BRAKE Page GENERAL... 9-2 SPECIFICATIONS... 9-3 COMPONENTS... 9-3 PARKING BRAKE... 9-3 BRAKE PEDAL... 9-4 DISC BRAKE... 9-5 DISC BRAKE... 9-8 REMOVAL INSTALLATION... 9-8 DISASSEMBLY INSPECTION REASSEMBLY... 9-10 DISK BRAKE ADJUSTMENT... 9-11 BRAKE DISC WHEEL... 9-12 REMOVAL INSTALLATION... 9-12 BRAKE PEDAL... 9-14 REMOVAL INSTALLATION... 9-14 BRAKE PEDAL ADJUSTMENT... 9-15 PARKING BRAKE... 9-16 REMOVAL INSTALLATION... 9-16 PARKING BRAKE ADJUSTMENT... 9-1 7
Service Manual Change History Description Page # Date 1 Added Change History Page 2 6/30/13 2 Added Information Bulletins page 3-4 6/30/13 3 Added SIB DM13-001 19-25 6/30/13
Information Bulletins affecting Models 7FBEU15-20, Service Information Bulletin 1 SIB CC05-003 Accelerator Pedal Response (Tuning 12) (7FBE(H)U15-20) 2 SIB CC05-007 MB Contactor Cover (7FBEU15-20) 3 SIB CC05-011 Low Battery Voltage / Performance Reduction 4 SIB CC09-003 Error Codes 31-1, 31-2 and 31-3 5 SIB CC13-004 Motor Controller Change 6 SIB CE05-001 Key Switch Change (All Models) 7 SIB CE05-002 Addiitonal Pump Motor Cooling Fan Kit 8 SIB CE05-006 Pump Motor Cooling Fan 9 SIB CE05-008 Voltage Conversion 10 SIB CE06-005R Display Battery Replacement 11 SIB CE09-004 A5, A5-1, or 1-1 Error Codes for OPSS 12 SIB CE10-006 Motor Sensor Bearing Change 13 SIB CE11-001R Clamp Release Interlock (Mini Lever Units) 14 SIB CE11-003 Clamp Release Interlock (Standard Lever Units) 15 SIB CY04-001 New V & FSV Lift Cyl. Sealsfor 1~3 Ton 7 Series Trucks 16 SIB DM07-001 Modification of Drive Motor Rotation Sensor Bearing Section 17 SIB DM09-002 Pump Motor Cable Clearance 18 SIB DM12-001 Inner Drive Motor Bearing Installation 19 SIB DM13-001 AC Motor Bearing Change (RPM Sense) 20 SIB DU13-002 Planetary Oil Inspection at PDI (includes Updated PDI Check sheet 2/28/2013) 21 SIB FA07-001R Front Axle Shaft Change 22 SIB FA11-001R Front Axle Repair Kits 23 SIB FA12-002 Front Axle Revisions 24 SIB HS05-003 Mini Lever Pressure Relief (7FBEU15-20) 25 SIB HS08-002 Addition of Back-Tilt Lock Valve 26 SIB HS10-001 Steering Circuit Hydraulic Schematics 27 SIB MA05-004 Counterweight Bolt Torque Change (7FBE(H)U15-20) 28 SIB MA05-005 Default Tuning Values Changed (Mini Lever Units Only) (7FBE(H)U15-20) 29 SIB MA05-008 Repair Manual Correction (Front Axle Bearing Preload Specification) 30 SIB MA05-009 Option Set Menu Changes 31 SIB MA06-003 Hoisting Prodedure 32 SIB MA07-005 Maintenance Indicator Changes 33 SIB MA12-002 Repair Manual Corrections 34 SIB MS03-001 Introduction of Optional Quad Mast for 7FBEU15~20 35 SIB RA05-002 Steer Axle Retainer Bolts Changed 36 SIB RA07-001 Rear Axle Flange Change 37 SIB ST03-001 SST's for Electrical Troubleshooting 38 SIB ST06-001 Recommended Special Service Tools 39 SIB ST08-001 Recommended Special Service Tools 40 SIB ST99-001R Recommended Special Service Tools Technical News Brief 1 TNB-2009-04 Static Strap Change 2 TNB-2003-04 Steer System - Air Purging Procedure 3 TNB-2003-07 Allowable Variance On Mast Shimming 4 TNB-2004-07 Hydraulic Oil Change 5 TNB-2006-02 Rear Axle Flange 6 TNB-2006-03 Coutweight Squeeking 7 TNB-2006-09 Series Electric ROM Write
Information Bulletins affecting Models 7FBEU15-20, 8 TNB-2006-13 Hydraulic Fluid for Cold Storage 9 TNB-2008-06 Proper Method Of Hydraulic Fluid Inspection Hotline Tech Tips 1 HTT-2004-11 Gradeability 2 HTT-2004-12 Gradeability 3 HTT-2005-01 Motor Bearing/RPM Sensor; E3 Display; Hour Meter on 7FBEU 4 HTT-2005-03 CB-2 Error Codes Contactor Covers For Dusty Environments 5 HTT-2005-05 Seat Switch Testing 6 HTT-2005-06 Thicker Floor mat; Battery Correction Mode and Lift Interrupt Settings 9 HTT-2005-09 Units With Mini-Levers 10 HTT-2005-10 Wrench Icon 11 HTT-2005-11 Load Sensor, Contactor Tip Replacement, Slow Travel 13 