09491-36005 Suzuki Jet, Main 180

Table 1
Required Tools
Tool Part Number Part Description Qty
A 8S-7640 Stand 2
8S-7611 Tube 2
8S-7615 Pin 2
8S-8048 Saddle 2
B(1) 9U-7536 Lift Stand 1
447-0910 Electric Hydraulic Pump Gp (115V) 1
447-0911 Electric Hydraulic Pump Gp (230V) 1
B1 OR
504-9826 Lift Gp (60Hz)(2) 1
504-9827 Lift Gp (50Hz)(3) 1
C 477-8635 Load Leveler 1
(1) Use Tooling (B) or (B1) based on requirements.
(2) Operating-Voltage (380-500V)
(3) Operating-Voltage (180-300V)Start By:
Remove the cooling system package.
Remove the hoist, brake hydraulic tank.
Remove the power train oil cooler.
Remove the brake, hoist oil cooler.
Removing the engine from the truck with the body of the truck in the UP position will change the balance point of the truck. The shift in the balance point could allow the front of the truck to unexpectedly raise off the ground.This unexpected movement could cause injury or death.To stabilize the truck, always install the specified tooling to stabilize the truck before removing the engine and torque converter.
Personal injury can result from hot oil or hot components.At operating temperature, oil is hot and under pressure. Hot oil can cause burns.Remove the fill cap only when the engine is stopped, and the fill cap is cool enough to touch with your bare hand.Do not allow hot oil or components to contact skin.
Personal injury can result from hot coolant, steam and alkali.At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand.Cooling System Conditioner contains alkali. Avoid contact with skin and eyes.
Personal injury can result from hydraulic oil pressure and hot oil.Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.
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, PERJ1017, "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.
Note: Install caps and plugs to all connections to prevent system contamination.
Drain the engine oil. Refer to Operation and Maintenance Manual, "Engine Oil and Filter - Change" for the correct procedure to drain the engine oil.
Drain the oil from the torque converter. Refer to Operation and Maintenance Manual, "Torque Converter and Transmission Oil - Change" for the correct procedure to drain the oil from the torque converter.
Drain the hoist and the brake hydraulic tank. Refer to Operation and Maintenance Manual, "Hoist and Brake Tank Oil - Change" for the correct procedure to drain the hoist and the brake hydraulic tank.
Drain the steering hydraulic tank. Refer to Operation and Maintenance Manual, "Steering System Oil - Change" for the correct procedure to drain the steering hydraulic tank.Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, hoses, and tubes. This helps to prevent fluid loss and keep contaminants from entering the system.Show