Brake Pad and Disc Replacement Instructions
Contents
1. wear surface Discard and replace discs that have grooves deeper than 17mm or are thinner than 17mm 669 in after re surfacing If rotor replacement or reconditioning is not required proceed to Caliper Pad Installation Measure A aie Disc Thickness oe hi aaa Pi Cd T SB 0066 3 PROCEDURE Continued Hub and Rotor Disc Removal 6 Drain the hub lubricant FIGURE 1 7 7 Remove the hub cap using the heavy duty snap ring tool Hi Tec 87 Extra Large Snap ring Pliers or equivalent Scrape the paint from the hub and snap ring lube with penetrating oil and loosen the snap ring in the groove before attempting to remove the ring FIGURE 1 8 IMPORTANT The snap ring may be corroded into the hub and can be difficult to remove In some cases the snap ring may need to be destroyed in order to remove it Refer to the Snap ring Removal section in this bulletin 8 Remove the drive shaft and gear sets and then put them to the side 9 Remove the spindle nut The spindle nut is staked deeply in four places and is impossible to un stake for removal with a wrench The nut must be destroyed to remove it Always replace the Ring Nut with a new one when assembling the hub spindle To remove the nut mark and drill the rim of the nut in two places 180 degrees apart at one of four keyway slots Use a chisel to split the nut EF lt through the drilled area Spread the nut usi2. have O rings Separator FIGURE 1 25 a e Force pistons outward by applying compressed air to the port Pry the seals from the caliper body using a small screwdriver Remove the dust seals from the pistons using a small screwdriver or other suitable tool FIGURE 1 26 SB 0066 9 f Withdraw the pistons and the spring located behind each piston Discard the springs FIGURE 1 27 g Withdraw the sealing O rings from the bores 2 Reassemble the Caliper a Clean the calipers and pistons thoroughly using brake cleaner or solvent Install new sealing O rings in the caliper bores b Install the new dust seals to the pistons Ensure that seal garters are not twisted in the piston groove Lubricate the pistons and O rings with hydraulic oil or assembly lube and install the pistons FIGURE 1 28 c Seat the dust seal bodies in the caliper bore and drive into place with a 2 OD driver NOTE Do not cut or damage the dust seal FIGURE 1 28 d Note the previous assembly markings and assemble the caliper halves and separators as they were disassembled NOTE Ensure that new separator O rings are installed in the correct position FIGURE 1 29 e Tighten the caliper bolts to a torque of 50 lb ft FIGURE 1 30 SB 0066 10 Remove springs from all calipers Install separator O rings in pressur Use reference marking and reassemble Caliper with new o rings Figure 1 30 His and seals f Insta
3. Els T g SERVICE BULLETIN E Repair Instructions Subsidiary of Federal Signal Corporation SUBJECT Brake Repair Instructions for Pelican DATE 3 19 2010 NP NR and NS Sweepers NUMBER SB 0066 TO All Dealer Principals Service Managers Parts Managers and Regional Managers ALWAYS REFER TO THE OPERATOR MANUAL FOR SAFETY INSTRUCTIONS BEFORE STARTING WORK PURPOSE Improved brake rotors have been released to enhance brake wear performance of NP NS and NR sweepers Some sweepers may experience rotor wear that does not meet your customers expectations If this condition exists the rotor should be replaced during a routine brake repair job UNITS TO SERVICE All Pelican NP NR and NS sweepers prior to NP NS NR2000 WARRANTY COVERAGE If the NP NS or NR sweeper is less than 2 years old from the date of first use and has less than 1600 operating hours and has discs rotors thinner than 17mm 669 Elgin will cover the cost of parts and labor on a case by case basis as a goodwill gesture to your customer Contact your Regional Service and Parts Manager for goodwill consideration if you have a customer that is eligible Claims will not be approved without RSPM authorization prior to beginning the repair TOOLS ay Hub Service Kit 7970350 i Open end Wrenches metric and Standard SAE 4 ORFS Plugs i Torque Wrench 290 lb ft min Impact Wrench 2 Drill and Bits 14mm Hex Wrench Parts List Pa
