt (2) and the breather assembly.

3. Check the condition of the seal on the breather

1. Remove the fuel filter element with a strap-type
assembly cover. Replace the seal if the seal is
wrench. Discard the used filter.
damaged.
2. Clean the filter housing base. Make sure that all
4. Wash the breather assembly cover and the
of the old seal is removed from the filter base.
element in a clean, non flammable solvent.
3. Apply a thin film of clean engine oil to the new
5. Shake the element dry or use pressure air to dry
filter element seal.
the element.
4. Install the oil filter element by hand. Tighten the
6. Inspect the outlet hose for damage. Replace the
filter element until the sealing surface contacts
hose, if necessary.
the filter base. Tighten the filter element by an
additional 3/4 of a turn.
7. Install breather assembly (3) and bolt (2).
Note: There are rotation index marks on the filter,
8. Install the outlet hose and tighten hose clamp
that are spaced 90 degrees (1/4 turn) apart. Use
(1).
these rotation marks as a guide when tightening the
filter.

5. Prime the fuel system.

Reference: For information on priming the fuel

system, refer to the Operation and Maintenance
Manual, “Fuel System - Prime” for the machine that
is being serviced.

6. Start the engine and inspect the filter for leaks.

Make any necessary repairs.

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EVERY 1000 SERVICE HOURS OR and mandates.

6 MONTHLY Wipe covers and surfaces around the openings

before checking or adding oil. Park on a level
Brake Accumulator - Check surface.

Correct brake accumulator charge pressure is

necessary for efficient hydraulic brake operation.

Special tools and equipment are required to test the

accumulator.

Reference: For the correct testing and charging

procedures for the brake accumulator, refer to 1. Position the wheels so that the final drive fill/
Systems Operation, Testing and Adjusting, “Testing drain plugs are facing downward. Remove the
and Charging the Accumulator” for the machine that fill/drain plugs and allow the oil to drain into a
is being serviced, or consult Barloworld. suitable container. Clean the drain/fill plugs and
install the drain/fill plugs.
Differential and Final Drive Oil - Change

Hot oil and components can cause injury. Do not

allow hot oil or components to contact the skin.

Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting and repair of the
product. Be prepared to collect the fluid with suitable
containers before opening any compartment or
disassembling any component containing fluids. Location of the front differential drain plug

Refer to Special Publication, NENG2500,

“Caterpillar Tools and Shop Products Guide”, for
tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations

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Location of the rear differential drain plug 4. Remove the rear differential fill plug. Fill the
differential to the bottom of the plug opening.
2. Remove the differential drain plugs and allow
the oil to drain into a suitable container. Clean Reference: For information on lubricants and refill
the drain plugs and install the drain plugs. capacities, refer to the Operation and Maintenance
Manual, “Lubricant Viscosities and Refill Capacities”
for the machine that is being serviced.

5. Clean the fill plugs and install the fill plugs.

Location of the front differential fill plug

3. Remove the front differential fill plug. Fill the

differential to the bottom of the plug opening.
6. Position the wheels so that the fill/drain plugs
are even with the centre line of the wheel.
Remove the fill/drain plugs.

7. Fill the final drives slowly to the bottom of the

fill/drain openings.

Reference: For information on lubricants and refill

capacities, refer to the Operation and Maintenance
Manual, “Lubricant Viscosities and Refill Capacities”
for the machine that is being serviced.

8. Clean the fill/drain plugs and install the fill/drain

plugs.

9. Operate the machine for a few minutes and

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recheck the oil level. The oil level should reach Transmission Oil Change
the bottom of the fill/drain plug opening.

Reference: For information on lubricants and refill

capacities, refer to the Operation and Maintenance
Manual, “Differential and Final Drive Oil Level -
Check” for the machine that is being serviced. Hot oil and components can cause injury. Do not
allow hot oil or components to contact the skin.

Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting and repair of the
product. Be prepared to collect the fluid with suitable
containers before opening any compartment or
disassembling any component containing fluids.

Refer to Special Publication, NENG2500,

“Caterpillar Tools and Shop Products Guide”, for
tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Location of the front differential breather Dispose of all fluids according to local regulations
and mandates.

1. Operate the machine for a few minutes in order

to warm the transmission oil.

2. Park the machine on a level surface. Lower the

bucket to the ground and apply slight downward
pressure. Engage the parking brake. Stop the
engine.

Location of the rear differential breather

10. Remove the front and rear Differential

breathers.

11. Wash the breathers in clean, non flammable

solvent.

12. Install the clean breathers.

3. Remove drain plug and drain the oil into a
suitable container.

4. Change the transmission oil filter element.

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Reference: For the correct procedure, refer to the

Operation and Maintenance Manual, “Transmission
Oil Filter - Replace” for the machine that is being
serviced.

