09116-06121 Suzuki BOLT (6X25)

REFERENCE LITERATURE: Exchange of Parts
Each Remanufactured Engine is built to an original engine arrangement, as given in the chart. No modification or parts exchange is necessary if the replacement engine arrangement is the same as the original engine arrangement. Some modification or parts exchange may be necessary when the Remanufactured Engine Arrangement reference number is different than the original engine arrangement number.Use the reference literature indicated when necessary to exchange parts between the original and new engines. Although parts on the new engine may be different from those on the original engine, an exchange may not be necessary, depending upon the specific application. In some cases, it may be more advantageous to make minor modifications to the machine frame or engine mounting rails, rather than to exchange components between the Remanufactured Engine and the original engine.Before installation of the Remanufactured Engine, make sure the flywheel housing, flywheel and vibration damper/crankshaft pulley are compatible with your application.Each Remanufactured Engine is rated at a specific horsepower (kW) at a specific rpm. The Remanufactured Engine that is to be installed will not necessarily have the same exact horsepower (kW)/rpm rating as the original engine that it is replacing. If necessary, the horsepower (kW) and rpm setting of the Remanufactured Engine can be adjusted to the same horsepower (kW) and rpm as the original engine. Always refer to the FUEL SETTING INFORMATION LIBRARY and/or the FUEL SETTING AND RELATED INFORMATION microfiche before making any changes to the fuel setting.For maximum life of the Caterpillar Remanufactured Engine, be sure the following components are checked during installation:Air Compressor
Since the air compressor uses engine oil for lubrication, be sure it is clean inside. Foreign material from a failure of the former engine can decrease engine life. Worn air compressors can, also, be a source of "oil consumption", by pumping oil into the engine air intake pipe, or the vehicle air tanks.Air Cleaner
Install a new filter element in the air cleaner. Install all hoses and clamps as necessary. Check all piping and connections for leaks.Radiator
Make sure the radiator is clean inside and out. Install new hoses and clamps. Check for leaks. If the engine is equipped with a viscous fan clutch, check fan speed to be sure of proper operation.Water Separator
The Remanufactured Engine does not have a water separator; however, it is a Caterpillar recommendation that one be installed. Either transfer the water separator from the original engine, or install a new water separator on the Remanufactured Engine.Oil Pan
Compare the oil pan configuration on the Remanufactured Engine with that of the original engine. If they are different, it will be necessary to change the oil pan on the new engine to match the original engine. When the oil pan is changed, it will be necessary to change the oil pump suction bell to fit the oil pan sump location. The dipstick and guide tube may also need to be changed and/or recalibrated for a particular application.Fuel System
Check the fuel and power setting given on the engine information plate of the Remanufactured Engine, and compare this information with the same settings of the original engine. If the settings are different, it is possible that some fuel system adjustment will be necessary. Use the reference numbers to obtain the necessary information about governor springs, torque control groups, etc., from the Parts Book, Service Manual and the FUEL SETTING INFORMATION LIBRARY and/or the FUEL SETTING AND RELATED INFORMATION microfiche. It may be necessary to change some of these parts, or the settings, for a specific engine application. Whenever an engine is reset to new specifications, always install a 4W5140 Plate with the new settings stamped on it, on top of the original engine information plate on the valve cover.Sperry-New Holland Combines
For those Remanufactured Engines that are to be installed in Sperry-New Holland Combines: 1. Remove the load stop pin and install a 4W9007 Torque Control Pin (spring end up). 2. Remove the torque control group and install an 8N3840 Temperature Compensator Conversion Group. 3. Remove the governor "outer spring" and install the correct outer spring as a replacement. Refer to the April 8, 1985 Service Magazine, the April, 1985 Engine News and the Service Manual for procedure. Use the chart that follows as an aid in finding reference information. Flywheel
Remove, clean and inspect the flywheel of the original engine. If the original flywheel cannot be used again, refer to the specific Parts Book to find the correct part number flywheel to use. Install the flywheel on the Remanufactured Engine and tighten the bolts to the correct torque. See the Service Manual for the torque specification.Governor (Accelerator) Control
Remove the needed governor (accelerator) control linkage from the original engine and install it on the Remanufactured Engine. Adjust as necessary; see the Service Manual for procedure.Miscellaneous
Remove any other components that are needed, such as starter motor, alternator, etc. from the original engine for cleaning, inspection and/or installation on the Remanufactured Engine. If parts from the original engine are not in a condition to be used, either recondition them, or see the Parts Book for part numbers for new parts.Lift Truck Engine
The 3208 DINA Engine in a Caterpillar Lift Truck can have one of the three different 3208 DINA hp (kW) and rpm settings that are used in these machines. The 0R1777 Remanufactured Engine that is available for use in Caterpillar Lift Trucks, is factory set for a 117 hp @ 2270 rpm (87 kW @ 2270 rpm) rating. (This is one of the ratings used for a Caterpillar Lift Truck.) If an 0R1777 Remanufactured Engine is to be installed as a replacement for one of the other two engine ratings given in the chart that follows, it will be necessary to make an adjustment to the fuel setting and/or bare engine high idle. For other possible engine differences see the chart for 0R1777 in this instruction. When fuel setting adjustment is necessary, refer to Special Instruction Form SMHS7013, entitled USE OF 5P4203 FIELD SERVICE TOOL GROUP OR 5P6577 FUEL SETTING TOOL