B50D HYDRAULIC PUMP ALIGNMENT PROCEDURE

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1 B50D HYDRAULIC PUMP ALIGNMENT PROCEDURE Machine NEW MACHINES EX-FACTORY WITH THIS CHANGE: DATE VIN Part Manuals Affected B50D AH500D INTERCHANGEABILITY (ICA) YES = New and Old parts are interchangeable NO = New and Old parts are not interchangeable SU = Supersedes = New part can be used instead of Old part but not vice-versa NEW P/NO. DESCRIPTION QTY ICA OLD P/NO. DESCRIPTION QTY This SIB has been created to assist service personnel to carry out hydraulic pump alignment on a B50D. AFFECTS VALIDITY YES NO Implementation Date: OPERATION CIRCULATION YES NO Warranty: Hitachi: On repair/as requested: John Deere: Special equipment required: Bell Customers: P/No change/addition/supersession: Bell Dealers: Use up stock on hand: Parts Team: Scrap stock on hand: Sales Team: Return stock for credit: Service Team: Mod into Production: Lubrication affected: REASON FOR BULLETIN YES NO Safety: Improvement: Urgency: Reactionary: Page 1 of 11

2 1. GENERAL INFORMATION 1.1. Scope This document covers the procedure to be followed to align the coupling of the hydraulic pump with the engine PTO flange, after the hydraulic pump and engine have been installed to the chassis. It also provide the information in respect of machines used in the field, where the hydraulic pump rubber mountings have already settled, resulting in a change of the angle of alignment between the hydraulic pump coupling and the engine PTO flange Inspection and Safety Check that Parts to be assembled or fitted are clean and not damaged Report any damage before commencing work Special Tools Page 2 of 11

Fig. 1 1.3.1. The following special tools will be used (Fig. 1): 1 Tool, Inclinometer - part/no. 280630.

3 Fig The following special tools will be used (Fig. 1): 1 Tool, Inclinometer - part/no Tool, align, pump, PTO- part/no Coupling puller - part/no Locking spanner - part/no Page 3 of 11

2. HYDRAULIC PUMP TO ENGINE ALIGNMENT NOTE: It is essential that the engine has been properly installed and aligned with the transfer case before the alignment of the hydraulic pump in respect of the

4 2. HYDRAULIC PUMP TO ENGINE ALIGNMENT NOTE: It is essential that the engine has been properly installed and aligned with the transfer case before the alignment of the hydraulic pump in respect of the engine PTO adaptor flange is done Install the Pump to PTO Flange Alignment Tool Fig. 1 NOTE: The pump to PTO alignment tool (1) is used and installed so that the inclinometer tool has a perfectly level surface to be placed on Fasten the pump PTO alignment tool (1) to the PTO flange adaptor (2) on the rear right hand side of the engine, using two nyloc nuts (3) part/no (Fig. 1). Page 4 of 11

2.2. Install the Hydraulic Pump Coupling Fig. 1 2.2.1. Apply Loctite 638 Green (1) - part/no. 280088 to the splines of the hydraulic pump coupling (2) - part/ no. 207352 (Fig. 1). Fig. 2 2.2.2. The hydraulic pump coupling (1) will be installed to the shaft of the hydraulic pump using the coupling puller tool (2).

5 2.2. Install the Hydraulic Pump Coupling Fig Apply Loctite 638 Green (1) - part/no to the splines of the hydraulic pump coupling (2) - part/ no (Fig. 1). Fig The hydraulic pump coupling (1) will be installed to the shaft of the hydraulic pump using the coupling puller tool (2). The threaded bolt part (3) will be inserted through the coupling (1) and screws into the threaded hole in the shaft of the hydraulic pump (Fig. 2). CAUTION When screwing the coupling puller tool into the threaded hole of the hydraulic pump shaft, do not use excessive force. Use a 19mm flat spanner on the flat machined planes at the end to counter the force when screwing the large nut with the 50mm flat spanner to pull the coupling (1) onto the splined shaft. Page 5 of 11

Fig. 3 2.2.3. Align the splines of the hydraulic pump coupling (1) to the splined shaft of the hydraulic pump and push it on by hand, as far as it will go (Fig. 3). 2.2.4.

6 Fig Align the splines of the hydraulic pump coupling (1) to the splined shaft of the hydraulic pump and push it on by hand, as far as it will go (Fig. 3) Screw the smaller threaded end of the puller tool into the hydraulic pump shaft and then use a 19mm flat spanner (3) at the rear end to screw it in fully (Fig. 3) Use a 50mm spanner on the large hexagon nut (2) to screw and pull the coupling (1) fully onto the shaft of the hydraulic pump (Fig. 3) Unscrew and remove the puller tool. Page 6 of 11

Fig. 4 2.2.7. Before securing the hydraulic pump coupling (1) to the splined shaft of the hydraulic pump, apply medium strength thread locker, blue -part/no.

100944 and washer (4) - part/no. 160009 securely. Torque to 22 Nm. (Fig. 4). 2.3.