15. Remove transmission breather. Wash the

transmission breather in clean, non flammable
solvent. Install the breather.

5. Remove the four bolts, cover and the seal that 16. Remove the oil filler cap and fill the transmission
hold the magnetic screen assembly in place. with oil.

6. Remove the magnetic screen assembly from Reference: For information on lubricants and refill
the transmission housing. capacities, refer to the Operation and Maintenance
Manual, “Lubricant Viscosities and Refill Capacities”
7. Remove the magnetic tube assembly from the for the machine that is being serviced.
screen.
17. Start and run the engine at low idle. Inspect the
8. Wash the tube assembly and the screen in a machine for leaks.
clean, non flammable solvent.
18. Apply the service brakes.
9. Clean the magnets with a cloth, stiff bristle
brush, or pressure air. 19. Disengage the parking brake. Slowly operate
the transmission controls in order to circulate
the transmission oil.

20. Move the transmission directional control to the

NEUTRAL position. Engage the parking brake.
Do not drop or wrap the magnets against any hard
objects. Replace any damaged magnets. 21. Maintain the transmission oil level between the
“LOW” and “FULL” marks on dipstick with the
10. Clean the cover. Inspect the cover seal. engine running at low idle.
Replace the seal if it is damaged.
22. Remove the oil filler cap and add oil, if necessary.
11. Insert the magnets in the screen.
23. Clean and install oil filler cap.
12. Insert the screen, tube and magnets in the
torque converter housing. 24. Stop the engine.
13. Install the seal, the cover and the four bolts.

14. Clean the drain plug and install the drain plug.

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Rollover Protective Structure (ROPS) - EVERY 2000 SERVICE HOURS OR

Inspect 1 YEAR
Brake Discs - Check

Do not attempt to straighten the ROPS structure. Do

not repair the ROPS by welding reinforcement plates
to the structure.

If there are any cracks in the welds, in the castings,

or in any metal section of the ROPS, consult
Barloworld for repairs.

It is necessary to monitor brake disc wear to

maintain an efficient braking system and prevent
unnecessary wear to brake system components. The
wheel brake disc wear can be checked without
having to remove the wheel brake assembly.
Reference: For information on checking the brake
disc wear, refer to Systems Operation, Testing and
Adjusting, “Brake Disc Wear - Check” for the
machine that is being serviced.

Crankshaft Vibration Damper - Inspect

Inspect the ROPS for bolts that are loose or

damaged. Use original equipment parts only to
replace bolts that are damaged or missing. Tighten
the mounting bolts to the correct torque.

Reference: For the correct bolt torques, refer to the

Power Train Specifications, “Cab Mounting” for the
machine that is being serviced.

Note: Apply thread lubricant to all ROPS bolt threads

before installation. Failure to apply lubricant can
result in improper bolt torque.

Replace ROPS mounting supports if the ROPS

rattles or makes a noise when the machine is
operated on a rough surface.

Do not repair the ROPS by welding reinforcement

plates to the ROPS. Consult Barloworld for repair of
cracks in any welds, in any castings, or any metal
section of the ROPS.

Ensure any certification labels are firmly fixed and The crankshaft vibration damper is located at the rear
legible. of the machine on the front of the engine.

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Damage to the vibration damper or failure of the The initial adjustment is necessary due to initial wear
vibration damper will increase torsional vibrations. of the valve train components and seating of the valve
These vibrations will result in damage to the train components.
crankshaft and in damage to other engine
components. A deteriorating vibration damper will This maintenance is recommended by Barloworld as
cause excessive gear train noise at variable points part of a lubrication and preventative maintenance
in the speed range. schedule in order to help provide maximum engine life.

Barloworld recommends replacing the vibration

damper for any of the following reasons:

z The engine has had a failure because of a

broken crankshaft. Only qualified service personnel should perform this
z The S-O-S oil analysis detected a worn maintenance. Refer to the Service Manual or
crankshaft front bearing. Barloworld for the complete valve lash adjustment
z The S-O-S oil analysis detected a large amount procedure.
of gear train wear that is not caused by a lack of
oil. Operation of Caterpillar engines with improper valve
z The alignment marks on the hub and on the adjustments can reduce engine efficiency. This
outer ring are not in alignment because the reduced efficiency could result in excessive fuel
rubber seal has separated usage and/or shortened engine component life.

The vibration damper can be used again if none of

the above conditions are found and the damper is
not damaged.
Ensure that the engine can not be started while
Inspect the vibration damper assembly for dents in this maintenance is being performed. To help
the outer case. Dents in the outer case may cause prevent possible injury, do not use the starting
failure of the damper assembly. Install a new motor to turn the flywheel.
vibration damper if the damper is damaged.
Hot engine components can cause burns. Allow
Engine Mounts - Inspect additional time for the engine to cool before
measuring/adjusting valve lash clearance.

