02162-05167 Suzuki BOLT

Start By:a. remove hoodb. remove fan & fan guard assemblyFluid Spillage Containment
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "Tools and Shop Products Guide, NENG2500", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates. Drain all fluids in a suitable container for storage or disposal. 1. Open left hand access panel door (1). 2. Remove eight bolts (3) and the washers.
Be careful, the freon has NOT be removed from the system. Freon under pressure can cause personal injury.
Remove the refrigerant condenser by setting aside without removing the air conditioning lines.3. Pull the refrigerant condenser (4) forward away from the hydraulic oil cooler.4. Remove four bolts (2), the washers and refrigerant condenser bracket (5).
At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Drain the coolant only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap from the radiator slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to avoid personal injury.
Drain the coolant in a suitable container for storage or disposal. 5. Loosen valve (6) to drain the radiator through the radiator hose, which is located at the bottom of the machine below the radiator. 6. Remove lower radiator hose clamp (7) and lower radiator hose (8). Remove the hose only from the radiator side. 7. Remove radiator overflow hose (9) from the radiator.
At operating temperature, the hydraulic oil tank is hot and under pressure. Hot oil can cause burns. Remove the filler cap on the hydraulic oil tank only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Be sure all the hydraulic pressure is released before any fittings, hoses or components are loosened, tightened, removed or adjusted. Release Of Pressure In The Hydraulic System
8. Release the pressure in the implement hydraulic circuits (boom, stick, and bucket) before any hydraulic lines or components are disconnected or removed, as follows: a. Fully retract the stick cylinder rod.b. Adjust the position of the bucket so that 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 place key in the "ON" position. Put the hydraulic activation control lever in the "UNLOCK" position.e. Move the control levers for boom, stick and swing to all full stroke positions. This will release any pressure that might be present in the pilot system.f. Return the key to "OFF" position.g. Slowly loosen the fill plug on the hydraulic tank and release the pressure.h. Tighten the fill plug on the hydraulic tank. Tighten the fill plug to a Torque of 68 7 N m (50 5 lb ft).i. The pressure in the hydraulic system has been released and lines and components can be removed. As the lower hose is slid away from the hydraulic oil cooler, the hydraulic oil tank will drain. 9. Loosen lower hose clamps (10). 10. Slide the lower hose (11) away from the hydraulic oil cooler. As the lower hose (11) is slid away from the hydraulic oil cooler, the hydraulic oil tank will drain. Drain the hydraulic oil tank in a suitable container. 11. Remove four mounting bolts (12) and the washers from the bottom of the hydraulic oil cooler and the radiator assembly. 12. Remove two bolts (13) and the washers from the supporting braces on each corner of the radiator. 13. Loosen two hose clamps (14). 14. Disconnect upper hydraulic oil cooler hose (15).15. Using Tooling (A) and a lifting sling, attach a hoist to the hydraulic oil cooler/radiator assembly.16. Remove hydraulic oil cooler/radiator assembly. The weight of the hydraulic oil cooler/radiator assembly is 124 kg (273 lb). 17. Support the hydraulic oil cooler, while removing bolts (16) and the washers.18. Remove the hydraulic oil cooler from the radiator. The weight of the hydraulic oil cooler is 68 kg (150 lb). The following steps are for the installation of the hydraulic oil cooler/radiator assembly.19. Install the hydraulic oil cooler to the radiator.20. Install bolts (16) and the washers.21. Using Tooling (A) and a lifting sling, attach a hoist to the hydraulic oil cooler/radiator assembly.22. Install hydraulic oil cooler/radiator assembly.23. Install upper hydraulic oil cooler hose (15).24. Install and tighten two hose clamps (14).25. Install two bolts (13) and the washers to the supporting braces on each corner of the radiator.26. Install four mounting bolts (12) and the washers to the bottom of the hydraulic oil cooler and the radiator assembly.27. Install lower hose (11) to the hydraulic oil cooler.28. Install and tighten lower hose clamps (10).29. Install radiator overflow hose (9) to the radiator.30. Install lower radiator hose (8) and lower radiator hose clamp (7).31. Install refrigerant condenser bracket (5), four bolts (2), and the washers.32. Install eight bolts (3) and the washers.33. Close left hand access panel door (1). Refer to the Topic "Lubricant Viscosities and Refill Capacities" in the "Operation and Maintenance Manual" for the proper filling procedure and the proper levels for the hydraulic oil and coolant systems.End By:a. install fan & fan guard assemblyb. install hood