Technical Service Bulletin

Meridian FEL Hydraulic Pump CV Drive
Shaft Replacement Procedure

Date: February 17, 2017
Bulletin Name: FEL-TSB-032
Models: Meridian Front Loader 78
Units Affected: In-service dates of 1/1/2016 -

1/31/2017

Purpose:
McNeilus Truck and Manufacturing requires the Meridian Front Loader hydraulic pump CV drive shaft be replaced
because the shafts may be too short and are suspect to disengaging. The hydraulic pump CV drive shaft can
break or twist. A hydraulic pump CV drive shaft failure will affect hydraulic pump operation which controls refuse
body functions and does not affect chassis driving functions. You must replace the hydraulic pump CV drive shaft,
even if you have recently replaced it.

Notice:
• This bulletin should be read and understood in its entirety before performing this update procedure.
• All procedures outlined in the bulletin must be performed by skilled service personnel. Refer to the product
service manual for descriptions of maintenance procedures.

SAFETY NOTICE

Perform your company’s Lockout/Tagout
procedure. If your company does not have a
Lockout/Tagout procedure, follow OSHA
1910.147 and 1910.146 Confined Space as
appropriate.

SAFETY NOTICE

Use appropriate Personal Protective
Equipment (PPE) as required by your
company.

Tools and Equipment Required (Customer to supply own):
•
•
•
•
•
•

Tape measure
Torque wrench
Ratchet extension
Wrenches (see procedure for varying sizes)
Machinist’s marker
Loctite® 263

1

Procedure 1: Safety Set-Up
1. Place unit on a flat surface, block truck tires, and observe all conditions of the Safety Notice concerning
Lockout/Tagout posted in this bulletin.
2. Battery Disconnect Switch
If your vehicle is equipped with a battery disconnect switch, it is located near the battery box. Use the battery
disconnect switch when performing any maintenance so the vehicle cannot accidentally be started.
1. Turn the battery disconnect switch (Figure 1, Item 1) counterclockwise so the hole on the switch aligns with
the hole in the bracket (Figure 1, Item 2).
2. Install the safety lockout device ring (Figure 2, Item 1) through the holes on the battery disconnect switch
and the bracket.
3. Install a padlock (Figure 2, Item 2) onto the safety lockout device ring, lock it, and put the key in your
pocket. If more than one person is working on the vehicle, each person must install his or her own padlock.

al of
Unauthorized remov
result
this lock/tag may rge.
in immediate discha
Remarks:

e has
This energy sourc
OUT!
been LOCKED

2

1

DANGER

1

ON

ON

2

Figure 2

Figure 1

Battery Cable Disconnect
If your vehicle is not equipped with a battery disconnect switch, disconnect the negative (black) battery cable
first, then disconnect the positive (red) cable.

WARNING

For trucks without a battery disconnect switch,
to prevent accidental vehicle start-up, which
could cause death or serious injury, disconnect
battery cables (negative cable first) before
proceeding.
Disconnect negative (-) battery cable first. If
positive (+) cable should contact ground with
negative (-) cable connected, the resulting
sparks can cause a battery explosion, which
could result in death or serious injury.

2

Procedure 2: Inspect the Hydraulic Pump CV Shaft
1. The hydraulic pump CV shaft is in good working condition and does not need to be replaced if all of the
following four conditions are met,
a. If the hydraulic pump CV shaft does not show damage.
b. If the pump mount shaft side is torqued correctly at 35 ft.-lbs. per bolt.
c. If there is 1/8” gap between the pump and CV shaft (Figure 3).
1/8” GAP BETWEEN
PUMP AND CV SHAFT

Figure 3

d. If the hydraulic pump CV shaft has approximately 1” of movement when gripped and moved back and
forth.
◦◦ Use a machinist’s marker to mark a location on the shaft near the cover (location not critical) (Figure 4).

Mark shaft near cover

Figure 4

◦◦ Using your hand, move the shaft in one direction and check that it moves 3/8” to 1/2” from the mark
(Figure 5). Repeat in the other direction. NOTE: Shaft should move back and forth a total of 3/4” to 1”.

Figure 5

3

• If the conditions are met, this bulletin is complete. Remove your company’s Lockout/Tagout per your
company’s procedure. If your company does not have a Lockout/Tagout procedure, follow OSHA 1910.147
and 1910.146 Confined Space as appropriate. Return truck to service.
2. If the hydraulic pump CV shaft is damaged, is not torqued correctly, has more or less than 1/8” gap between
pump and CV shaft, or moves more or less than 3/4” to 1” back and forth, the hydraulic pump CV shaft must
be replaced. Follow the remainder of this bulletin for instructions to measure the shaft length and install a new
shaft.

