17661-ZW9-900 Honda BULB, PRIMER

At operating temperature, the hydraulic oil is hot and under pressure. Hot oil can cause burns. To prevent possible personal injury, release the pressure in the implement hydraulic circuits (boom, stick and bucket) before any hydraulic lines or components are disconnected or removed.
1. Release the pressure in the hydraulic system as follows:a. Fully retract the stick cylinder rod.b. Adjust the position of the bucket so it will be flat on the ground when the boom is lowered.c. Lower the boom until the bucket is flat on the ground.d. Stop the engine.e. Place the engine start switch in the "ON" position without starting the engine.f. Move the control levers for the boom, stick, bucket and swing to all full stroke positions. This will release any pressure that might be present in the pilot system.g. Slowly move the travel pilot control pedal to "FORWARD" and "REVERSE" travel positions. This will release any pressure in the travel circuit.h. Slowly loosen and remove the pressure cap on the hydraulic tank to release the hydraulic pressure.i. Reinstall and tighten the pressure cap on the hydraulic tank.j. The pressure in the hydraulic system has been released and implement/travel lines and components can be removed.
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 slowly to relieve pressure in the cooling system. Cooling system conditioner contains alkali. Avoid contact with skin and eyes to prevent personal injury.
2. Release the pressure in the cooling system by slowly loosening the fill cap on the radiator.3. Remove the fan assembly from the engine. See the topic "Remove & Install Fan Assembly" in this module.
View From Under Machine4. Remove four bolts (2) and cover (1) from under the engine.
View From Under Machine5. Drain the coolant from the cooling system into a suitable container for storage or disposal. The capacity of the cooling system is 35 liters (9.1 U.S. gal).6. Loosen the clamp, and disconnect lower radiator hose assembly (3) from the bottom of the radiator.
View From Under Machine7. Remove bolt (4), the washer and nut that hold the radiator enclosure to the right hand rear corner of the frame assembly.
View From under Machine8. Remove two bolts (5), the washers and nuts that hold the left hand side of the radiator enclosure in position. 9. Open access door (6) on the radiator enclosure, and fasten it in the "Open" position. 10. Remove two sound suppression mounting bolts (7) from the plate assemblies. Carefully remove the sound suppression liner group from the radiator enclosure. 11. Disconnect two wires (8) from the horn.12. Remove four mounting bolts (9) and horn (10) from the radiator enclosure. 13. Fasten Tool (A) and a hoist to radiator enclosure (11) as shown. Carefully remove the radiator enclosure from the machine. The weight of the radiator enclosure is 27 kg (60 lb). 14. Disconnect hose assemblies (12) and (13) from the bottom of the hydraulic oil cooler. Put plugs in the hose assemblies to prevent oil loss and to keep contaminants out of the hydraulic system. 15. Remove two nuts (14), the washers and bolts that hold the radiator group to the frame of the machine. 16. Fasten Tool (A) and a hoist to radiator group (15) as shown. Carefully remove the radiator group from the machine. The weight of the radiator group is 82 kg (180 lb). 17. Put a drain pan in position under the radiator group. Remove two caps (16) from the bottom of the hydraulic oil cooler. Oil will drain out of the cooler. 18. Remove four bolts (17) and the washers that hold reservoir (18) in position. 19. Disconnect hose assemblies (19) and (20) from reservoir (18). Remove the reservoir from the radiator. 20. Loosen clamp (21), and remove hose assembly (19) from the radiator. 21. Remove eight bolts (22) and top support (23). 22. Remove eight bolts (24) from side support (25). 23. Remove drain valve assembly (26) from the bottom of the radiator. 24. Remove connector (27) from drain valve assembly (26). 25. Position the radiator with the front side facing up as shown. Remove five bolts (28) and bottom support (29). 26. Remove side support (30). 27. Using two persons, separate the radiator (31) from the hydraulic oil cooler and shroud frame (32). The weight of the radiator is 29 kg (65 lb). 28. Remove the four rivets that hold hydraulic oil cooler (33) to shroud frame (32). Using two persons, separate the cooler from the frame. The weight of the hydraulic oil cooler is 36 kg (80 lb). The following steps are for the installation of the radiator and the hydraulic oil cooler.29. Check the condition of the radiator and hydraulic oil cooler prior to installation. Remove any dirt or debris that may restrict the flow of air through the cores. If any of the cooling fins are bent, they should be straightened. Make sure the cores do not leak. 30. Using two persons, put hydraulic oil cooler (33) in position on shroud frame (32). Install four new rivets to hold the hydraulic oil cooler in position. 31. Using two persons, put radiator (31) in position on shroud frame (32). 32. Install side support (30). 33. Install bottom support (29) and five bolts (28). 34. Install connector (27) on drain valve assembly (26). 35. Install drain valve assembly (26) in the bottom of the radiator in its original orientation. 36. Install eight bolts (24) in side support (25). 37. Install eight bolts (22) in top support (23). 38. Install hose assembly (19) on the radiator. Install clamp (21) that holds it. 39. Put reservoir (18) in position on the radiator. Connect hose assemblies (19) and (20) to the reservoir. 40. Install the four washers and bolts (17) that hold the reservoir in position. 41. Install two caps (16) at the bottom of the hydraulic oil cooler.