09103-06044 Suzuki Bolt 6x28

Table 1
Revision History
Revision Summary of Changes
01 Updated Effectivity Some machines may appear to have excess oil in the sight glasses for the flywheel housing coupling, which can lead to misdiagnosis of a failed crankshaft seal.Use the procedure below to determine the root cause of excessive oil, if the sight glasses appear full on the flywheel housing coupling.
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
Procedure
Park the machine on the level ground.Note: The machine must sit no less than 8 hours since being operated last to allow the fluid temperatures to reach ambient temperatures.
If the oil level is within or below the sight gauge and an external leak is observed, use the following procedure.
Document the oil level in the sight glass of the coupling housing by photographing sight glass.
Repair the external leak in the pump housing system.
If the oil level is above the sight gauge, use the following procedure.
Document the oil level in the sight glass of the flywheel housing by taking a photo of the sight glass.
Drain the flywheel housing fluid into a measuring container for 30 minutes.
Record the volume of the drained fluid in the container.
Refill the coupling housing with 650 mL (22 oz) of oil per spec.
Document the oil level in the coupling housing by taking a photo of the sight glass.
Ensure that the engine oil and hydraulic levels for the machine are topped off. If the machine has more than 20 service hours, add UV dye (1U5572 or equivalent) to the engine crankcase as defined by the manufacturer.Note: Ensure that the hydraulic fluid does not have any dye present.
Run the machine a minimum of one full shift.
Park the machine on level ground.Note: The machine must sit no less than 8 hours since being operated last to all the fluid temperatures to reach ambient temperatures.
Document the oil level in the sight glass of the flywheel housing by taking a photo of the sight glass.
If the oil level does not appear to have increased in the sight glass, return the unit to service and continue to monitor the fluid levels.
If the oil level appears to have increased in the sight glass, perform the following.
Drain the flywheel housing fluid into a measurement container for 30 minutes and document the volume.
Assess the dye transfer to the coupling housing using a UV light.
If the dye is not present in the drained oil, the source of the excessive oil is from the hydraulic pump. Repair the hydraulic pump as necessary.
If the dye is present in the drained oil, then use the procedure that follows to find the source of the engine oil transfer.
Upon separation of the engine and flywheel, document with attach photos from at least 4 different angles the crankshaft to seal mating area.
If areas of the seal are not in contact with the crank, document this separation with close up photos.
Document with photos if a wear sleeve was previously installed before removal of the sleeve.
Remove the seal without damaging the seal if possible. Return the seal to IPSD through the SIB process if required.
Install a new 528-5684 Crankshaft Seal Gp using the 563-9214 Tool Gp. Document the replacement seal date code.
After completion of the required repairs, attach the documentation to the warranty claim (FAR or equivalent).