9559A 5 Mercruiser GEAR HOUSING ASSEMBLY (BASIC)

At operating temperature, the hydraulic oil tank 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 implement hydraulic circuits (boom, stick, and bucket) before any hydraulic lines or components are disconnected or removed as follows:a. Start the engine.b. Fully retract the stick cylinder rod.c. Adjust the position of the bucket so that it will be flat on the ground when the boom is lowered.d. Lower the boom until the bucket is flat on the ground.e. Shut off the engine, and place key in the "ON" position. Put the hydraulic activation control lever in the "UNLOCK" position.f. Move the control levers for boom, stick and swing to all full stroke positions. This will release any pressure that might be present in the pilot system.g. Return the key to "OFF" position.h. Slowly loosen the fill plug on the hydraulic tank, and release the pressure.i. Tighten the fill plug on the hydraulic tank to as torque of 68 7 N m (50 5 lb ft).j. The pressure in the hydraulic system has been released and lines and components can be removed.2. Drain the oil from the hydraulic oil tank into a suitable container for storage or disposal. The capacity of the hydraulic oil tank is 140 liters (37 U.S. gal). 3. Remove four bolts (1), the washers and support assembly (2).
Do not damage the hydraulic oil cooler core when the air conditioner condenser is being removed.
4. Remove four bolts (3) that hold air conditioner condenser (4) to the hydraulic oil cooler. Lay the air conditioner condenser out of the way of the hydraulic oil cooler. 5. Place a drain pan under the hydraulic oil cooler. Oil will flow from the hose connections when they are disconnected.6. Loosen two clamps (5) on hose assembly (6). Loosen two clamps (10) on hose assembly (11).7. Remove two clamps (8) and four bolts (9).8. Remove tube assemblies (7) and (12) from the hydraulic oil cooler. 9. Fasten a hoist to hydraulic oil cooler (14) as shown. Remove four bolts (13) that hold the hydraulic oil cooler in position. Remove the hydraulic oil cooler from the machine. The weight of the hydraulic oil cooler is 79 kg (175 lb). The following steps are for the installation of the hydraulic oil cooler.10. Check the condition of the hydraulic oil cooler prior to installation. Remove any dirt or debris that may restrict the flow of air through the core. If any of the cooling fins are bent, they should be straightened. 11. Fasten a hoist to hydraulic oil cooler (14) as shown. Carefully install the hydraulic oil cooler in the machine. Install four bolts (13) that hold it in position. 12. Install tube assemblies (7) and (12).13. Install two clamps (8) and four bolts (9).14. Tighten two clamps (10) on hose assembly (11).15. Tighten two clamps (5) on hose assembly (6). 16. Put air conditioner condenser (4) in position on the hydraulic oil cooler. Install four bolts (3) that hold it in position. 17. Install support assembly (2), the washers and four bolts (1).18. Fill the hydraulic oil tank with oil to the correct level. Refer to the Operation & Maintenance Manual for the correct filling procedure.End By:a. install hood assembly