Engine Valve Rotators - Inspect

When inspecting the valve rotators, protective

glasses or face shield and protective clothing
must be worn, to help prevent being burned by
hot oil or spray.

A valve rotator which does not operate properly will

Barloworld recommends inspecting the engine mounts accelerate valve face wear and valve seat wear and
for deterioration and for proper bolt torque. This will shorten valve life. If a damaged rotator is not
help to prevent excessive engine vibration that is replaced, valve face guttering could result and
caused by improper mounting. cause pieces of the valve to fall into the cylinder.
This can cause piston and cylinder head damage.
Engine Valve Lash - Check/Adjust
Valve rotators cause the valve to rotate when the
The initial valve lash adjustment on new engines, engine runs. This helps to prevent deposits from
rebuilt engines, or remanufactured engines is building up on the valve and the valve seats.
recommended at the first scheduled oil change.

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Engage the parking brake and stop the engine.

Perform the following steps after the valve lash is

set, but before the valve covers are installed:
1. Relieve the system pressure by moving the
1. Start the engine. Operate the engine at low idle bucket controls - before removing the oil filler
cap.
2. Observe the top surface of each valve rotator.
The valve rotators should turn slightly when the 2. Remove oil filler cap slowly to relieve any
valves close. remaining pressure.

If the valve fails to rotate, contact Barloworld.

Hydraulic System Oil - Change

Hot oil and components can cause injury. Do not

allow hot oil or components to contact the skin.
3.

Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting and repair of the Remove hydraulic tank drain plug. (Shown here
product. Be prepared to collect the fluid with suitable with tank removed and on its side).
containers before opening any compartment or
disassembling any component containing fluids. 4. Install a 1 inch NPT pipe nipple to unseat the
drain valve. Allow the oil to drain.
Refer to Special Publication, NENG2500,
“Caterpillar Tools and Shop Products Guide”, for
tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations Install the drainpipe nipple only finger tight until oil
and mandates. starts to drain. DO NOT force the pipe into the
valve.
Operate the machine for a few minutes in order to This will damage the drain valve and cause leakage.
warm the hydraulic system oil.
5. Change the hydraulic system oil filters.
Park the machine on level ground. Lower the bucket
to the ground and apply slight downward pressure. Reference: For the correct procedure, refer to the

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Operation and Maintenance Manual, “Hydraulic 15. If necessary, tighten any loose clamps or any
System Oil Filter - Replace” for the machine that is loose connections. Replace any damaged hoses.
being serviced.
EVERY 3000 SERVICE HOURS OR
6. Remove the strainer from the hydraulic oil filler
tube. 2 YEARS
7. Wash the oil filler cap and the strainer in clean, Cooling System Coolant (DEAC) -
nonflammable solvent. Allow the oil filler cap Change
and the strainer to dry.

8. Inspect the oil filler cap gasket. Use a new

gasket if the used gasket is damaged. Install the
strainer in the filler tube.
Pressurised system: Hot coolant can cause
9. Remove the pipe nipple from the drain valve. serious burn. To open cap, stop engine, and
wait until radiator is cool. Then loosen the cap
10. Inspect the drain plug seal. Replace the seal, if it slowly to relieve the pressure.
is damaged. Clean and install the tank drain plug.

11. Fill the hydraulic tank with clean oil. Make sure
that the oil level is at the “FULL” mark on the
sight gauge. Install the filler cap.
Care must be taken to ensure that fluids are
Reference: For information on lubricants and refill contained during performance of inspection,
capacities, refer to the Operation and Maintenance maintenance, testing, adjusting and repair of the
Manual, “Lubricant Viscosities and Refill Capacities” product. Be prepared to collect the fluid with suitable
for the machine that is being serviced. containers before opening any compartment or
disassembling any component containing fluids.
12. Start the engine and run the engine at low idle.
Refer to Special Publication, NENG2500, “Caterpillar
Check for leaks.
Tools and Shop Products Guide”, for tools and
supplies suitable to collect and contain fluids on
Caterpillar products.

Dispose of all fluids according to local regulations

and mandates.

Do not change the coolant until you read and

understand the cooling system information in
Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations”.

Failure to do so could result in damage to the

cooling system components.
13. Maintain the oil level above the “ADD COLD”
Note: This procedure pertains only to Caterpillar
mark in sight gauge. Add more oil, if necessary
Diesel Engine Antifreeze/Coolant (DEAC). This
through filler tube.
procedure does not pertain to machines that are
shipped from the factory with Extended Life Coolant
Note: The oil must be free of bubbles. If bubbles are
(ELC) and machines that are maintained with
present in the oil, air is entering the hydraulic
Extended Life Coolant (ELC).
system. Inspect the hydraulic suction line hoses and
the hose clamps.
If the coolant is dirty or if you observe any foaming
in the cooling system, drain the coolant before the
14. Stop the engine.
recommended interval.

