09205-03032 Suzuki PIN

1. Open the engine enclosure.2. Move the disconnect switch to the OFF position.
At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap from the radiator slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.
3. Drain the radiator. The capacity of the cooling system is 30.0 liters (8 U.S. gallons).
At operating temperatures, the oil tank is hot and under pressure. Hot oil can cause burns. Remove the fill plug only when the engine is stopped and when the fill plug is cool enough to touch with your bare hands.
Identify all hydraulic lines as they are removed for reinstallation purposes. Cap and plug all lines and fittings to prevent any contaminants from entering the system.4. Release the pressure in the hydraulic system by slowly loosening the fill cap located on the top of the hydraulic oil tank.5. Drain the hydraulic oil from the hydraulic oil tank. The capacity of the hydraulic oil tank is 80 liters (21.1 U.S. gallons). Use steps 6 through 13 only if the machine is equipped with air conditioning. 6. Loosen the clamp, and remove coolant hose (4) from the top of the hydraulic oil tank frame.7. Remove rivet (1) and hose (6) from seal (7).8. Remove two clamps (5) from hose (3).9. Remove the two bolts that hold air dryer (2) to the hydraulic oil tank. Move the air dryer out of the way. 10. Disconnect hose (8) from the top of the radiator and move out of the way.11. Remove clamp (11) from hose (6).12. Remove bolt (13) from support bracket (12) and remove hose (6). Install bolt (13) after removing hose (6).13. Remove four bolts (9) from the radiator and move air condenser (10) out of the way. 14. Remove the nut that fastens disconnect switch (14) to the hydraulic oil tank frame. Remove the bolt and clamp (17) from the hydraulic oil tank frame. Move the disconnect switch and cables out of the way.15. Loosen clamp (16). Remove the two bolts, and remove fuel tube (15) from the hose and the hydraulic oil tank frame. Cover the opening to the fuel tank.16. Remove the two bolts that fasten water separator (20) to the hydraulic oil tank frame.17. Disconnect two hose assemblies (18) from the fan motor. Cap and plug immediately. Remove the bolt and clamp (21) that fastens the two hose assemblies to the fan guard.18. Disconnect two hose assemblies (22) from the hydraulic oil tank. Cap and plug immediately.19. Remove oil level indicator (19). 20. Disconnect electrical connector (23).21. Loosen the hose clamp, and remove coolant hose (24) from the engine.22. Disconnect hose assemblies (25) from the hydraulic oil tank. Cap and plug immediately. 23. Disconnect two electrical connectors (26). 24. Remove bolts (27) and remove the battery cable from the hydraulic oil tank frame. 25. Remove the remaining two bolts that fasten air cleaner bracket (28) to the hydraulic oil tank.26. Attach Tooling (A) to the hydraulic oil tank frame. Attach a suitable hoist and lifting chains to Tooling (A). 27. Remove four bolts (30), and remove hydraulic oil tank (29), radiator and hydraulic oil cooler as a unit from the machine. The weight of the hydraulic oil tank, radiator and hydraulic oil cooler as a unit is approximately 227 kg (500 lb). For the installation of the radiator, hydraulic oil cooler and hydraulic oil tank, reverse the removal steps. After the radiator, hydraulic oil cooler and hydraulic oil tank have been installed, fill the cooling system with coolant to the correct level. Fill the hydraulic oil system with hydraulic oil to the correct level. See the Operation & Maintenance Manual, Form No. KEBU7503, for the correct procedures.Disassemble & Assemble Radiator, Hydraulic Oil Cooler & Hydraulic Oil Tank
Start By:a. remove radiator, hydraulic oil cooler & hydraulic oil tank 1. Remove four bolts (1) from support brace (2) and remove the support brace. 2. Loosen the two clamps and remove coolant hose (3) from hydraulic oil tank (4) and radiator (5). 3. Disconnect hose assembly (6) from the hydraulic oil tank. Cap and plug immediately. 4. Disconnect two hose assemblies (7) from hydraulic oil cooler (9). Cap and plug immediately.5. Remove four bolts (8) and remove hydraulic oil cooler (9) from radiator (5).6. Remove the bolts that fasten two braces (10) to hydraulic oil tank (4) and hydraulic oil tank frame (5). 7. Attach lifting straps and a hoist to hydraulic oil tank (4) as shown.8. Remove four bolts (12) from hydraulic oil tank frame (11). Remove hydraulic oil tank (4) from the hydraulic oil tank frame. The weight of the hydraulic oil tank is 60 kg (132 lb). 9. Position the hydraulic oil tank frame as shown. Remove remaining five bolts (13) and remove fan guard assembly (14).10. Remove eight nuts and spacers (15) and remove radiator shroud (16). 11. Remove four bolts (18), and remove fan (17) from fan motor (20).12. Remove two bolts (21), and remove fan motor (20) from guard (19). 13. Attach Tool (A) and a suitable hoist to radiator (8). 14. Remove eight nuts and spacers (22) and remove radiator (5) from hydraulic oil tank frame (11). The weight of the radiator is 82 kg (180 lb). For assembly of the radiator, hydraulic oil cooler and hydraulic oil tank, reverse the disassembly steps.End By:a. install radiator, hydraulic oil cooler & hydraulic oil tank