Procedure 3: Determine Length of the Hydraulic Pump CV Drive Shaft
To determine the required length of the new hydraulic pump CV drive shaft, measure the length of the area the
hydraulic pump CV shaft occupies on the truck.
1. Remove and retain the hardware (Figure 6, Item 1) from the square Pump Mount cover (Figure 6, Item 2).
NOTE: Do not remove the circular cover.

2

1

Figure 6

2. Use a tape measure to measure from the PTO flange to the front face of the pump on the vehicle (Figure 7
shown with the CV shaft removed for illustrative purposes only. There is no need to remove the CV shaft to
obtain the measurement).
3. Subtract 1/8” from the measurement. (This is to account for the gap between the pump and hydraulic pump
CV drive shaft.)
• Write down this measurement to order a new hydraulic pump CV drive shaft from McNeilus Parts.

Figure 7

4

4. Reinstall the square pump mount cover (Figure 8, Item 5) with the retained hardware (Figure 8, Item 6). Use a
torque wrench to torque the hardware to 28 ft-lbs.

2

1

Figure 8

5. Order the require parts and the new Hydraulic Pump CV Shaft that is listed on the Part Number List
according to the length needed. See all required parts and part number list below.
NOTE: Shaft lengths are in increments of 1”. Round measurement numbers as follows:
For numbers .000” to .499” round DOWN.
For numbers .500” to .999” round UP.

Parts Required per Truck:
Purchase the following parts from McNeilus Truck and Manufacturing, Inc. by calling 888-686-7278.
Hydraulic Pump CV Shaft Lengths and Part Numbers
Length

Part Number

24

1562473

25

1550456

29

1488014

30

1484576

31

1488017

32

1484577

34

1488021

35

1484578

36

1488022

37

1547495

38

1552189

39

1552191

40

1560608

41

1558837

5

Item

Part Number

1

Varies - See Part
Number Listed

2

—————

3

Description

Qty.

Hydraulic Pump CV Drive Shaft (assembly contains
hardware items 2 through 4)

1

6MM ALLEN HEAD BOLT*

2

1140169

SCR, CAP, HEX .38-24X1.00 G8 ZY

4

4

0120302

WASH, LK, IN .38X.69X.04 ZC

4

5

1552174

COVER, MTG, BRKT, CV, SHAFT, WLDT

1

*The (2) 6mm Allen head bolts will come with the hydraulic pump CV drive shaft as part of the flange assembly.
NOTE: The flange on the PTO side will come attached to the hydraulic pump CV drive shaft; however, the flange
on the Pump side will come detached for ease of installation. The six bolts to attach the flange to the CV shaft will
be included separately.

PROCEDURE 4: Replace Hydraulic Pump CV Drive Shaft
Once you receive the new hydraulic pump CV drive shaft, follow these steps to remove the old drive shaft and
install the new drive shaft.

Tools and Equipment Required per Truck:
•
•
•
•
•

Torque wrench
Ratchet extension
Wrenches (see procedure for varying sizes)
Machinist’s marker
Loctite® 263

Remove Existing Hydraulic Pump CV Drive Shaft
1. Refer to Procedure 1 on Page 2 for Safety Setup and Lockout/Tagout.
2. Remove and retain the hardware using the appropriate wrenches (Figure 9, Items 3 and 4) from the support
plate (Figure 9, Item 2) to disconnect the circular Pump Mount cover (Figure 9, Item 1) from the support plate.
• NOTE: Item 2 is the support plate that is attached to the transmission. The circular cover attaches to the
support plate. The plate is shown detached from the transmission for illustrative purposes only. Do not
detach the plate from the transmission.
3. Remove and retain the hardware (located on topside and bottom side of the cover) (Figure 9, Item 7) from the
square Pump Mount cover (Figure 9, Items 5 and 6).
4. Remove and retain the hardware connecting the square pump mount cover to the pump (hardware not
shown, but location shown in Figure 9, Item 8).
5. Remove both halves of the square pump mount cover (Figure 9, Items 5 and 6).
6. Retain the pump mount cover that was not connected to the pump (Figure 9, Item 5). Discard the pump
mount cover that was connected to the pump (Figure 9, Item 6).

6

2

4

3

5
1

7

8
6

Figure 9

7. Remove the hydraulic pump CV drive shaft from the vehicle using the appropriate tools. Discard hydraulic
pump CV drive shaft.

Install New Hydraulic Pump CV Drive Shaft
1. Slide the circular Pump Mount cover onto the new hydraulic pump CV drive shaft the same way it was
originally.
2. Starting on the PTO connection side, apply Loctite 263 to the new four (4) bolts (P/N 1140169).
3. Use the bolts and new four (4) lock washers (P/N 0120302) to install the CV shaft to the PTO (Figure 10).
4. Use a torque wrench to torque each bolt to 37 ft.-lbs. (Figure 10).