HTT-2006-01 Erratic Display; Drive Unit Part Numbers 14 HTT-2006-04 OPSS R/M; Board Replacement 15 HTT-2006-05 Travel Alarm 16 HTT-2006-06 Battery Consumption 17 HTT-2006-07 Slow Motor Speed 18 HTT-2006-08 E2-1 Error Code 19 HTT-2006-09 Drive Unit P/N 20 HTT-2007-01 Hydraulic Oil for Cold Storage; Motor Bearing Seal Install; 6 Bolt Axle Flange 21 HTT-2007-04 Class 1 gear case oil 22 HTT-2007-07 New Hydraulic Oil 23 HTT-2007-08 Optional 12V Power Supply 24 HTT-2007-10 Class 1 OPSS II, Load Sensor, and P7 & P8 Current Sensors 25 HTT-2007-11 Code 31-1, 31-2, 31-3 26 HTT-2007-12 Class 1 Alarm with OPSS 27 HTT-2008-02 Drive Unit Part Numbers 28 HTT-2008-03 Error Codes 64-2 & H9-2 29 HTT-2008-04 No Display with EZ Pedal 30 HTT-2008-06 Front Hub Induction Hardening and Drive Axle Clattering 31 HTT-2008-08 Internal Gear Hardened 32 HTT-2008-10 Drive Axle Connector Rod Adjustment 33 HTT-2008-11 UL Ratings 34 HTT-2008-12 Diagnostic Tips 35 HTT-2009-01 Slow Lowering or Incorrect Staging During Lowering 36 HTT-2009-02 C2-2 or C2-3 Error Codes and Trouble Shooting Error Codes H9-1,2,3 Or 64-1,2,3 37 HTT-2009-03 Static Strap Mounting and Lift Interrupt Settings 38 HTT-2009-04 Battery Voltage Setting On PDI, Parking Brake Warning and String Cutters 39 HTT-2009-05 Error Codes After Card Replacement 40 HTT-2009-06 Error Codes A6-1, A6-2, A6-3, A6-5 or A6-6 at Key-On 41 HTT-2009-11 A5 Error Code On Forklifts With OPSS, 42 HTT-2010-02 Switch Adjust, RF Interference on AC Trucks 43 HTT-2010-05 Front Axle Repair Kits 44 HTT-2011-02 Common Electrical Acronyms, Error Codes 72-1, 72-2 or Missing Manager's Functions 45 HTT-2011-04 RPM Sensor Bearing Damage 46 HTT-2011-05 Adding Electrical Devices,
GENERAL
SPECIFICATIONS Item Foot brake type Parking brake type Model All models Mechanical disc brake Mechanical disc brake Brake wheel mm (in) Diameter Thickness 203 (8.0) 9.0 (0.4) Brake pad Area Thickness cm2(in2) mm(in) 35.28 x 2 x 2 (5.468 x 0.079 x 0.079) 6 (0.2) COMPONENTS PARKING BRAKE
BRAKE PEDAL 4701 (WIDE PEDAL) 2 1 4701-21 5A
DISC BRAKE
4716 01 [RH] 02[LH] r=== I I I I I I L1-= 111.1 471 6-037 I I I
DISC BRAKE REMOVAL INSTALLATION Removal Procedure Raise the inner mast and securely fix it to prevent lowering. [Point I] Remove the brake cover. Remove the toe board (front and rear) and tilt cylinder cover. Remove the instrument panel. Disconnect the links from the brake pedal and parking brake. Disconnect the brake rods between frame and brake ASSY (LH and RH). Remove the brake ASSY (LH). Remove the brake ASSY (RH). Installation Procedure The installation procedure is the reverse of the removal procedure.
Point Operations [POINT I] Removal: Raise the inner mast and support it by putting wooden block inside the outer mast rail to prevent the inner mast lowering.
9-1 0 DISASSEMBLY INSPECTION REASSEMBLY T=N-m (kgfcm) [ftdbfl Disassembly Procedure 1 Remove the pin, castle nut and lever. 2 Separate the lever ASSY No.1 and 2. [Point I] Reassembly Procedure The reassembly procedure is the reverse of the disassembly procedure.
Point Operations [POINT I ] Inspection: Measure the pad thickness. Standard: 6.0 mm (0.24 in) Limit: 3.5 mm (0.14 in) DISK BRAKE ADJUSTMENT 1. Adjust the pad clearance with adjusting bolt. Pad clearance: 9.8 to 10.2 mm (0.39 to 0.40 in) 2. Adjust the clearance between the brake disc wheel and pad evenly with an adjusting bolt. Clearance: 0.4 to 0.6 mm (0.016 to 0.024 in) A=0.4 to 0.6 mm (0.016 to 0.024 in) B=9.8 to 10.2 mm (0.39 to 0.40 in) C=9 mm (0.35 in)
-- - BRAKE DISC WHEEL REMOVAL INSTALLATION Removal Procedure 1 Remove the disc brake ASSY. (See page 9-8.) 2 Remove the brake disc wheels (LH and RH). [Point I] Installation Procedure The installation procedure is the reverse of the removal procedure.
