Subsidiary of Federal Signal Corporation TO: ALL ELGIN DISTRIBUTORS SERVICE AND PARTS MANAGERS SUBJECT: Pelican P, PW, & SE Brake Master Cylinder Mandatory Campaign Effectivity: Sweepers: P4389D - P4469S, except P4432D, P4467D, P4468D, including PW Models. S9234D - S9270D, except S9235D, S9236D, S9262S, S9263D, S9265D, S9266D Master Cylinders: Elgin P/N s 6063344 and 1055327 with Date Codes 04M259 through 04M365 and 05M001 through 05M050 NOTE: Purpose: SERVICE BULLETIN Elgin Sweeper Company 1300 W. Bartlett Rd. Elgin, IL. 60120-7529 847-741-5370 The above Pelican Series P, Series PW, and Series SE sweepers shipped after October 1, 2004 and units that may have the above Elgin replacement Master Cylinder installed after 9/15/2004 need immediate attention! Anyone who might operate any of the machines listed above should be notified immediately to check for proper brake pedal height per the test procedure below. To provide instructions for evaluating the brake pedal position and instructions for installing new components in the brake system master cylinder. Owners of record of machines listed above have been notified by Elgin Sweeper of a possible defect in the brake master cylinder relief valve. This bulletin describes specific actions necessary to ensure safe operation and proper brake system performance. FSO kit 1081400 is available from Elgin Sweeper containing the parts and instructions needed to repair the master cylinder. These kits will be ordered by Elgin Dealers and installed by the dealer or customer per the instructions below. Operators and maintenance personnel should frequently review Elgin s website for Technical Tips and Updates regarding the operation and maintenance of Elgin products. (www.elginsweeper.com) OPERATION OF CERTAIN PELICAN SWEEPERS BEFORE REPLACING BRAKE CYLINDER PARTS COULD RESULT IN BRAKE FAILURE, LEADING TO PROPERTY DAMAGE, SERIOUS INJURY OR DEATH. FOLLOW THE INSTRUCTIONS OF THIS ELGIN SERVICE BULLETIN TO MAKE NECESSARY REPAIRS BEFORE FURTHER OPERATION OF THE AFFECTED SWEEPERS. ALWAYS REFER TO SAFETY SECTION IN OPERATORS MANUAL BEFORE STARTING WORK. 1. Machine Test Procedure 1.1. The first step is to test the brake system by checking the brake pedal(s) position per the procedure below. It is imperative to test the brake system before operation as instructed below. 1.1.1. Chock the front and rear of either front tire. 1.1.2. Start the engine and run at low idle, disengage the parking brake. 1.1.3. Push right side brake pedal hard (150-175 lbs [68 80 KG]), hold in the depressed position. 1.1.4. Measure the distance between the bottom of the brake pedal lever and the bottom of the kick plate slot (Fig.1 Dimension A). Repeat the pedal application and measurement five times. Repeat the above four steps on the left side brake pedal. The left side brake pedal is present on Pelicans equipped with dual steering. 1.1.5. If the pedal lever travels to bottom of the slot or any of the measurements are less than 1.0 [25 mm], the brake system may not operate properly. DO NOT OPERATE THE MACHINE UNTIL THE BRAKE SYSTEM HAS BEEN REPAIRED. RED TAG AND PARK THE MACHINE. 1.1.6. If the measurements are all greater than 1.0 [25 mm] the machine can be operated until the FIGURE 1 updated parts are installed. All machines covered by this campaign must have updated parts installed. 2. Description of problem: some Pelican Series P, Series PW, and Series S brake master cylinders may have relief valve end caps that can seize the valve spool and prevent correct brake operation. The 03/05 Page 1 0f 5
master cylinder has a low pressure circuit that provides rapid take up of the brake shoes and a high pressure circuit for brake application. If the master cylinder relief valve is seized, fluid will be applied by the high pressure circuit only and the brake shoes may not be capable of moving through a complete application stroke. Replacement of the end cap will prevent valve seizing and increasing the relief pressure will improve pedal height and stiffness. A new spring has been included with an end cap in the kit. 3. Follow the steps described below to install FSO Kit 1081400 to properly repair the machine. The kit may be installed by Elgin Dealers or customers who choose to complete the repair. Customers who complete the repair will receive a $100 parts coupon within two weeks of sending Elgin Sweeper the parts removed and the completed Campaign Data Sheet. The parts coupon is redeemable at any Elgin Dealer. 4. Each machine must be repaired and a record of the work performed must be reported back to Elgin Sweeper Company. The Campaign Data Sheet provided with this bulletin must be filled out completely and sent to Elgin Sweeper Company at the address provided. Failure to register the repair with this form will delay the delivery of the parts coupon and approval of the subsequent dealer warranty claim. 5. Machine Repair Procedure: 5.1. Fill out unit and customer data on Campaign Data Sheet at the end of this bulletin. Serial number is located inside cab on lower right wall (Fig. 2). 5.2. Remove the right side hydrostatic pedal and floor plate. 5.3. Thoroughly clean the master cylinder and surrounding area of all dirt, grease, oil, etc. before servicing the master cylinder. 5.4. Record the master cylinder date code and part number (Pg. 3, Fig. 5E) on the Campaign Data Sheet. 