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help avoid air locks, 20 L (5 US gal) per minute.

Reference: For information on lubricants and refill

capacities, refer to the Operation and Maintenance
Manual, “Lubricant Viscosities and Refill Capacities”
for the machine that is being serviced.

9. Start the engine. Run the engine with cooling

system pressure cap removed. Run the engine
until the water temperature regulator opens and
the coolant level stabilizes.

Note: If you are using Caterpillar antifreeze, do not

add supplemental coolant additive or change the
coolant conditioner element at this time.

1. Loosen the pressure cap slowly to relieve

cooling system pressure. Remove the pressure
cap.

10. Maintain the coolant level to within 13mm (0.50

inch) of the bottom of the filler pipe or to the
proper level in the sight gauge.

11. Install the cooling system pressure cap.

2. Remove the bottom guard. 12. Stop the engine.
3. Remove the drain plug for the engine cooling
system. Drain the coolant into a suitable
Cooling System Coolant Extender (ELC)
container. The drain plug is located on the - Add
bottom radiator tube.

4. Install the drain plug. Fill the system with clean

water and a 6 to 10 percent concentration of
cooling system cleaner. Personal injury can result from hot coolant,
steam and alkali.
5. Start and run the engine for 90 minutes. Stop
the engine and drain the cleaning solution into a At operating temperature, engine coolant is hot
suitable container. and under pressure. The radiator and all lines to
heaters or the engine contain hot coolant or
6. When the engine is stopped, flush the cooling steam. Any contact can cause severe burns.
system with water until the draining water is
clear. Drain the water into a suitable container. Remove cooling system pressure cap slowly to
relieve pressure only when engine is stopped
7. Install the drain plug. and cooling system pressure cap is cool enough
to touch with your bare hand.
8. Add the coolant solution. Add coolant slowly to

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Do not attempt to tighten hose connections when 1. Loosen the pressure cap slowly to relieve cooling
the coolant is hot, the hose can come off causing system pressure. Remove the pressure cap.
burns.
2. Inspect the pressure cap for damage, foreign
Cooling System Coolant Additive contains alkali. material and for deposits.
Avoid contact with shin and eyes.
3. Inspect the condition of the pressure cap seal.
1. Loosen the pressure cap slowly to relieve Replace the pressure if damaged. If the seal is
cooling system pressure. Remove the pressure not damaged, use a 9S-8140 Pressurising
cap. Pump to pressure test the cap. The correct cap
relief pressure is stamped on the radiator cap. If
2. It may be necessary to drain enough coolant the pressure cap does not hold the correct
from the radiator to allow for the addition of the pressure, install a new cap.
liquid supplemental coolant additive.
4. Install the pressure cap.
Note: Make sure that the coolant is drained into a
suitable container. EVERY 3 YEARS
3. Add the recommended amount of ELC Extender
to the cooling system.
Seat Belt - Replace

4. Clean the pressure cap and inspect the pressure

cap. Install the pressure cap.

5. Start the engine and check for leaks. Allow the

coolant level to stabilise.

6. If necessary, add premixed coolant in order to

bring the coolant to the proper level in the sight
gauge.

Cooling System Pressure Cap - Clean/ Regardless of the appearance of the seat belt, the
Replace seat belt should be replaced at every three year
interval. A date bale is attached to each seat belt.
Use this bale in order to determine the age of the
seat belt.

Consult Barloworld for replacement of the seat belt.

Pressurised system: Hot coolant can cause
serious burn. To open cap, stop engine, wait EVERY 6000 SERVICE HOURS OR
until radiator is cool. Loosen the cap slowly to
relieve the pressure. 4 YEARS
Cooling System Coolant Extender (ELC)
- Change

Pressurised system: Hot coolant can cause

serious burn. To open cap, stop engine, wait
until radiator is cool. Loosen the cap slowly to
relieve the pressure.

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Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting and repair of the
product. Be prepared to collect the fluid with suitable
containers before opening any compartment or
disassembling any component containing fluids.

Refer to Special Publication, NENG2500,

“Caterpillar Tools and Shop Products Guide”, for
tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations

and mandates.
1. Loosen the pressure cap slowly to relieve
cooling system pressure. Remove the pressure
cap.

Do not change the coolant until you read and

understand the cooling system information in Special
Publication, SEBU6250, “Caterpillar Machine Fluids
Recommendations”.

Failure to do so could result in damage to the

cooling system components.