4. ll the pads and pad retaining pins FIGURE 1 31 g Apply Blue Loctite to the caliper capscrews and tighten to a torque of 75 lb ft If calipers are installed while the hub is mounted to the sweeper two people will be required to align and start the caliper capscrews FIGURE 1 32 3 Install the replacement Hydraulic Reservoir Cap P N 1098610 a Remove and discard the original reservoir cap and install 2 psi cap P N 1098610 that will reduce residual hydraulic pressure on the brake pistons FIGURE 1 33 i Replace Cap with P N 1098610 y N SB 0066 11 Snap ring Removal IMPORTANT The snap ring may be corroded into the hub and can be difficult to remove In some cases the snap ring may need to be destroyed in order to remove it Remove the snap ring using a suitable tool FIGURE 1 34 If the snap ring is corroded or stuck in the bore there are a few possible techniques that may be used to loosen it 1A Rust penetrant and vibration a Scrape the paint from the hub and snap ring Lubricate them with penetrating oil b Use either a hammer and punch or an air hammer if available to apply a vibrating force all around the ring Do not apply force to the ring gear casting snap ring groove or the ring gear may be damaged FIGURE 1 35 c Attempt to remove the snap ring using the Snap ring tool d Ifthe snap ring is still stuck apply force with the snap ring tool and repeat the application of penet
5. ng E m 5S3z3 a pry bar and remove the nut Thoroughly clean out any remaining chips before re y assembly FIGURE 1 9 4 CWO places ii rT a NOTE Protect the hub components from drilling chips Chips may be removed with either a magnet or vacuum Do not blow the chips with compressed air If the inner bearing is contaminated by chips disassemble the hub clean the bearing thoroughly and then replace the wheel seal 10 Pry and rotate slightly to loosen the hub inner seal from the spindle Remove the hub and rotor assembly It is possible to remove the assembly by hand but it may be easier to use the hub lifting fixture shown in Appendices 1 and 2 at the end of this section If possible keep the hub tilted slightly outward so that any remaining chip debris can be washed out using brake cleaner or solvent Do not allow chips to contaminate the inner wheel bearing and oil seal 11 Inspect the wheel studs and replace any that are damaged 12 Place the hub on a work surface and remove the brake disc rotor using a 14mm hex allen Brake disc capscrews _ r head wrench FIGURE 1 10 hub must be removed from spindle for access _ Figure 1 10 SB 0066 4 PROCEDURE Continued Mae Inner Bearing 13 Install the new disc Use Blue Loctite on fer J TAA the capscrew threads and tighten the disc capscrews to a torque of 255 lb ft 34 6 kNm Hub and Rotor Disc Installation 14 Dri
6. nimum operational thickness of the disc is Disc Thickness 17mm 669 Discard and replace any discs i io that are or will be thinner than 17mm 669 Bleeders after resurfacing eo Remove Calipers 1 Securely raise and block the sweeper so that the drive wheels can be removed FIGURE 1 2 2 Remove the drive wheels and place tow pins in the tow position FIGURE 1 3 SB 0066 2 PROCEDURE Continued 3 Remove the calipers as instructed in the service manual Calipers may be removed by accessing the 12mm socket head capscrews through the holes in the chassis FIGURE 1 4 and 1 5 Either the brake caliper lines must be plugged to prevent hydraulic oil from Inspect Caliper leaking out or the brake supply line must be Access Holes disconnected and plugged with a 4 ORFS male plug IMPORTANT It is not normally necessary to remove the complete hub assembly from the chassis to service the brake system Inspect the caliper bolt access holes in the chassis If the holes do not provide enough clearance for the caliper bolts to be removed the holes must be enlarged using a die grinder FIGURE 1 5 If more than four 4 holes are misaligned each wheel drive hub or the caliper bolts cannot be made accessible it may be advisable to remove the hub from the sweeper for brake replacement 4 Place the calipers on a work surface for pad replacement FIGURE 1 6 5 Inspect the brake disc rotor
7. r Replace RH or LH side Additional Brake Hub Replacement Operations Flat Rate Quantity if required Remove Stuck Rusted Snap Ring 1 Wheel Fault Code Brakes Hydraulic Brakes Rotor 1hr maximum Labor Code Brakes Hydraulic Brakes Rotor Remove Stuck Snap ring Grind Caliper Access Holes die grinder z Fault Code Brakes Hydraulic Brakes Brake Calipers Orm Og pee Labor Code Brakes Hydraulic Brakes Brake Calipers Enlarge Access Holes Replace Damaged Ring Gear and or Ring Gear O ring Seal Fault Code Brakes Hydraulic Brakes Rotor 1 Wheel Labor Code Brakes Hydraulic Brakes Rotor Replace damaged Ring Gear and Drive Seal Drive 60min maximum Drive Flat Rate for Caliper Spring Removal Remove Caliper Springs