01107-08452 Suzuki Bolt

At operating temperature, the hydraulic tank oil is hot and under pressure. Hot oil can cause burns. To prevent possible personal injury, release the pressure in the implement hydraulic circuits (boom, stick and bucket) before any hydraulic lines or components are disconnected or removed.
Release the pressure in the hydraulic system as follows: a. Fully retract the rod in the stick cylinder.b. Adjust the position of the bucket so it will be flat on the ground when the boom is lowered.c. Lower the boom until the bucket is flat on the ground.d. Shut off the engine, and put the hydraulic activation control lever in the "Lock" position.e. Move the control levers for the boom, bucket, stick and swing through their full travel strokes. This will relieve any pressure that may be present in the pilot system.f. Slowly loosen the air breather cap on the hydraulic oil tank to release the pressure.g. Tighten the air breather cap on the hydraulic oil tank.h. The pressure in the hydraulic system has now been released. Lines and components can now be removed. Drain the hydraulic tank oil into a suitable container for storage or disposal.
At operating temperature, the engine coolant is hot and under pressure. Steam can cause burns. Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with skin and eyes to prevent possible personal injury.
Drain the radiator coolant into a suitable container for storage or disposal. 1. Open the right access door to the engine compartment. 2. Remove cover (1).3. Disconnect electrical connection (3).4. Remove bolt (2) from the P-clamps. 5. Remove bolt (4) from the shield bracket. 7. Remove bolts (6) and washers.8. Reposition governor control unit (7) within the pump compartment.9. Remove all shields (5) and braces between the main control pump and the engine. 10. Disconnect hose assembly (8). Cap or plug immediately. Mark or identify for later installation.11. Disconnect hose assembly (9). Cap or plug immediately. Mark or identify for later installation.12. Disconnect hose assembly (10). Cap or plug immediately. Mark or identify for later installation.13. Disconnect hose assembly (11). Cap or plug immediately. Mark or identify for later installation.14. Disconnect hose assembly (12). Cap or plug immediately. Mark or identify for later installation.15. Disconnect hose assembly (13). Cap or plug immediately. Mark or identify for later installation.16. Disconnect hose assembly (14). Cap or plug immediately. Mark or identify for later installation.17. Remove four bolts (15) (not shown) and washers. Plug openings immediately. Check O-ring for wear or damage. Replace if necessary.18. Disconnect hose assembly (16). Cap or plug immediately. Mark or identify for later installation. 19. Loosen two bolts (18).20. Remove four bolts (17).21. Remove guard (19). 22. Remove bolt (20) and the P-clamp holding wiring harness (21).23. Disconnect ground strap (22). 24. Loosen nut (25).25. Loosen nut (26).26. Disconnect cable assembly (23) from the pulley. The pulley has a slot in which the end of the cable slides.27. Disconnect cable assembly (24) from the pulley. The pulley has a slot in which the end of the cable slides. 28. Disconnect all the wires and cables from starter (27) and alternator (28). 29. Remove bolt (29) and bolt (30). 30. Disconnect electrical connection (31).31. Remove bolt (32). 32. Disconnect electrical connections (33).33. Disconnect electrical connections (34).34. Remove bolt (35). 35. Remove bolt (36).36. Remove two screws (37). 37. Loosen two clamps (38).38. Disconnect two lines (39). Cap or plug immediately to avoid contamination. 39. Loosen hose clamp (40).40. Disconnect upper radiator hose assembly (41). 41. Loosen clamp (42).42. Disconnect hose (43).43. Loosen clamp (44).44. Disconnect hose (45).
View From Under Machine45. Loosen clamp (46).46. Disconnect hose (47). 47. Loosen clamp (48). Disconnect hose (49). 48. Remove bolts (50) and washers.49. Remove fan guards (51). 50. Remove bolts (52).51. Remove fan (53). 52. Remove four bolts (54) washers, washers and rubber mounts from the engine mounts. Only two of the bolts, washers and rubber mounts are shown. 53. Attach chains and a suitable lifting device to lifting brackets (55).
There is limited space in the engine compartment. Prior to removing the engine and main hydraulic pump, be sure all hose assemblies, tube assemblies, electrical connections, nylon tie wraps, clips and P-clamps have been disconnected.
54. Slowly and carefully lift the engine and main hydraulic pump from the machine as a unit. The combined weight of the engine and pump is approximately 544 kg (1200 lb). For installation of the engine, reverse the removal steps.55. Fill the cooling system with coolant to the correct level. Fill the hydraulic oil tank with oil to the correct level. See the Operation & Maintenance Manual for the correct filling procedures.56. Start the engine and check its operation. Also, check for coolant and hydraulic oil leaks.End By:a. install engine hood assembly