09492-80007 Suzuki JET, MAIN (80)

Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
A     6V-6146     Load Leveling Beam     1    
ZZ     179-4453     Cap     5    
179-4454 Cap     2    
9S-8927 Plug     2    
5P-2909 Plug     11    
9S-8895 Plug     2    
8S-4950 Cap     2    
8S-4951 Cap     11    
9S-8896 Cap     2    
5H-4019 Cover     1    
2J-2668 Cover     5    
2J-5608 Cover     2    Start By:
Connect the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect".
Release the pressure in the braking system. Refer to Disassembly and Assembly, "System Pressure - Release".
Remove the header tank. Refer to Disassembly and Assembly, "Radiator Tank (Header) - Remove".
Remove the air cleaner. Refer to Disassembly and Assembly, "Air Cleaner - Remove and Install".
Remove the rear hood. Refer to Disassembly and Assembly, "Hood (Rear) - Remove and Install".
Remove the upper drive shaft. Refer to Disassembly and Assembly, "Drive Shaft (Upper) - Remove and Install".
Remove the engine bottom guard. Refer to Disassembly and Assembly, " Bottom Guard (Engine) - Remove and Install".
Remove the transmission bottom guard. Refer to Disassembly and Assembly, "Bottom Guard (Transmission) - Remove and Install".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: Cleanliness is an important factor. Before the removal procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.Note: Put identification marks on all hoses, on all hose assemblies, on all wires and on all tube assemblies for installation purposes. Plug all hose assemblies and all tube assemblies. This will help to prevent fluid loss, and this will help to keep contaminants from entering the system.
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 Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.Dispose of all fluids according to local regulations and mandates.
Hot oil and components can cause personal injury.Do not allow hot oil or components to contact skin.
Personal injury can result from contact with refrigerant.This system is under pressure at all times, even if the engine is not running. Heat should never be applied to a charged system.Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury.Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant.Always use caution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, evacuate the system recovering the refrigerant before removing the fitting.Personal injury or death can result from inhaling refrigerant through a lit cigarette.Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or death.Do not smoke when servicing air conditioners or wherever refrigerant gas may be present.Before any checks of the air conditioning and heating system are made, move the machine to a smooth horizontal surface. Lower all implements to the ground. Make sure the transmission is in neutral or park and that the parking brake is engaged. Keep all other personnel away from the machine or where they can be seen.
Turn the battery disconnect switch to the OFF position.
Recover the air conditioner refrigerant from the air conditioner system. Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the procedure. Refer to Special Publication, NEDG5065, "Air Conditioning Tools" for the tools.
Drain the hydraulic tank into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Capacities (Refill)" for the capacity of the hydraulic tank for the machine that is being serviced. Refer to Operation and Maintenance Manual, "Hydraulic System Oil - Change" for the proper draining procedure.
Illustration 1 g01193741
Remove two bolts (2) and clamp (1) .
Illustration 2 g01193742
Remove clamp (3) and the gaske