Mixing ELC with other products reduces the

effectiveness of the coolant and shortens coolant
life. Use only Caterpillar products or commercial
products that have passed the Caterpillar EC-1
specifications for premixed or concentrate coolants.
2. Remove the bottom guard.
Use only Caterpillar Extender with Caterpillar ELC.
Failure to follow these recommendations could result
3. Remove the drain plug for the engine cooling
in damage to cooling system components.
system. Drain the coolant into a suitable
container. The drain plug is located on the
If ELC cooling system contamination occurs see the
bottom radiator tube.
topic Extended Life Coolant (ELC) in the Operation
and Maintenance Manual, SEBU6250, Caterpillar
4. Install the drain plug. Fill the system with clean
Machine Fluids Recommendations”.
water and a 6 to 10 percent concentration of
cooling system cleaner.
Note: This procedure pertains to machine using
Extended Life Coolant (ELC) only.
5. Start and run the engine for 90 minutes. Stop
the engine and drain the cleaning solution into a
If the coolant is dirty or if you observe any foaming
suitable container.
in the cooling system, drain the coolant before the
recommended interval.
6. When the engine is stopped, flush the cooling
system with water until the draining water is
clear. Drain the water into a suitable container.

7. Install the drain plug.

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OPERATORS/MAINTENANCE MANUAL MAINTENANCE

8. Add the coolant solution. Add coolant slowly to The water temperature regulator should be
help avoid air locks, 20 L (5 US gal) per minute. replaced after the cooling system has been
cleaned. Replace the water temperature
Reference: For information on lubricants and refill regulator while cooling system is completely
capacities, refer to the Operation and Maintenance drained or while cooling system coolant is
Manual, “Lubricant Viscosities and Refill Capacities” drained to a level that is below the water
for the machine that is being serviced. temperature regulator housing.

9. Start the engine. Run the engine with cooling

system pressure cap removed. Run the engine
until the water temperature regulator opens and
the coolant level stabilizes.
Failure to replace the engine’s water temperature
regulator on a regularly schedules basis could cause
severe engine damage.

Note: If you are only replacing a water temperature

regulator, drain the cooling system coolant to a level
that is below the water temperature regulator housing.

Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting and repair of the
product. Be prepared to collect the fluid with suitable
containers before opening any compartment or
disassembling any component containing fluids.
10. Maintain the coolant level to within 13mm (0.50
Refer to Special Publication, NENG2500,
inch) of the bottom of the filler pipe or to the
“Caterpillar Tools and Shop Products Guide”, for
proper level in the sight gauge.
tools and supplies suitable to collect and contain
fluids on Caterpillar products.
11. Install the cooling system pressure cap.
Dispose of all fluids according to local regulations
12. Stop the engine.
and mandates.
Cooling System Water Temperature
Regulator - Replace

Pressurised system: Hot coolant can cause

serious burn. To open cap, stop engine, wait
until radiator is cool. Loosen the cap slowly to
relieve the pressure.

Replace the water temperature regulator on a

regular basis in order to reduce the chance of
unscheduled downtime and of problems with
the cooling system.

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MAINTENANCE OPERATORS/MAINTENANCE MANUAL

1. Remove water temperature regulator housing.

Engine Water Pump - Inspect

2. Remove the gasket, the water temperature

regulator and the seal from the water
temperature regulator housing.

Former water temperature regulators may be used,

if they meet the test specifications and are not
damaged or have excessive buildup or deposits.

Since Caterpillar engines incorporate a shunt design

cooling system, it is mandatory to always operate
the engine with a water temperature regulator. A water pump that has failed may cause severe
engine overheating problems. The engine
Depending on load, failure to operate with a water overheating problems could result in the following
temperature regulator could result in either in problems:
overheating or an overcooling condition.
z Cracks in the cylinder head.
z Piston seizure.
z Other potential engine damage.

Visually inspect the water pump for leaks. If leaks

If the water temperature regulator is installed
are found, all of the seals on the water pump must
incorrectly, it will cause the engine to overheat.
be replaced.
3. Install a new seal in the water temperature
Note: For further information, refer to Disassembly and
regulator housing. Install the water temperature
Assembly, “3306B Engine” for the machine that is
regulator and a new gasket. Install the water
being serviced.
temperature regulator housing and hose.

4. Refill the cooling system.

Reference: For all cooling system requirements,

refer to the Operation and Maintenance Manual,
SEBU6250 “Caterpillar Machine Fluids
Recommendations”.

Reference: For information on lubricants and refill

capacities, refer to the Operation and Maintenance
Manual, “Lubricant Viscosities and Refill Capacities”
for the machine that is being serviced.