and Re assemble Caliper with new Seals 1 hr and 30 min for are 6 Calipers Fault Code Brakes Hydraulic Brakes Brake Calipers Labor Code Brakes Hydraulic Brakes Brake Calipers Remove Springs 6 Calipers Remove and Replace The Hydraulic Cap with New Part Fault Code Brakes Hydraulic Brakes Hydraulic Tank Labor Code Brakes Hydraulic Brakes Replace Cap 6 calipers used per sweeper Warranty Claim Submission Instructions Use the following information when submitting a warranty claim CAUSAL PART 1086400 To create the FAULT CODE and LABOR CODE See the labor chart above In the FAULT FOUND dropdown list select Design Upgrade In the CAUSED BY dropdown list select Product Improvement SB 0066 14
8. rant and vibration Heating the snap ring with an acetylene torch may also help to loosen the snap ring IMPORTANT If heat is applied to the snap ring or the ring is bent during removal the snap ring must be replaced 1B Cut the snap ring in pieces to remove a Ifthe snap ring cannot be loosened and removed by non destructive methods it must be carefully cut into pieces with an acetylene torch FIGURE 1 36 IMPORTANT Only an experienced torch operator should attempt to cut the snap ring The ring gear ring groove may easily be damaged by incorrect torch work b Cut the snap ring in 3 or 4 places and remove the individual pieces using a hammer and chisel Do not damage the hub casting FIGURE 1 37 SB 0066 Figure 1 37 PROCEDURE Cont d 2 Remove cap a Remove the hub cap Aslide hammer with an adapter fabricated to fit the cap drain fill holes may be used to assist in pulling the cap FIGURE 1 38 i Figure 1 38 b Clean the hub snap ring groove cap and snap ring thoroughly and replace the cap sealing O ring FIGURE 1 39 c Install a replacement snap ring if the original was destroyed or damaged FIGURE 1 40 Figure 1 40 SB 0066 13 EFFECTIVE DATE 03 2010 Flat Rate for Brake Replacement Operation Remove and Replace Brake Pads and Disc Rotor includes seal replacement 1 Wheel Fault Code Brakes Hydraulic Brakes Rotor an LO Drive Labor Code Brakes Hydraulic Brakes Roto
9. re that caliper brake fitting threads are correctly engaged before final tightening Calipers or lines may be damaged if threads are cross threaded 5 Apply Blue Loctite to the caliper capscrews and tighten to torque of 75 lb ft FIGURE 1 20 If calipers are installed while the hub is mounted to the sweeper two people will be required to align and start the caliper Capscrews 6 Re connect the service brake line if previously unplugged 7 Bleed the service brakes as instructed in the Pelican Service Manual Two people may be required for the brake bleeding procedure 8 Fill the hub gear case with SHC629 lubricant until level with the check plug in the horizontal position see the Operator Manual Bleed the brake calipers using the procedure found in the Service Manual FIGURES 1 21 and 1 22 SB 0066 PROCEDURE Continued 9 Install the wheel and tighten the wheel nuts to 290 lb ft FIGURE 1 23 10 Remove the axle blocking lower the hopper and operate the sweeper to ensure proper operation and to check for leaks Repair any leaks or failures that are discovered Appendix Weld a suitable clevis loop or Fabricated Hub i A A ring for attaching the hoist eng ace ale Fabricate device from 1 x2 med wall tubing or equivalent Weld and gusset as required for strength Attachment plate is 2 x4 3 8 or thicker with 1 hole for stud attachment SB 0066 8 Caliper Sp
10. ring Removal and Hydraulic Cap Replacement PURPOSE At the first brake pad service interval remove the caliper springs from beneath the pistons and replace the hydraulic vent cap with 2psi cap P N 1098610 Replacement of the hydraulic cap removal of the caliper springs and use of replacement disc rotor will improve brake rotor life UNITS TO SERVICE NP NS NR with RR hub TOOLS PARTS LIST aly 40mm Hex Wrench Brake Caliper Seal Kit 3 calipers whl O ring Pick Hydraulic Reservoir Cap Small Screwdriver Scribe or Marking Paint a Usual Mechanic Hand Tools PROCEDURE Brake disc wear on Pelican NP NS and NR sweepers may be improved by performing several steps at the first brake service interval e Install Hydraulic Reservoir cap with 2psi rating to replace the original 7psi cap e Remove the piston assist springs from the caliper assemblies e Install new brake discs rotors 1 Caliper Service Remove Springs a Remove calipers as instructed in Brake Disc and Pad Replacement section of this bulletin Remove the pad retaining pins and remove the brake pads FIGURE 1 24 b Place the caliper in a vise and mark the caliper halves and separators for reassembly FIGURE 1 24 c Remove the four caliper capscrews FIGURE 1 24 d Separate the caliper assembly and note the position of the O rings present in the brake separator plates NOTE Only the passages A Caliper used for brake operation will