Point Operations [POINT I] Removal: Raise the inner mast and support it by putting wooden block inside the outer mast rail to prevent the inner mast lowering. [POINT 21 Inspection: Inspect the brake disc wheel thickness. Standard: 9.0 mm (0.35 in) Limit: 8.0 mm(0.31 in)
9-1 4 BRAKE PEDAL REMOVAL e INSTALLATION T=N.m (kgfcm) [ftdbfl Removal Procedure 1 Remove the toe board (front and rear) and tilt cylinder cover. 2 Remove the instrument panel. 3 Remove the brake pedal set bolt. 4 Disconnect the link and remove the brake pedal. 5 Disconnect the parking brake wire. 6 Remove the brake pedal adjusting nut. 7 Remove the brake pedal link. 8 Remove the parking brake adjusting nut. 9 Remove the parking brake link. 10 Remove the brake ASSY link. 11 Remove the brake link ASSY. 12 Remove the brake link ASSY pin. Installation Procedure The installation procedure is the reverse of the removal procedure. Note: Inspect the bushing for wear and damage and replace it if necessary.
BRAKE PEDAL ADJUSTMENT 1. Inspect brake pedal height A (from pedal to the upper side of the pedal). Standard: A = 11 0 to 11 5 mm [4.3 to 4.5 in] Adjust if the pedal height is outside the specified range with a stopper bolt. 2. Tighten the adjusting nut until the equalizer is securely fixed. Adjust the pedal stroke B when the clearance between the brake pad and disc is within the standard (0.4 to 0.6 mm[0.016 to 0.024 in]). (Reference value): B = 30 to 35 mm [I.I8 to 1.38 in] 3. After the adjustment, inspect the ground clearance C (from the toe board to the top of the pedal) with fully depressing the brake pedal. If the ground clearance C is standard or below, adjust the clearance between the brake pad and disc. Standard: C = 55mm [2.17 in]
9-1 6 PARKING BRAKE REMOVAL INSTALLATION T=N.m (kgf.cm) [ft.lbfl Removal Procedure 1 Remove the instrument panel. 2 Disconnect the parking brake wire. 3 Remove the parking brake ASSY. Installation Procedure The installation procedure is the reverse of the removal procedure.
PARKING BRAKE ADJUSTMENT 1. Adjust the parking brake so that the front pole fits at the third or fourth notch of the sector when the parking brake lever operating force is at 150 N (15.3 kg) [33.7 Ib] (measure at the point in the illustration). 2. When the disc brake drags, adjust it so that the front pole fits at the fifth notch.
SERVICE INFORMATION BULLETIN Drive Motor DM13-001 May 31, 2013 7FBEU AC Motor Bearing Change (RPM Sense) 7FBEU15-20, 7FBEHU18 Subject: 7FBEU AC Motor Bearing Change (RPM Sense) Page 1 of 2 MODEL APPLICATION: 7FBEU15-20, 7FBEHU18 GENERAL INFORMATION: The bearing supplier has been changed and new bearings were released into production in August 2012. Please note that the parts from the old design and new design are not interchangeable. REPAIR INFORMATION: Please add the following pages to your repair manual CU330. *Pages 5-3A and 5-4A need to be inserted in your manual. *Pages 5-7, 9-2 and 9-6 replace the original pages in the manual. *Page 2 of this bulletin indicates the pump motor and the bearing (RPM Sense) were also changed but no torque specifications have been changed (just the motor end frame to accommodate the larger bearing).
Subject: 7FBEU AC Motor Bearing Change (RPM Sense) Page 2 of 2 Pump motor bearing 01A also was changed 8/2012. Motor end frame was changed (41) and bearing retainer (AV) was not changed.
5-3A (From August 2012) 1401
5-4A (From August 2012) 1401
5-7 DISASSEMBLY INSPECTION REASSEMBLY T=N m (kgf cm) [ft lbf] T= 3.0 7.0 (30.6 71.4) [2.2 5.2] 1 6 5 4 2 From August 2012 3 T= 3.0 7.0 (30.6 71.4) [2.2 5.2] T= 3.0 7.0 (30.6 71.4) [2.2 5.2] T= 31.2 46.8 (318.2 477.2) [23.0 34.5] Disassembly Procedure 1 Remove the terminal. 2 Remove the end frame. [Point 1] 3 Remove the rpm sensor bearing. 4 Remove the rotor ASSY. [Point 2] 5 Remove the stator ASSY. [Point 3] 6 Remove the bracket. [Point 4] Reassembly Procedure The reassembly procedure is the reverse of the disassembly procedure. Caution: Be sure not to apply impact to the rpm sensor bearing.
9-2 GENERAL Until August 2012 From September 2012
9-6 (Until August 2012) (From September 2012) 4716 4716