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OPERATORS/MAINTENANCE MANUAL REFERENCE INFORMATION

Reference Information Section Operation and Maintenance Manual, SEBU5898,

“Cold Weather Recommendations”
Reference Material Special Publication, PEHP7076, “Understanding the
S-O-S Services Test”
Caterpillar Reference Material
The following literature can be obtained through any Special Publication, PEHP6001, “How to Take a
Caterpillar dealer. Good Oil Sample”
Special Publication, PEHP8038, “Product Data Special Publication, PEHP4036, “Product Data
Sheet for Caterpillar Diesel Engine Oils (DEO)” Sheet for Caterpillar ELC”
CH-4 Engine Oils, (North America, Australia)
Special Publication, PEHP5033, “S-O-S Coolant
Special Publication, PEHP6046, “Product Data Analysis”
Sheet for Caterpillar Diesel Engine Oils (DEO)”
CG-4 Engine Oils (North America and Australia) Special Publication, SEBD0518, “Know Your Cooling
System”
Special Publication, PEHP7041, “Product Data
Sheet for Caterpillar Diesel Engine Oils (DEO)” Special Publication, SEBD0970, “Coolant and Your
CG-4 Engine Oils (International Markets) Engine”
Special Publication, LEDQ7315, “CG-4 Oil The Special Publication, PEEP5027, “Label - ELC
Preferred Oil for Caterpillar Engines” Radiator Label”
Special Publication, PEHP0005, “Product Data Special Instruction, SEHS7332, “Do Not Operate
Sheet for Caterpillar Hydraulic Oil (HYDO)” Warning Tag”
Special Publication, PEHP3050, “Product Data Special Instruction, SEHS7663, “Battery Test
Sheet for Caterpillar Multipurpose Tractor Oil (MTO)” Procedure”
Special Publication, PEHP7506, “Product Data Special Instruction, SEHS7768, “Use of 6V-2150
Sheet for CaterpillarTransmission/Drive Train Oil Starting Charging Analyzer Group”
(TDTO)”
Special Instruction, SMHS7867, “Battery Test
Special Publication, NEHP5621, “How To Select The Procedure”
Right Grease For Any Job”. This publication lists
the typical characteristics for eleven of Caterpillar’s Special Instruction, SEHS9031, “Storage Procedure
greases. for Caterpillar Products”
Special Publication, PEHP0003, “Product Data Operation and Maintenance Manual, SEBU6250,
Sheet for Multipurpose Lithium Complex Grease “Caterpillar Machine Fluids Recommendations”
(MPG)”
Operation and Maintenance Manual, SEBU6310, “
Special Publication, PEHP0002, “Product Data EMA Lubricating Oils Data Book For Engines”
Sheet for Multipurpose Lithium Complex Grease
with Molybdenum (MPGM)” Service Manual, RENR6923, “R1300G Load Haul
Dump”
Special Publication, PEHP0017, “Product Data
Sheet for Special Purpose Grease (SPG) Bearing Parts Manual, SEBP3603, “R1300G Load Haul
Lubricant” Dump”
Special Publication, NENG2500, “Tools and Shop Service Sheet, RENR6941, “R1300G Load Haul
Products Guide” Dump - 10 Hours/Daily to 6000 Hours/4 Years”
Special Publication, SEBD0640, “Oil and Your Maintenance Manual, RENR4501, “Emission Control
Engine” Systems”
Special Publication, SEBD0717, “Diesel Fuels and
Your Engine”

100 Revision 2
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REFERENCE INFORMATION OPERATORS/MAINTENANCE MANUAL

Systems Operation, Testing and Adjusting,

RENR4671, “Automatic Lubrication System -
Hydraulic Type”

Maintenance Manual, RENR4700, “Machine Repairs

and Welding Procedures”

Operation and Maintenance Manuals are available

in other languages. Consult your Caterpillar dealer
about obtaining these Operation and Maintenance
Manuals.

Additional Reference Material

ASTM D2896, “TBN Measurements” This can

normally be obtained from your local technological
society, from your local library or from your local
college.

SAE J313, “Diesel Fuels” This can be found in

the SAE handbook. Also, this publication can be
obtained from your local technological society, from
your local library, or from your local college.

SAE J754, “Nomenclature” This can normally be

found in the SAE handbook.

SAE J183, “Classification” This can normally be

found in the SAE handbook.
Engine Manufacturers Association, “Lubricating Oils
Data Book”

Engine Manufacturers Association

Two North LaSalle Street, Suite 2200
Chicago, Illinois, USA 60602
E-mail: [email protected]
(312) 827-8700
Facsimile: (312) 827-8737

Decommissioning and Disposal

SMCS Code: 1000; 7000

Disposal of your machine will vary with local

regulations. Consult your nearest Caterpillar dealer
for additional information on disposal.

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OPERATORS/MAINTENANCE MANUAL SERVICE SHEETS

LHD356 SERVICE SHEET (Daily - 10 Hour) Sheet 1

Use the following maintenance chart in conjunction with the machine Lubrication & Maintenance Guide
when performing machine service. For information on Specifications, Systems Operation, Testing &
Adjusting make reference to the specific section of the machine Service Manual.