7 Fig Before securing the hydraulic pump coupling (1) to the splined shaft of the hydraulic pump, apply medium strength thread locker, blue -part/no (equivalent of Loctite 243) to the hex head bolt (3) -part/no (Fig. 4) Use the locking spanner (1), inserting it from the back to retain the hydraulic pump coupling (2) while fastening the hex head bolt (3) - part/no and washer (4) - part/no securely. Torque to 22 Nm. (Fig. 4) Verifying the Degrees of Alignment Between Flanges NOTE: Inclinometer -Basic operation: To get the most accurate reading when placing the inclinometer on the surface to be measured, allow the unit to settle for 5 seconds before noting the angle. If you need to take a measurement with the inclinometer in an unreadable position, or if you need to temporarily lock in a reading while you record it, simply push the hold button while measuring the angle. (Make sure the inclinometer has been in position and still for 5 seconds). To release, press the hold button again. Fig Switch the inclinometer (2) on and place it vertically and flush to the surface of the PTO alignment tool (1) installed on the PTO flange on the right hand rear of the engine (Fig. 1). Page 7 of 11

2.3.2. While making sure the inclinometer is vertical and perfectly flush to the surface, press the ALT ZERO button. ALt then - 0 - and eventually 0.00 will be displayed in the display window (4).

8 While making sure the inclinometer is vertical and perfectly flush to the surface, press the ALT ZERO button. ALt then and eventually 0.00 will be displayed in the display window (4). The inclinometer is now zero-ed in respect of the engine PTO flange and will now be positioned on the hydraulic pump coupling in order to determine the degree of vertical alignment between these two components (Fig. 1). Fig Place the inclinometer (2) - which has been set to zero on the engine PTO flange - vertical and perfectly flush on the surface of the hydraulic pump coupling (1). (Fig. 2). NOTE: It is suggested that both methods of positioning the inclinometer (2) is performed, as shown above - Position A; Position B. This method of double-checking the reading will ensure an accurate reading (Fig. 2) Allow the inclinometer (2) to settle for 5 seconds, then press the HOLD button to freeze or hold the reading in the display window (the direction arrow in the reading will display in a flashing mode) (Fig. 2). NOTE:1. Take note of the direction in which the directional arrow (3) points, since the requirement is that the angle will be finally offset by 0.75 degrees to 1.1 degrees for newly assembled machines (For used machines, in which case the rubber mountings on the hydraulic pump has settled in, the degree of compensation (offset) is 0.35 degrees to 0.55 degrees). That means that the directional arrow will point in the direction shown above to get the required offset (Fig 2). 2. To achieve the required offset, the hydraulic pump coupling will be tilted at the top, towards the engine (Fig. 2). Page 8 of 11

9 Fig Above drawing shows the required degrees of alignment between the hydraulic pump coupling and the PTO flange on the engine. Take note of the table detailing the requirements for a newly assembled machine and for an older running machine. Take also note of the direction the arrow (1) must point to when final adjustment is done (Fig. 3). NOTE: The reason for overcompensating when aligning the hydraulic pump coupling is that the rubber mountings settle with time, having the effect that there is a change in the hydraulic pump s alignment with the engine PTO flange. Page 9 of 11

2.4. Shimming the Hydraulic Pump to Adjust the Angle Fig. 1 2.4.1. If the measured degrees do not fall within the required range, then the hydraulic pump will be adjusted by means of shims.

10 2.4. Shimming the Hydraulic Pump to Adjust the Angle Fig If the measured degrees do not fall within the required range, then the hydraulic pump will be adjusted by means of shims. NOTE:The hydraulic pump will only be shimmed at the two bottom mounts, and then only on the chassis side as indicated above Partly loosen the two sets of bolts, washers and stover nuts (1) and insert the 1mm shims (2) part/no two shims per side will adjust the angle by more or less 0.5 degrees (Fig. 1). NOTE:The stover nuts need only be replaced if they were fully removed from the bolts Fasten the two sets of bolts, washers and stover nuts (1) properly (Fig. 1). Page 10 of 11

Fig. 2 NOTE:The inclinometer cannot be re calibrated (new reading taken) when the hold feature is engaged. The hold feature is disengaged automatically when the unit shuts off or is turned off. 2.4.

11 Fig. 2 NOTE:The inclinometer cannot be re calibrated (new reading taken) when the hold feature is engaged. The hold feature is disengaged automatically when the unit shuts off or is turned off Place the inclinometer (2) on the flat plane of the hydraulic pump coupling (1) and measure the angle once again (Fig. 2) Repeat the necessary steps until the hydraulic pump coupling and the engine PTO flange are within the required angle of alignment, as specified in this procedure (Fig. 2). Fig Unscrew the two nyloc nuts (2) and remove the pump PTO alignment tool (1) from the PTO flange adaptor on the engine (Fig 3). THIS CONCLUDES THE PROCEDURE Page 11 of 11

Service Bulletin No. 1086

Service Bulletin No. 1086 Circulate to listed addressees COACH MODEL : C2045 BULLETIN TYPE : Field Change Program: NHTSA campaign number 01V-176 MANUAL & SECTION : Maintenance Manual : Chapter 11 - Body