90502-ZX2-003 Honda WASHER, WAVE (8MM)

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. Cooling system conditioner contains alkali. Avoid contact with skin and eyes to prevent personal injury.
1. Release the pressure in the cooling system by slowly loosening the filler cap on the radiator. Drain the coolant from the radiator. The capacity of the cooling system is 44 liters (11.4 U.S. gal).
At operating temperature, the hydraulic oil tank is hot and under pressure. Hot oil can cause burns. Remove the filler cap on the hydraulic oil tank only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Make sure all hydraulic pressure is released before any fitting, hose or component loosened, tightened, removed or adjusted.
2. Release the pressure in the hydraulic system as follows:a. Install the anti-pivot link.b. Move the lift control lever to the "Float" position.c. Shut off the engine.d. Move the lift control lever to the "Hold" position.e. Carefully loosen the filler cap on the hydraulic oil tank to release the pressure in the system.f. Carefully loosen the plugs located at the rear of the tilt cylinder. When the oil from the loosened plugs stops running, tighten the two plugs. To release the pressure in the attachment cylinders, carefully loosen the two large plugs near located near the plugs located at the rear of the tilt cylinder. When the oil from the two plugs stops running, tighten the two plugs.g. Tighten the filler cap on the hydraulic oil tank. The system pressure has now been released.3. Drain the oil from the hydraulic system. The capacity of the hydraulic system is 140 liters (36.4 U.S. gal). 4. Position a suitable floor jack under crankcase guard (1). Remove the six bolts that hold the crankcase guard to the frame of the machine. Remove the guard from under the machine. The weight of the crankcase guard is 54 kg (120 lb).
View From Under Machine5. Disconnect tube assembly (4) at the tube assembly which goes to the hydraulic oil cooler.6. Disconnect lower radiator tube assembly (2) from the radiator.7. Remove bolt (3) that holds the hose support bracket to the radiator shroud.
View From Under Machine8. Disconnect wiring harness (6). Remove two clips (5) from the frame of the machine. 9. Remove the bolt, washer and hose bracket (7) from the radiator shroud. 10. Loosen the two clamps that hold upper radiator tube assembly (8) in place. Remove the tube assembly.
Do not damage the radiator core during removal of the adapter and the fan assembly.
11. Fasten a lifting sling and a hoist to adapter (10) for the fan assembly as shown.12. Remove six nuts (9) and the washers that hold the fan adapter to the fan drive. Carefully place the fan assembly with the adapter against the radiator core. 13. Open the grill on the radiator guard group.14. Disconnect tube assembly (11) from the hydraulic oil cooler. 15. Remove one bolt (12) and the washer from each side of the radiator guard.16. Remove four bolts (13) and the washers from each side of the radiator guard. 17. Close the grill on the radiator guard group. Fasten tool (A) and a hoist to radiator and guard (14) as shown. Remove the radiator and guard as a unit. The weight of the unit is 590 kg (1300 lb). The following steps are for the installation of the radiator and guard.18. Fasten a hoist to radiator and guard (14). Put the unit in position on the frame of the machine. Open the grill.19. Install four bolts (13) and the washers on each side of the radiator guard.20. Install one bolt (12) and the washer on each side of the radiator guard.21. Connect tube assembly (11) to the hydraulic oil cooler.
Do not damage the radiator core during installation of the adapter and fan assembly on the fan drive.
22. Fasten a lifting sling and a hoist to adapter (10) for the fan assembly. Carefully place the adapter and fan assembly against the fan drive. Install six nuts (9) and the washers that hold it.23. Reinstall upper radiator tube assembly (8) and the two clamps which hold it.24. Put hose bracket (7) in position on the radiator shroud, and install the bolt and washer that holds it.25. Connect wiring harness (6), and install two clips (5) that hold it in position on the side of the frame.26. Put the hose support in position on the lower side of the radiator shroud, and install bolt (3) that holds it.27. Connect lower radiator tube assembly (2) to the radiator.28. Reconnect tube assembly (4).29. Fill the cooling system with coolant and the hydraulic oil tank with oil to the correct levels. See the Operation & Maintenance Manual for the correct filling procedures.30. Start the engine, and check for leaks.31. Reinstall crankcase guard (1).