Machine Model: Date Serviced:

Customer Unit No.: Job No.:

Serial No.: Serviced By:

Service Meter Reading:

Item Service Lube P ag e

1. Walk around inspection. Service inspection.

2. Engine. Check oil level. Top up if necessary.

Inspect coolant in the sight glass

3. Cooling System. (Radiator Top Tank). Top up if
necessary.

4. Engine Air Cleaner. Clean if necessary.

5. *Air Reservoirs –starter. Drain moisture and sediment.

6. Scrubber Auxiliary Tank. Top up with water to the filler neck.

7. Transmission. Check oil level & top up if necessary.

8. Hydraulic System. Check oil level & top up if necessary.

Drain water and sediment, top up with

9. Fuel Tank.
fuel.

10. Seat Belt. Inspect for wear and damage.

11. Articulated Hitch Bearing. Lubricate 2 fittings.

12. Belts. Inspect/Adjust/Replace.

13. Braking System. Test.

14. Bucket Pivot Bearings. Lubricate 2 fittings.

15. Ejector Pivot Bearings. Lubricate 2 fittings.

16. Ejector Cylinder Bearings. Lubricate 4 fittings.

17. Gauges. Inspect and Test.

18. Lift Arm and Cylinder Bearings. Lubricate 6 fittings.

19. Rear Axle Trunnion Bearings. Lubricate 2 fittings.

20. Steering Cylinder Bearings. Lubricate 4 fittings.

21. Tilt Cylinder and Lever Bearings. Lubricate 3 fittings.

22. Tilt Linkage Bearings. Lubricate 2 fittings.

102 Revision 2
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SERVICE SHEETS OPERATORS/MAINTENANCE MANUAL

LHD356 SERVICE SHEET (Daily - 10 Hour) Sheet 2

Use the following maintenance chart in conjunction with the machine Lubrication & Maintenance Guide
when performing machine service. For information on Specifications, Systems Operation, Testing &
Adjusting make reference to the specific section of the machine Service Manual.

Machine Model: Date Serviced:

Customer Unit No.: Job No.:

Serial No.: Serviced By:

Service Meter Reading:

Item Service Lube P ag e

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

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OPERATORS/MAINTENANCE MANUAL SERVICE SHEETS

LHD356 SERVICE SHEET (Weekly - 50 Hour)

Use the following maintenance chart in conjunction with the machine Lubrication & Maintenance Guide
when performing machine service. For information on Specifications, Systems Operation, Testing &
Adjusting make reference to the specific section of the machine Service Manual.

Machine Model: Date Serviced:

Customer Unit No.: Job No.:

Serial No.: Serviced By:

Service Meter Reading:

NOTE: Perform the previous “SERVICE HOURS” requirements first.

Item Service Lube P ag e

Every 50 Service Hours or Weekly

Measure inflation pressure - inspect for

1. Tyres.
damage. Adjust pressure if necessary.

2. Jockey Pulley & Fan Bearings. Lubricate 2 fittings.

3. Wheel Nuts. Torque to 475 + 50 N.m.

4. Scrubber Tank. Clean the inside of the tank/Inspect.

N o. C h eck Comments

1.

2.

3.

4.

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SERVICE SHEETS OPERATORS/MAINTENANCE MANUAL

LHD356 SERVICE SHEET (Monthly - 250 Hour) Sheet 1

Use the following maintenance chart in conjunction with the machine Lubrication & Maintenance Guide
when performing machine service. For information on Specifications, Systems Operation, Testing &
Adjusting make reference to the specific section of the machine Service Manual.

Machine Model: Date Serviced:

Customer Unit No.: Job No.:

Serial No.: Serviced By:

Service Meter Reading:

NOTE: Perform the previous “SERVICE HOURS” requirements first.

Item Service Lube P ag e

Every 250 Service Hours or Monthly

1. Engine Crankcase. Change oil and filters.

2. Articulated Hitch Bearings. Inspect.

3. Intake System (Flametrap). Inspect/Cean.

4. Drive Shaft Spline/Universal. Inspect/Lubricate 9 Fittings.

5. Collet Pin Bolt. Check torque.

Add cooling system conditioner

6. Cooling System.
(1/2 litre).

Replace the filter (maintenance)

7. Coolant Conditioner Unit.
element.

8. Differential and Final Drive. Check oil level.

9. Exhaust System. Inspect.

10. Primary Fuel Filter. Clean/Replace.

11. Hydraulic Tank Breather. Clean.

12. Axle Trunnion Bearings. Inspect.

13. Steering Stop. Check.

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OPERATORS/MAINTENANCE MANUAL SERVICE SHEETS

LHD356 SERVICE SHEET (Monthly - 250 Hour) Sheet 2

Use the following maintenance chart in conjunction with the machine Lubrication & Maintenance Guide
when performing machine service. For information on Specifications, Systems Operation, Testing &
Adjusting make reference to the specific section of the machine Service Manual.

