09103-06120 Suzuki BOLT

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
ZZ     6V-9509     Face Seal Plug     1    
6V-9830 Cap As     1    
6V-9508 Face Seal Plug     2    
6V-9829 Cap As     2    
6V-9511 Plug     1    
6V-9832 Cap As     1    Start By:
Release the hydraulic system pressure. Refer to Disassembly and Assembly, "Hydraulic System Pressure - Release".
Remove the muffler. Refer to Disassembly and Assembly, "Muffler - Remove and Install".
Remove the fan guard. Refer to Disassembly and Assembly, "Fan Guard - Remove and Install".
Remove the fan. Refer to Disassembly and Assembly, "Fan - Remove and Install".
Remove the engine enclosure. Refer to Disassembly and Assembly, "Engine Enclosure Group - Remove and Install".
Remove the gear pump (fan drive). Refer to Disassembly and Assembly, "Gear Pump (Fan Drive) - Remove".Note: SERVICE DATA: TOOLING (ZZ) WILL NOT BE IDENTIFIED IN PHOTOGRAPHS IN THE REMOVAL OR THE INSTALLATION. THIS TOOLING IS SHOWN IN ORDER TO ASSIST THE EXPERIENCED SERVICEMAN.Note: Put identification marks on all hoses, on all hose assemblies, on all harness assemblies, and on all tube assemblies for installation purposes. Plug all hose assemblies and all tube assemblies. This helps to prevent fluid loss, and this helps to keep contaminants from entering the system.
Keep all parts clean from contaminants.Contamination of the hydraulic system with foreign material will reduce the service life of the hydraulic system components.To prevent contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected. Cover any disassembled components and clean them properly before assembly.Clean the hydraulic system properly after any major component exchange or especially after a component failure, to remove any contamination.
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.
At operating temperature, the hydraulic oil is hot and under pressure. Hot oils can cause burns.To prevent possible personal injury, release the pressure in the implement hydraulic circuit (boom, stick, bucket, and swing), travel circuits, and the hydraulic oil tank at the filler cap before any hydraulic lines or components are disconnected or removed.Remove the filler cap only when the engine is stopped and the filler cap is cool enough to touch.
Move the battery disconnect switch to the OFF position.
Disconnect the battery cable on the negative terminal of the battery. Move the battery cable away from the terminal.
Drain the coolant from the cooling system into a suitable container for storage or disposal. The capacity of the cooling system is approximately 39 L (10 US gal).
Drain the hydraulic oil from the system into a suitable container for storage or disposal. The capacity of the hydraulic oil system is approximately 255 L (67 US gal).
Illustration 1 g00918356
Loosen hose clamps (1) and disconnect hoses (2) .
Disconnect the lower radiator hose.
Illustration 2 g00918358
Loosen hose clamps (3) and disconnect hoses (4) .
Illustration 3 g00918359
Disconnect hoses (7) and harness assembly (6) .
Remove bolts (5) and tank (8) .
Illustration 4 g00918360
Disconnect harness assembly (9) and remove clip (10) .
Illustration 5 g00918361
Disconnect hose assemblies (11) .