11. roperly seated in pockets FIGURES 1 13 and 1 15 23 Remove the Disengage Pin from the cap and clean the pin thoroughly Remove the O ring from the cam and replace with a new O ring 24 Lubricate the Disengagement Pin with grease and reinstall in the cap 25 Remove the cap O ring FIGURE 1 16 and clean the cap thoroughly 26 Install the replacement O ring in the cap Lightly lubricate the cap O ring and place the cap in the hub Tap the cap with a rubber mallet to seat and install the snap ring FIGURE 1 16 Caliper Pad Installation IMPORTANT At the first pad service interval when calipers are removed for pad replacement remove the caliper piston assist springs as instructed in Caliper Spring Removal section of this bulletin Also replace the Hydraulic Reservoir cap with P N 1098610 1 Remove the pad retaining pins and discard the old pads FIGURE 1 17 A 2 Install new pads in the calipers using the a Original retaining pins FIGURE 1 18 If the pins are badly corroded damaged or missing the snap ring replace with 7175720 Pin Kit 3 Clean the calipers rotors and pads with brake cleaner to remove debris or oil from the friction Surfaces on Figure 1 18 SB 0066 6 PROCEDURE Continued 4 Insert a 3 4 spacer fabricate from wood or steel stock to hold the pistons in the retracted position and install the calipers in their original positions FIGURE 1 19 IMPORTANT Ensu
12. rts required for brake pad and disc replacement for two 2 Wheel Drives aly aty 1099451 Brake Disc 1 disc whl 7475719 6 Brake Caliper Seal Kit 7175717 Brake Pad Kit 3 calipers whl eae 4 Loctite blue removable Usual Mechanic Hand Tools i Slide Hammer w Cap Adapter 1 1 5 16 Socket Wrench 12mm Hex Wrench 1098610 Hydraulic Reservoir Cap 7175689 Spindle Ring Nut 1 nut whl Seal and O ring Kit Caliper Seal Kit is required as part of brake wear 7175715 2 h l l l Complete Hub improvement that removes the piston assist springs Hydraulic Reservoir Cap 2psi is required as part Contains park brake piston and ring gear seals not of brake wear improvement that replaces the original required for service brake replacement Tpsi cap Additional Parts Dealer stock of these parts should be available in case of damage or wear 7175501 AR may be damaged during i N pe 7175720 Caliper Pin Kit Brake Pad and Disc Replacement Periodically inspect the Pelican disc brakes for wear 500 hours or more often BRAKE PADS FIGURE 1 1 e Pad backing plates must not contact the disc If any backing plate is within 050 of the disc the pads must be replaced and the disc thickness measured e Pads with less than 2mm of friction material i remaining must be discarded and replaced T with new pads jg BRAKE DISCS FIGURE 1 1 i gt E New disc is 18 1mm 712 thick Measure ee e Mi
13. ve or pry the seal from the hub FIGURE 1 11 15 Remove the bearing Clean the bearing and hub thoroughly with solvent 16 Install the bearing in the hub and drive or press the new seal in place using a suitable driver FIGURE 1 12 Ensure that the bearing cones are assembled to mate with their original cups 17 Lightly lubricate the seal surface and install the hub bearing assembly on the spindle and install the outer bearing Ensure that the bearings are clean and free from any ae oe l Ring Nut Wrench remaining drilling debris before installation j P N 7970354 Thread the replacement nut on the spindle IE NOTICE Make sure that the bearing races cones are completely seated before setting the preload 18 Seat the bearing cups by tightening the nut to 289 lb ft 89 Kg M Allow the hub to complete a number of revolutions Loosen the nut and re tighten to a torque of 79 4 lb ft Rolling torque should be between 6 and 10 lb ft 0 8 1 5 Kg M FIGURE 1 12 19 Using a drift punch and hammer stake the ring nut into a stub axle slot to prevent ring nut movement 20 Ensure that the gear components are very clean before reassembly Place the inner gear set to engage the housing over the spindle splines FIGURE 1 13 21 Place outer gear set into the hub FIGURE 1 14 SB 0066 5 PROCEDURE Continued 22 Place and align the drive shaft and outer gear Ensure that the disconnect spring is p
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