Machine Model: Date Serviced:

Customer Unit No.: Job No.:

Serial No.: Serviced By:

Service Meter Reading:

N o. C h eck Comments

10

11

12

13

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SERVICE SHEETS OPERATORS/MAINTENANCE MANUAL

LHD356 SERVICE SHEET (3 Months - 500 Hour)

Use the following maintenance chart in conjunction with the machine Lubrication & Maintenance Guide
when performing machine service. For information on Specifications, Systems Operation, Testing &
Adjusting make reference to the specific section of the machine Service Manual.

Machine Model: Date Serviced:

Customer Unit No.: Job No.:

Serial No.: Serviced By:

Service Meter Reading:

NOTE: Perform the previous “SERVICE HOURS” requirements first.

Item Service Lube P ag e

Every 500 Service Hours or 3

Months

1. Fuel Tank Cap & Strainer. Wash tank cap and strainer.

2. Hydraulic System. Change the two filter elements.

3. Transmission. Change filter element.

Change secondary filter – prime fuel

4. Fuel System. (Secondary)
system.

5. Engine Crankcase Breather. Wash breather element.

N o. C h eck Comments

1.

2.

3.

4.

5.

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OPERATORS/MAINTENANCE MANUAL SERVICE SHEETS

LHD356 SERVICE SHEET (6 Months - 1000 Hour)

Use the following maintenance chart in conjunction with the machine Lubrication & Maintenance Guide
when performing machine service. For information on Specifications, Systems Operation, Testing &
Adjusting make reference to the specific section of the machine Service Manual.

Machine Model: Date Serviced:

Customer Unit No.: Job No.:

Serial No.: Serviced By:

Service Meter Reading:

NOTE: Perform the previous “SERVICE HOURS” requirements first.

Item Service Lube P ag e

Every 1000 Service Hours or 6

Months

Change oil, wash suction screen &

1. Transmission.
magnets, clean breather.

2. Brake Accumulator Check.

3. Differential and Final Drive. Change oil.

Rollover Protective Structure

4. Inspect - tighten bolts.
(ROPS).

N o. C h eck Comments

1.

2.

3.

4.

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SERVICE SHEETS OPERATORS/MAINTENANCE MANUAL

LHD356 SERVICE SHEET (1 Year - 2000 Hour)

Use the following maintenance chart in conjunction with the machine Lubrication & Maintenance Guide
when performing machine service. For information on Specifications, Systems Operation, Testing &
Adjusting make reference to the specific section of the machine Service Manual.

Machine Model: Date Serviced:

Customer Unit No.: Job No.:

Serial No.: Serviced By:

Service Meter Reading:

NOTE: Perform the previous “SERVICE HOURS” requirements first.

Item Service Lube P ag e

Every 2000 Service Hours or 1 Year

1. Brake Discs. Check disc wear.

Change oil, wash filter screen, inspect

2. Hydraulic System.
suction hose.

3. Crankshaft Vibration Damper. Inspect.

4. Engine Mounts. Inspect.

5. Engine Valve Lash. Measure – adjust if necessary.

6. Engine Valve Rotation. Check valve rotation.

N o. C h eck Comments

1.

2.

3.

4.

5.

6.

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OPERATORS/MAINTENANCE MANUAL SERVICE SHEETS

LHD356 SERVICE SHEET (2 Years - 3000 Hour)

Use the following maintenance chart in conjunction with the machine Lubrication & Maintenance Guide
when performing machine service. For information on Specifications, Systems Operation, Testing &
Adjusting make reference to the specific section of the machine Service Manual.

Machine Model: Date Serviced:

Customer Unit No.: Job No.:

Serial No.: Serviced By:

Service Meter Reading:

NOTE: Perform the previous “SERVICE HOURS” requirements first.

Item Service Lube P ag e

Every 3000 Service Hours or 3 Year

1. Cooling System Coolant (DEAC). Change.

Cooling System Coolant Extender

2. A dd.
(ELC).

3. Cooling System Pressure Cap. Clean/Replace.

N o. C h eck Comments

1.

2.

3.

110 Revision 2
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SERVICE SHEETS OPERATORS/MAINTENANCE MANUAL

LHD356 SERVICE SHEET (4 Year - 6000 Hour)

Use the following maintenance chart in conjunction with the machine Lubrication & Maintenance Guide
when performing machine service. For information on Specifications, Systems Operation, Testing &
Adjusting make reference to the specific section of the machine Service Manual.

Machine Model: Date Serviced:

Customer Unit No.: Job No.:

Serial No.: Serviced By:

Service Meter Reading:

NOTE: Perform the previous “SERVICE HOURS” requirements first.

Item Service Lube P ag e

Every 6000 Service Hours or 4 Year

1. Cooling System Coolant Extender Change.

(ELC).

2. Water Pump. Inspect.

3. Water Temperature Regulator. Replace.

N o. C h eck Comments

1.

2.

3.

Revision 2 111