To PTO

Use Loctite 263 and
torque to 37 ft.-lbs.
Figure 10

7

5. Apply Loctite 263 to the new two (2) 6mm Allen head bolts.
6. Install the CV shaft adapter flange into the pump spline until there is a 1/8” gap between the pump and flange
(Figure 11).
7. Tighten the bolts, but do not torque at this step.

To Pump

Apply Loctite 263

Insert flange into spline
until 1/8” gap between
pump and flange
Figure 11

8. Apply Loctite 263 to the new six (6) bolts.
9. Use these bolts to attach the Pump Mount adapter flange to the new CV shaft (Figure 12).
10. Use a torque wrench to torque each bolt to 30 ft.-lbs.

To Pump Mount Side

Apply Loctite 263 and
torque to 30 ft.-lbs.

Figure 12

11. Use a torque wrench to torque each 6 mm Allen head bolt to 35 ft.-lbs. on the flange.

8

12. Using the appropriate wrenches, reinstall the retained hardware (see Figure 13, Items 3 and 4) to attach the
circular Pump Mount cover (Figure 13, Item 1) to the support plate (Figure 13, Item 2). Tighten hardware until
tight.

4

2

3

1
Figure 13

13. Use a machinist’s marker to mark a location on the shaft near the cover (location not critical) (Figure 14).

Mark shaft near cover

Figure 14

14. Using your hand, move the shaft in one direction and check that it moves 3/8” to 1/2” from the mark (Figure
15). Repeat in the other direction. NOTE: Shaft should move back and forth a total of 3/4” to 1”.
IMPORTANT: If the shaft moves more or less than 3/4” to 1” back and forth, it may be installed incorrectly or the
wrong length. Contact a McNeilus National Service Representative at 888-686-7278 for assistance.

Figure 15

9

15. Using appropriate wrenches, install the new pump mount cover (P/N 1552174) (Figure 16, Item 1) using the
retained hardware (Figure 16, Item 2) to the pump mount support plate (Figure 16, Item 3).

2
1

3
Figure 16

16. Install the existing half of the pump mount cover (Figure 17, Item 1) using the retained hardware (Figure 17,
Item 2). Use a torque wrench to torque the hardware to 28 ft.-lbs.

2

1

2

Figure 17

17. Procedure is complete.
18. Remove your company’s Lockout/Tagout per your company’s procedure. If your company does not have a
Lockout/Tagout procedure, follow OSHA 1910.147 and 1910.146 Confined Space as appropriate.

10

Reimbursement of Costs:
Upon receipt of the parts, complete the Hydraulic Pump CV Drive Shaft Replacement Procedure for each
affected unit. The time of accomplishment may vary due to a number of factors; however, the estimated time for
completion of the inspection and measuring procedures is 1 hour under normal circumstances. The estimated
time for completion of the new hydraulic pump CV drive shaft installation procedure is 1 hour under normal
circumstances. Affected units shall be repaired using the customer’s own qualified service technicians.

Labor Reimbursement:
In order to receive credit if you qualify, claims must be submitted through the normal McNeilus Warranty claim
system*. Claims must be received within 30 days of the repair. Claims must include the McNeilus serial number
of the truck, the customer asset number, and the number of this bulletin. NOTE: One claim per truck.
Labor Reimbursement: 1 Hour for Inspection and Measuring Procedures (Procedures 2 and 3)

1 Hour for new hydraulic pump CV drive shaft Installation Procedure

(Procedure 4)

Parts Reimbursement:
Parts and ground shipping will be reimbursed to the customer. Parts necessary for this repair must be ordered
from McNeilus Parts at 888-686-7278.
Claims must be submitted through the normal McNeilus Warranty claim system. Claims must be received
within 30 days of the repair. Claims must include the McNeilus serial number of the truck, the customer asset
number, and this bulletin’s number. NOTE: One claim per truck.

Deadline:

If required, this service update should be performed at the earliest opportunity. The following terms must be
met to qualify for reimbursement cost.
• For reimbursement, a warranty claim form with proof of installation must be submitted by: August 17, 2017
* File a labor reimbursement claim for the 1 hour of inspection and measuring procedures after the inspection
and measuring procedures are completed. If it is necessary to replace the hydraulic pump CV drive shaft, file a
labor reimbursement claim for the 1 hour of installation procedure after the procedure is completed.

Contact:

If you have questions or need further information, please contact a McNeilus National Service Representative at
888-686-7278.

Continuous Improvement:

The change included in this bulletin is part of the
McNeilus® Continuous Improvement Process.
McNeilus® Company’s quality policy is Providing Customer
Satisfaction through Innovative Products, Dedicated Service,
and a constant focus on Continuous Improvement.
“The Customer is our Boss!”
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(888) 686-7278
www.streetsmartparts.com