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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine. |
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Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve the pressure. |
To relieve the pressure from the coolant system, turn off the machine. Allow the cooling system pressure cap to cool. Remove the cooling system pressure cap slowly to relieve pressure.
To relieve the pressure from the fuel system, turn off the engine.
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Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death. |
The high-pressure fuel lines are the fuel lines that are between the high-pressure fuel pump and the high-pressure fuel manifold and the fuel lines that are between the fuel manifold and cylinder head. These fuel lines are different from fuel lines on other fuel systems because of the following differences:
- The high-pressure fuel lines are constantly charged with high pressure.
- The internal pressures of the high-pressure fuel lines are higher than other types of fuel system.
Before any service or repair is performed on the engine fuel lines, perform the following tasks:
- Stop the engine.
- Wait for 10 minutes.
Note: Fuel pressure can be monitored by Caterpillar Electronic Technician (ET).
Do not loosen the high-pressure fuel lines to purge trapped air from the fuel system.
To relieve the pressure from the engine oil system, turn off the machine. Verify that pressure has been released before performing any service.
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Hydraulic oil pressure can remain in the hydraulic system on this machine after the engine and pump have been stopped. Serious injury can result if this pressure is not released before any service is done on the hydraulic system. In order to prevent possible injury, release the hydraulic system pressure before working on any fitting, hose, or hydraulic component. Lower all work tools to the ground before service is started. If the hydraulic system must be serviced, tested, or adjusted with the work tool in the raised position, the work tool and lift cylinders must be supported properly. Always move the machine to a location away from the travel of other machines. Be sure that other personnel are not near the machine when the engine is running and tests or adjustments are being made. |
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Escaping fluid under pressure, even a pinhole size leak, can penetrate body tissue, causing serious injury, and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak. |
Note: Use this procedure to drain pressure from all accumulators and release trapped pressure in all systems.
Note: Permit only one operator on the machine. Keep all other personnel away from the machine or in the operator's sight.
- Move the machine to a hard, level surface.
- Place the transmission direction and speed control in the NEUTRAL position and in any speed position.
- Engage the parking brake. Place wheel blocks in front of the wheels and behind the wheels.
- When the work tool is raised for testing or for adjusting, make sure that the work tool is supported correctly. Also, make sure that the work tool is fully in the DUMP position. The lift circuit has high oil pressure when the lift arms raise the front of the machine.
Note: Do not stop the machine with the front of the machine off the ground unless this is required for a test. Lower the machine to the ground and stop the engine.
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Illustration 1 g06192122 - Position bucket just above the ground at a slight downward angle. This position will ensure that the head end of the lift cylinder is pressurized.
- If the machine is equipped with a ride control system, increase the engine speed above 1500 rpm, press, and hold the ride control switch to activate the service mode. Move the joystick control lever to the Float position, to relieve all the hydraulic pressure in the ride control accumulator.
- Decrease the engine speed to low idle.
- Stop the engine.
- Install the steering frame lock. Refer to Operation Maintenance Manual, "Steering Frame Lock".
- Move the key start switch to the ON position.
- Move the joystick control lever to the FLOAT position.
- Move the control lever to the Tilt back position. This action allows the bucket to tilt back while the lift arms are lowered.
The bottom of the bucket should rest flat on the ground. The weight of the linkage should be supported by the ground. The pressure from the head end of the lift cylinders and from the ride control accumulator is now vented to the hydraulic tank.
- When the bucket has settled to the ground, move the joystick control lever to the HOLD position. Repeatedly cycle the joystick control lever through all positions to purge any remaining pressure from the implement hydraulic system and drain the pilot accumulator completely.
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Illustration 2 g06266798 - Using monitor display (1), access Menu > Service > Parameters > Implements > Tilt Cylinder Pressure. If there is any pressure on the gauge, move the joystick control lever through the full range of travel until pressure is removed from the system.
- Turn the engine start switch to the OFF position.
- Depress the breaker relief valve on the hydraulic tank to release the pressure in the hydraulic tank.
- The pressure in the hydraulic system has now been released. The lines, fittings, and components can be removed.
Release Procedure (Steering System and Braking System)
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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. |
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Escaping fluid under pressure, even a pinhole size leak, can penetrate body tissue, causing serious injury, and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak. |
- Move the machine to a hard, level surface.
- Place the transmission direction and speed control in the NEUTRAL position and in any speed position.
- Engage the parking brake. Place wheel blocks in front of the wheels and behind the wheels.
- Lower the bucket to the ground and stop the engine.
- Install the steering frame lock. Refer to Operation Maintenance Manual, "Steering Frame Lock".
- Turn the engine start switch to the On position.
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Illustration 3 g06266798 - Using monitor display (1), access Menu > Service > Parameters > Brakes > Brake Accumulator Oil Pressure. Depress the service brake pedal repeatedly until there is no oil pressure in the brake hydraulic system.
- Depress the breaker relief valve on the hydraulic tank to release the pressure in the hydraulic tank.
- To release pressure from steering cylinders, the machine must not be operated for a minimum of 10 minutes. 10 minutes will allow sufficient time for the pressure in the steering system to dissipate.