09205-05009 Suzuki Pin, Clutch lever shaft

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.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Clamp assemblies MUST only be used once. Discard all clamp assemblies after use.
Bellows assemblies MUST only be used once. Discard all bellows assemblies after use.
Drain the coolant from the cooling system to a level below the turbochargers into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".
Remove the air cleaner.
Illustration 1 g01351417
Loosen clamp assemblies (1) and clamp assemblies (2). Remove the bellows assemblies, clamp assemblies (1), and clamp assemblies (2) from turbocharger (3). Discard the bellows assemblies, clamp assemblies (1), and clamp assemblies (2).
Illustration 2 g01351521
Loosen clamp assembly (7). Remove bolts (11). Remove bellows assembly (10) and clamp assembly (7) from turbocharger (3). Discard bellows assembly (10) and clamp assembly (7).
Disconnect tube assembly (6), tube assembly (8), and tube (9). Remove tube assembly (4).
Attach a suitable lifting device to turbocharger (3). The weight of turbocharger (3) is approximately 135 kg (300 lb).
Remove bolts (5) and turbocharger (3). Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A - Loctite C5A 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Clamp assemblies MUST only be used once. Discard all clamp assemblies after use.
Bellows assemblies MUST only be used once. Discard all bellows assemblies after use.
Illustration 3 g01351521
Attach a suitable lifting device to turbocharger (3). The weight of turbocharger (3) is approximately 135 kg (300 lb).
Position turbocharger (3) on the mounting bracket. Apply Tooling (A) to the threads of bolts (5). Install bolts (5). Do not tighten bolts (5) at this time.
Install tube assembly (4). Connect tube (9), tube assembly (8), and tube assembly (6). Note: Ensure that the bellows assembly is in the proper orientation during installation. The spacing between the ridges of the bellows assembly should be equal.
Apply Tooling (A) to the threads, the bearing surfaces, and the inner surface of clamp assembly (7). Install new bellows assembly (10), bolts (11), and new clamp assembly (7). Tighten clamp assembly (7) to a torque of 10 1 N m (90 9 lb in). Lightly tap around the diameter of the clamp assembly with a soft hammer. Tighten clamp assembly (7) to a torque of 10 1 N m (90 9 lb in).
Illustration 4 g01351417Note: Ensure that the bellows assembly is in the proper orientation during installation. The direction of flow arrow must point in the correct direction. The spacing between the ridges of the bellows assembly should be equal.
Apply Tooling (A) to the threads, the bearing surfaces, and the inner surface of clamp assemblies (2) and clamp assemblies (1). Install new bellows assemblies, new clamp assemblies (2), and new clamp assemblies (1) on turbocharger (3). Tighten clamp assemblies (2) and clamp assemblies (1) to a torque of 7.5 1.0 N m (65 9 lb in). Lightly tap around the diameter of the clamp assemblies with a soft hammer. Tighten clamp assemblies (2) and clamp assemblies (1) to a torque of 7.5 1.0 N m (65 9 lb in).
Tighten the bolts that attach turbocharger (3) to the standard torque.
Install the air cleaner.
Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change".