61636-98600 Suzuki Roller, Engine Lower Cover Hack

Illustration 1 g00104545Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch or to the controls before the engine is serviced or before the engine is repaired. Attach the warning tags to the engine and to each operator control station. When appropriate, disconnect the starting controls.Do not allow unauthorized personnel on the engine, or around the engine when the engine is being serviced.
Tampering with the engine installation or tampering with the OEM supplied wiring can be dangerous. Personal injury, death and/or engine damage could result.
Vent the engine exhaust to the outside when the engine is operated in an enclosed area.
If the engine is not running, do not release the secondary brake or the parking brake systems unless the vehicle is blocked or unless the vehicle is restrained.Unless other instructions are provided, perform the maintenance under the following conditions:
The key switch is in the OFF position.
The engine is stopped. Ensure that the engine cannot be started.
The protective locks or the controls are in the applied position.
Engage the secondary brakes or parking brakes.
Block the vehicle or restrain the vehicle before maintenance or repairs are performed.
After the ECM has powered down, disconnect the batteries when maintenance is performed or when the electrical system is serviced. Disconnect the battery ground leads. Use electrical insulating tape on the leads to help prevent sparks.
If equipped, disconnect the connectors for the unit injectors that are located on the valve cover base. This action will help prevent personal injury from the high voltage to the unit injectors. Do not come in contact with the unit injector terminals while the engine is operating.
Do not attempt any repairs or any adjustments to the engine while the engine is operating.
Do not attempt any repairs that are not understood. Use the proper tools. Replace any equipment that is damaged or repair the equipment.
For initial start-up of a new engine or for starting an engine that has been serviced, make provisions to stop the engine if an overspeed occurs. The stopping of the engine may be accomplished by shutting off the fuel supply and/or the air supply to the engine. Ensure that only the fuel supply line is shut off. Ensure that the fuel return line is open.
Start the engine from the operators station (cab). Never short across the starting motor terminals or the batteries. This action could bypass the engine neutral start system and/or the electrical system could be damaged.Engine exhaust contains products of combustion which may be harmful to your health. Always start the engine and operate the engine in a well ventilated area. If the engine is in an enclosed area, vent the engine exhaust to the outside.To help prevent spraying or splashing of pressurized fluids, hold a rag over the part that is being removed.Remove the following parts with caution.
Filler caps
Grease fittings
Pressure taps
Breathers
Drain plugsUse caution when cover plates are removed. Gradually loosen, but do not remove the last two bolts or nuts that are located at opposite ends of the cover plate or the device. Before removing the last two bolts or nuts, pry the cover loose to relieve any spring pressure or other pressure.
Illustration 2 g00702020
Do not stand on the engine.
Wear a hard hat, protective glasses, and other protective equipment, as required.
Caterpillar recommend that you do not stand next to an exposed running engine unless it is necessary when carrying out daily checks or maintenance procedures. The appropriate Personal Protective Equipment (PPE) must be worn when standing next to an exposed running engine.
Do not wear loose clothing or jewelry that can snag on controls or on other parts of the engine.
Ensure that all protective guards and all covers are secured in place on the engine.
Never put maintenance fluids into glass containers. Glass containers can break.
Use all cleaning solutions with care.
Report all necessary repairs.Pressurized Air and Water
Pressurized air and/or water can cause debris and/or hot water to be blown out. This action could result in personal injury.When pressurized air and/or pressurized water is used for cleaning, wear protective clothing, protective shoes, and eye protection. Eye protection includes goggles or a protective face shield.The maximum air pressure for cleaning purposes must be below 205 kPa (30 psi). The maximum water pressure for cleaning purposes must be below 275 kPa (40 psi).Fluid Penetration
Pressure can be trapped in the hydraulic circuit long after the engine has been stopped. The pressure can cause hydraulic fluid or items such as pipe plugs to escape rapidly if the pressure is not relieved correctly.Do not remove any hydraulic components or parts until pressure has been relieved or personal injury may occur. Do not disassemble any hydraulic components or parts until pressure has been relieved or personal injury may occur. Refer to the OEM information for any procedures that are required to relieve the hydraulic pressure.
Illustration 3 g00687600Always use a board or cardboard when you check for a leak. Leaking fluid that is under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If fluid is injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury.Containing Fluid Spillage
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.Dispose of all fluids according to local regulations and mandates.Static Electricity Hazard when Fueling with Ultra-low Sulfur Diesel Fuel
The removal of sulfur and other compounds in ultra-low sulfur diesel fuel (ULSD fuel) decreases the conductivity of ULSD and increases the ability of ULSD to store static charge. Refineries may have treated the fuel with a static dissipating additive. Many factors can reduce the effectiveness of the additive over time. Static charges can build up in ULSD fuel while the fuel is flowing through fuel delivery systems. Static electricity discharge when combustible vapors are present could result in a fire or