09492-50008 Suzuki Jet, Pilot 50

Introduction
This special instruction covers the procedure to upgrade the axle and brake system on the above R3000H Load Haul Dump Machines. This supplemental product support literature should be used with the appropriate Service Manual and the appropriate Parts Manual that is available for this standard machine.Read the entire Special Instruction. Understand the information before you perform any procedures. Understand the information before you order any parts.Safety Section
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive.Ensure that all personnel are safe when using a tool, procedure, work method, or operating technique not recommended by Caterpillar. Ensure that the product will not be damaged or the product made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.
Personal injury or death can result from machine articulation or movement.Machine frames can move and a person can be crushed.Connect the steering frame lock link between the front and rear frames before working on machine.
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.
Personal injury or death can result from escaping fluid under pressure.Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.Always use a board or cardboard when checking for a leak.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
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, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Reference: Disassembly and Assembly, UENR1483, "R3000H Load Haul Dump Machine System".Reference: Disassembly and Assembly, UENR1475, "R3000H Load Haul Dump Power Train".Reference: Operation and Maintenance Manual, SEBU8320, "R3000H Load Haul Dump".Reference: Systems Operation Testing and Adjusting, UENR1479, "R3000H Load Haul Dump Braking System".Reference: Disassembly and Assembly, UENR2734, "AD60 Underground Articulated Truck Power Train".Required Tooling
Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7576 Link Bracket 1
B 8T-0070 Bolt 2
C 210-1752 Axle Lifting Lug 2
8T-0667 Bolt 8
6V-8237 Washer 8
D 369-9451 Grease 1