5.5. Document the current right side brake pedal position using Steps 1.1.1 through 1.1.4 above. Record the measurement on the Campaign Data Sheet at the end of this bulletin. 5.6. Loosen lower tube nut on tubing assembly (Diag. 1, 1) FIGURE 2 and remove the upper tube nut on the tubing assembly from the elbow fitting (Diag. 1, 2). Loosen tube nuts with a 7/16 flare nut wrench. Rotate tubing assembly away from master cylinder (Pg. 3, Fig. 3A). 5.7. Remove the end cap (Diag. 1, 3) from the piston and body assembly (Pg. 3, Fig. 3B) using a 1-3/8 wrench. Note: The spring (Diag. 1, 4) will be pushing on the end cap (Diag. 1, 3). The piston and body assembly need not be removed from the housing (Diag. 1, 6). Retain end cap, spring, and elbow for return to Elgin. 5.8. Withdraw the spring (Diag. 1, 4) from the master cylinder bore (Pg. 3, Fig. 4C). (If the relief assembly is stuck to the cap (Pg. 3, Fig. 4D), carefully twist the cap loose, being careful to hold the cartridge in the upright position). Keep the spool in the bore, and do not tip the cartridge up side down. Tipping the cartridge may dislodge a metering pin that could cause the relief valve to malfunction. If the metering pin falls out, remove the valve spool, reinstall the metering pin, and reinstall the spool. Gently slide the relief cartridge down into the master cylinder if it lifts out. 5.9. Install the new spring (Diag. 1, 4) into the piston and body assembly. 5.10. Lubricate the o-ring on the end cap (Diag. 1, 3) with clean brake fluid. Install replacement cap. Torque to 65-70 lb-ft [88 95 Nm] (Pg. 3, Fig. 5). 5.11. Install the elbow fitting (Diag. 1, 3) in end cap. Torque the elbow to DIAGRAM 1 Subsidiary of Federal Signal Corporation Service Bulletin Page 2 0f 5 03/05
Bulletin Subsidiary of Federal Signal Corporation Service 9-15 lb-ft. [12 20 Nm] while properly positioning elbow. 5.12. Install tubing assembly leaving upper tube nut (Fig. 6G) loose. Use a 7/16 flare nut wrench to tighten the lower tube nut (Fig. 6F) to 9-15 lb-ft. [12 20 Nm]. 5.13. Fill the brake fluid reservoir with DOT #3 brake fluid. The proper level is 1/8 1/4 [3 6 mm] below the fill cap housing threads. Note: Be sure the breather hole (Pg 2, Diag. 1) in the filler plug is free of all contaminants. A B 5.14. Press the brake pedal slowly to bleed air from the tube FIGURE 3 assembly and tighten the fitting before the pedal reaches the bottom of stroke. Use a 7/16 flare nut wrench to tighten the tube nut (Fig. 6G) to 9-15 ft-lb. [12 20 Nm]. 5.15. Depress the brake pedal firmly with the engine off. A transition in pedal pressure should be felt as the pedal is C depressed through its stroke. This transition is when the master cylinder shifts from the low pressure piston to the D high pressure piston. 5.16. Check the brake system for leaks. Bleed the brake lines if necessary per the Pelican Service Manual. 5.17. Repeat the steps 1.1.1 through 1.1.4 above to document FIGURE 4 the brake pedal position after the rework is complete. Record the pedal position measurement on the Campaign Data Sheet. The pedal height should be greater than 1.0 [25 mm] and higher than the initial measurement. If the pedal height is the same or lower than the height measured before the repair contact Elgin Sweeper Company Service Department at 1-847-741-5370 or 1- E 877-DIAL EPG (1-877-324-5374) for additional instructions. 5.18. Fill the brake fluid reservoir with DOT #3 brake fluid. The proper level is 1/8 1/4 [3 6 Nm] below the fill cap housing threads. 5.19. Reinstall the right side floorboard and hydrostatic pedal. 6. Campaign Documentation: 6.1. Customer Instructions (machine repaired by customer) 6.1.1. Record all data required on the Campaign Data Sheet, and pack the sheet with each spring, end cap, and elbow to be returned. Use the box the parts were packed in and the label provided. 6.1.2. Ship the parts and Campaign Data Sheet to Elgin Sweeper Company, 1300 W. Bartlett Road, Elgin, IL. 60120 Attention: Service Bulletin 0703089. 6.2. Dealer Instructions (machine repaired by dealer) FIGURE 5 F FIGURE 6 G 6.2.1. Record all data required on the Campaign Data Sheet, and pack the sheet with each spring, end cap, and elbow to be returned. Use the box and label provided. 6.2.2. Ship the parts and Campaign Data Sheet to Elgin Sweeper Company, 1300 W. Bartlett Road, Elgin, IL 60120 Attention: Service Bulletin 0703089. 6.2.3. Dealers must file a warranty claim with Elgin Sweeper for the FSO Kit and labor. 03/05 Page 3 0f 5
THIS PAGE IS INTENTIONALLY BLANK Page 4 0f 5 03/05
Campaign Data Sheet Pelican P, PW, and S Brake Master Cylinder Repair Machine Serial Number: Machine Hours: Customer Unit Number: Machine Miles: Brake Master Cylinder Assembly Part #: Date Code: Brake Pedal Position Measurement Before Repair: Brake Pedal Position Measurement After Repair: Customer Name: Customer Mailing Address: Customer Email Address: Customer Contact Person: Contact Person Phone: Elgin Dealer Name: Elgin Dealer Address: Service Technician Name (Print): Service Technician Name (Signature): Date Work Was Completed: Work Completed By: Elgin Dealer Customer (Check one) The old parts and this form MUST be returned to Elgin Sweeper Company, 1300 W. Bartlett Road, Elgin, IL 60120 Attention: Service Bulletin 0703089 QUESTIONS? Contact the Elgin Sweeper Service Department at: 1-847-741-5370 or 1-877-DIAL EPG (1-877-324-5374) 03/05 Page 5 0f 5