09116-08100 Suzuki BOLT

Start By:a. install body retaining pins Fluid Spillage ContainmentCare 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 Product Guide, NENG2500", for tools and supplies suitable to collect and containe fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.
At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot water or steam. Any contact can cause severe burns. Look at the sight gage to check the coolant level. The coolant level should be in the green range. If necessary, remove the fill cap only after the engine has been stopped and the cap is cool enough to remove with your bare hand. Remove the cooling system fill cap slowly to relieve pressure. Cooling system condition contains alkali that can cause personal injury. Avoid contact with the skin and eyes and do not drink. Allow cooling system components to cool before draining.
1. Drain the coolant from the engine cooling system in a suitable container for storage or disposal. The capacity of the cooling system is 221 liters (58.5 U.S. gal). 2. Open front hood assembly (3). Remove four bolts (4) and the washers that hold front hood assembly (3) to the frame assembly. Remove cotter (1) and the washer that holds prop assembly (2) to front hood assembly (3). Close front hood assembly (3). 3. Remove ten bolts (6) and the washers that hold rail assembly (5) to front hood assembly (3). Put lifting slings in position around rail assembly (5). Attach the lifting slings to a suitable lifting device. Remove rail assembly (5) from front hood assembly (3). The weight of rail assembly (5) is 25 kg (55 lb).4. Remove five bolts (7) and the washers that hold front hood assembly (3) to cowling assembly (8). 5. Install Tooling (A) on front hood assembly (3). Attach Tooling (A) to a suitable lifting device. Remove front hood assembly (3). The weight of front hood assembly (3) is 62 kg (136 lb). 6. Remove nut (10) that secures ground level shutdown switch (9) to cowling assembly (8). 7. Install Tooling (A) on cowling assembly (8). Attach Tooling (A) to a suitable lifting device.8. Remove ten bolts (11) and the washers that hold cowling assembly (8) to the frame assembly. Remove cowling assembly (8). The weight of cowling assembly (8) is 90 kg (198 lb). It is not necessary to purge the air conditioning system when removing the condenser from the radiator.9. Remove four bolts (12), the nuts and the washers that hold condenser assembly (13) to the plate. 10. Set condenser assembly (13) aside. Remove bolt (14) and the clips from the radiator group. 11. Remove the four bolts from each elbow (16) and (17). Disconnect two elbows (16) and (17) from radiator top tank assembly (15). Remove the gasket from each elbow (16) and (17).12. Remove four straps (18) that hold harness assembly (19). Set harness assembly (19) aside. 13. Remove the four bolts that hold elbows (20) and (21) to radiator bottom tank assembly (22). Disconnect two elbows (20) and (21) from radiator bottom tank assembly (22). Remove the gasket from each elbow (20) and (21). 14. Remove eight bolts (24) and the washers. Remove two fan guard assemblies (23) from strips (25). 15. Disconnect ether starting aid tube assembly (26). Disconnect harness assembly (28) at electrical connection (27).16. Remove three bolts (29) and the clips that secure harness assembly (28) to the radiator group.
Prior to removal of the fan assembly, put a piece of cardboard between the fan spider assembly and the folded cores. Failure to do so could result in parts damage.
17. Put a lifting sling around the fan assembly. Fasten the lifting sling to a suitable lifting device. Remove six bolts (30). Remove fan adapter (31) and the fan spider assembly as a unit from fan pulley hub (32). The weight of fan adapter (31) and the fan spider assembly as a unit is 59 kg (130 lb). 18. Install Tooling (A) to radiator group (34). Attach Tooling (A) to a suitable lifting device.19. Remove four bolts (33) and the washers. Remove radiator group (34). The weight of radiator group is 775 kg (1705 lb). The following steps are for the installation of the radiator group. Replace all gaskets prior to installation of the radiator group. 20. Install Tooling (A) on radiator group (34). Fasten Tooling (A) to a suitable lifting device. Put radiator group (34) in position on the frame assembly. 21. Install four bolts (33) and the washers.
Prior to installing the fan assembly, put a piece of cardboard between the fan spider assembly and the radiator cores. Failure to do so could result in parts damage.
22. Put a lifting sling in position around the fan assembly. Attach the lifting sling to a suitable lifting device. Put fan adapter (31) and the fan spider assembly as a unit in position on fan pulley hub (32). Install six bolts (30). 23. Connect harness assembly (28) at electrical connection (27). Install three bolts (29) and the clips that hold harness assembly (28) to the radiator group.24. Connect ether starting aid tube assembly (26). 25. Put two fan guard assemblies (23) in position on strips (25). Install eight bolts (24). 26. Clean all gasket material off mating surfaces of two elbows (20) and (21).