48591-94500 Suzuki Screw

Start By:a. remove radiator and guardb. remove air cleaner housingc. remove muffler For ease in removal of some bolts it may be desirable to remove the front belly guard. 1. Remove eight nuts (1), gasket (2) (not shown), and exhaust elbow (3) from exhaust manifold.
Effective July 1, 1992 regulations prohibit the venting of any refrigerant into the atmosphere. Refer to Caterpillar publication SENR3334-01, SENR5664 and NEDG5065-01 for the proper procedure, equipment and tools to reclaim refrigerant from any Caterpillar machine.
Always wear goggles when working on air conditioning systems. The system is under pressure at all times, engine running or not. Escaping refrigerant R-12 (C C12F2 Dichloro Difluoro Methane) and refrigerant R-134A can cause freezing of human flesh. Do not smoke while working on air conditioning. Inhaling Refrigerant R-12 or R-134A through any smoking material, although not toxic or flammable, can cause violent illness. Also heat must never be applied to a charged system. See Air Conditioning And Heating Service Manual Form No. SENR3334-01 and SENR5664, for more information on removal and installation of lines and refrigerant from the system.
2. Using the proper reclaiming equipment, purge the air conditioning system. Mark and identify all wires and hose assemblies connected to the air conditioning compressor. Disconnect two wiring harnesses (4) and (5) at the quick disconnects and disconnect two hose assemblies (6) and (7). Remove bolt (8) and set hose assembly (6) aside. 4. Insure that the battery is disconnected. Remove tie straps around wiring harness located at the left front side of the firewall. Mark and identify all wires. Disconnect wiring harness (9), (10), (11), (12) and (13) at the quick disconnects. Follow wiring harness (14) through the firewall and disconnect wiring (14) at the quick disconnect (not shown) under the dash and carefully pull the wiring through the firewall. 5. Disconnect wiring harness (15) and ground cable (16) from the firewall. 6. Disconnect two wiring harnesses (17) and (18) at the quick disconnect located behind the right lift cylinder as shown. 7. Disconnect wiring assembly (19) from the alternator and remove all the tie straps that hold wiring assemblies (19) to the engine and set wiring assembly (19) to the side. 8. Remove bolt (20) holding clip and remove two bolts (21) and remove the air conditioning drier from the firewall with wiring harness and two hose assemblies still attached to the air conditioning drier. 9. Remove bolt and washer (22). Bolt (22) holds a clip on the inside of the firewall which holds a heater hose assembly. 10. Remove floor mat (23). Remove twelve bolts and washers (24) from cover (25) and remove cover (25) from the cab. 11. Disconnect four rods (26), (27), (28) and (29). 12. Remove nineteen bolts (3) from cab dash. 13. Attach a suitable lifting device to the top of the cab and remove three bolts and washers (31) and shims and caps (32) on each side of the cab. Lower the cab onto wood blocks approximately 2 inches thick. Locate the blocks on the front of the fuel tank and hydraulic tank between the cab and the tanks. This will support the weight of the cab and prevent damage to the tanks. 14. Loosen two nuts (33) and (34) and remove two cotter pins (35 and (36) and set aside decelerator cable assembly (37) and governor control cable (38). 15. Remove four bolts and washers and nuts (39) on each side of the firewall (40). 16. Attach tool (A) to firewall (40) as shown. Using the cab an one additional person, carefully lift firewall (40) off the machine. The weight of firewall is 222 kg (490 lb). 17. Disconnect and plug heater hose (41) and remove bolt (42) and set heater hose (41) aside. 18. Turn fuel shut-off valve located on the fuel tank off. Disconnect and plug two fuel line hoses (43) and (44) and remove bolt (45) and set fuel line hoses (43) and (44) aside. 19. Disconnect and plug heater hose (46) from the engine and remove clip (not shown) holding the heater hose (46) to tube assembly (47). 20. Remove two clips