09160-06104 Suzuki WASHER

Removing The Engine
INADVERTENT STARTING OF THE ENGINE CAN CAUSE PERSONAL INJURY. SHUT THE ENGINE DOWN AND REMOVE THE KEY FROM THE IGNITION SWITCH.
BATTERY SWITCH1. Set the battery switch at "Off" and disconnect the battery ground (-) cable from the battery. 2. Open the drain valve and drain the fuel tank. 3. Remove the air stack extension and muffler. Cover the openings in the air cleaner and the engine. 4. Remove the upper radiator grill and upper pump cowling.5. Unbolt and remove as a unit the radiator cowling, engine cowling and front and rear pump cowling. 6. Remove the ducting from between the engine and the air cleaner, then cover the openings in the engine and air cleaner.7. Unbolt the mounting bracket from the engine, then remove the air cleaner and mounting bracket.8. Unbolt and remove the radiator support bracket from between the engine and the radiator.9. Drain the radiator, then remove the upper and lower hoses from between the engine and radiator.
THE HYDRAULIC SYSTEM CAN TOLERATE VERY LITTLE, IF ANY, DIRT. BEFORE BEGINNING WORK ON A HYDRAULIC SYSTEM, CLEAN THE WORK AREA AND ALL CONNECTIONS THOROUGHLY. ONCE HYDRAULIC LINES ARE OPENED, CAP OR PLUG ALL OPENINGS IMMEDIATELY.
10. Close the shutoff valves in the pump supply lines. Mark for identification during reassembly, then disconnect the hoses from the oil cooler. Cap or plug all openings immediately. 11. Unbolt the fan shroud from the radiator.12. Attach a lifting device to the radiator and oil cooler, remove the bolts which attach the radiator and oil cooler bracket to the engine skid, then lift the radiator and oil cooler straight up and away. 13. Relieve the accessory pump drive belt tension, then remove the belt.14. Repeat step 13 for the water pump drive belt. 15. If the machine is not equipped with an auxiliary cutter, skip this step and step 16. Otherwise, mark the hoses for identification during assembly, thoroughly clean around the auxiliary cutter drive pump and hose connections, then disconnect the hoses from the pump. Cap or plug all openings immediately.16. Attach a lifting device to the auxiliary cutter drive pump, remove the mounting bolts, move the pump straight back until the pump shaft is clear of the gearbox, then move the pump away.17. Thoroughly clean around the wheel drive pump and hose connections, then disconnect the hoses from the pump. Cap or plug all openings immediately.18. Disconnect the wheel drive pump control cable mounting bracket and cable from the pump and lay them aside where they will not be damaged. DO NOT ALTER THE CONTROL CABLE ADJUSTMENT.19. Attach a lifting device to the wheel drive pump, remove the mounting bolts, move the pump straight back until the pump shaft is clear of the gearbox, then move the pump away.20. Remove the cutter drive shaft (see Cutter 3.0-7). 21. Disconnect the throttle cable and lay it aside where it will not interfere with engine removal.22. Disconnect the fuel supply and return hoses from the engine. 23. Mark for identification during reassembly, then disconnect all wiring harness wires from the terminals at the following engine components: a. Starter.b. Fuel solenoid.c. Oil pressure sender.d. Oil pressure switch.e. Water temperature sender.f. Alternator.g. Hour meter.24. Check the engine over to be sure all wires, cables and hydraulic lines which would interfere with engine removal have been disconnected. 25. Attach a lifting device to the engine skid and take enough of a strain in the lifting lines to support the engine.26. Remove the uppermost nut from each of the three engine skid support bolts.27. Lift the engine and engine skid straight up and away.Building The Engine Up
The simplest way to build up a new engine is to position the new engine beside the old one and properly support both so they can safely be worked on. Then remove one component at a time from the old engine and install it on the new engine until all required components have been transferred to the new engine. Components that may have to be transferred include: 1. The pump drive gearbox. See page 4.0-2 for removal and installation procedures.2. The throttle bracket.3. The engine oil pressure switch and sender.4. The water temperature sender.5. The hour meter and bracket.6. The fan shroud.After all the necessary components have been transferred, use the following procedures to mount the new engine on the engine skid.1. Attach a lifting device to the old engine and take enough of a strain in the lifting lines to support the engine. 2. Remove the bolts which hold the engine to the skid.3. Raise the engine out of the skid and move it to a place where it can safely be stored.4. Attach the lifting device to the new engine.5. Lift the engine into position on the engine skid.6. Install the bolts which hold the engine and pump drive gearbox to the engine skid.Installing the Engine
1. Check that the mounting area on the machine is clear of all hoses, wires, control cables, etc. 2. Attach a lifting device to the engine skid.3. Move the engine and skid into position on the skid support bolts. Loosely install the uppermost nuts on the support bolts.4. Install the cutter drive shaft (see Cutter 3.0-9). 5. Attach a lifting device to the wheel drive pump, move the pump into position on the pump drive gearbox, then install the mounting bolts.6. If the machine is equipped with an auxiliary cutter, repeat step 5 for the auxiliary cutter drive pump.7. Thoroughly clean around the pump ports and hose connections, then connect the hoses to the pumps. 8. Attach a lifting device to the radiator and oil cooler, position the radiator and oil cooler at the front of the engine, and install the bolts that connect the bracket to the engine skid.9. Install the radiator support bracket between the engine and the radiator.10. Bolt the fan shroud to the radiator.11. Install the upper and lower radiator hoses.12. Thoroughly clean the connections, then connect the hydraulic hoses to the oil cooler. 13. Connect the wiring