4CBT2R, 3R 4CBTK4R, 4cbtyk4r Ce676 PDF

FOREWORD
This Manual contains maintenance, specifications and repair procedures for the
chassis, body and material handling system of the TOYOTA ELECTRIC POWERED
TOWING TRACTOR 4CBT2R, 3R • 4CBTY2R • 4CBTK4R • 4CBTYK4R.
Please use this manual for providing quick, correct servicing of the corresponding
towing tractor.
This manual deals with the above model as of Mar. 2006. Please understand that
disagreement can take place between the descriptions in the manual and actual
vehicles due to change in design and specifications. Any change or modifications
thereafter will be informed by Toyota Industrial Equipment Parts & Service News.
SECTION INDEX
NAME SECTION
GENERAL 0
BATTERY 1
CONTROLLER 2
TROUBLESHOOTING 3
MOTOR 4
FRONT AXLE 5
REAR AXLE 6
STEERING 7
BRAKE 8
BODY • FRAME 9
REMOTE CONTROLLER SPECIFICATION 10
APPENDIX 11
0-1
GENERAL
Page Page
0
EXTERIOR VIEW OF PRECOATED BOLTS............... 0-15 1
VEHICLE .............................. 0-2 HIGH PRESSURE HOSE 2
VEHICLE MODELS................ 0-4 FITTING TIGHTENING
FRAME NUMBER .................. 0-4
TORQUE ............................ 0-16 3
RECOMMENDED LUBRICANT
HOW TO USE THIS
QUANTITY AND TYPES .... 0-16 4
MANUAL .............................. 0-5
EXPLANATION METHOD .......... 0-5
LUBRICATION ..................... 0-17 5
PERIODIC MAINTENANCE. 0-18
TERMINOLOGY .......................... 0-6 6
ABBREVIATIONS ....................... 0-6 PERIODIC REPLACEMENT
OF PARTS AND 7
OPERATING TIPS ................. 0-7 LUBRICANTS .................... 0-21
GENERAL INSTRUCTIONS ....... 0-7
EXPLANATION .................... 0-22
8
JACKING UP............................... 0-8
DEVELOPMENT OBJECTIVE.. 0-22 9
HOISTING THE VEHICLE........... 0-9
SELLING POINT....................... 0-22
WIRE ROPE SUSPENSION 10
MASTER CONTROL ................ 0-25
ANGLE LIST ........................... 0-10
SAFE LOAD FOR
OPS........................................... 0-28 11
EACH WIRE ROPE
SUSPENSION ANGLE ........... 0-10
VEHICLE DIMENSIONS ........... 0-29 12
TOWING THE VEHICLE ........... 0-11 13
GRADIENT AND TOW
CAPACITY .............................. 0-11 14
ELECTRICAL PARTS
INSPECTION........................... 0-12
15
BOLT & NUT TIGHTENING 16
TORQUES .......................... 0-13
BOLT STRENGTH CLASS
17
IDENTIFICATION METHOD AND
TIGHTENING TORQUE .......... 0-13 18
0-2
EXTERIOR VIEW OF VEHICLE

4CBT2R·3R·4CBTK4R
0-3
4CBTY2R·4CBTYK4R
The diagram is of a vehicle with battery slide-out specifications
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
0-4
VEHICLE MODELS
Type Tow capacity Vehicle model Voltage
Sit-down 4CBT2R
2.0 tonnes
Standup 4CBTY2R
Sit-down 3.0 tonnes 4CBT3R 48 V
Sit-down 4CBTK4R
4.0 tonnes
Standup 4CBTYK4R
FRAME NUMBER
Vehicle model Punching format Punching position
Frame No.
4CBT2R 4CBT2R-10011
4CBTY2R 4CBTY2R-10011
4CBT3R 4CBT2R-10011
4CBTK4R 4CBT2R-10011
4CBTYK4R 4CBTY2R-10011
Upper right front section of frame
0-5
HOW TO USE THIS MANUAL

EXPLANATION METHOD
1. Operating procedure
(1) Operating procedures are described using either pattern A or pattern B.
0
Pattern A : Each step of the operation is explained with its own illustration.
Pattern B : The entire operation is indicated by step numbers in one illustration, followed by cautions,
notes, and point operations.
1
Example of pattern B 2
DISASSEMBLY • INSPECTION • REASSEMBLY
Tightening torque unit→[N·m(kgf·cm) [ft·lbf]] 3
• Some step numbers may be omitted
in some illustrations.
4
4
5
• When a part requiring tightening 1
2
torque instruction is not indicated in
3
the illustration, the part name is
described in the illustration frame.
7
6
5 6
7
T=46.1 to 48.1
(470 to 490)
[34.0 to 35.5]
8
8
9
5
10
11
9 1
Disassembly Procedure
1. Remove the cover. [Point 1] 12
2.
3.
Remove the bushing. [Point 2] Ã Operation to be explained in following pages.
Remove the gear.
13
Point Operations 14
Explanation of operation point with illustration.
15
[Point 1]
Disassembly: É
Make match marks before removing the pump cover.
[Point 2]
16
Inspection:
Measure the bushing inside diameter. 17
18
Limit: 19.12 mm
0-6
2. How to read component figures

(1) The component figures use the illustration in the parts (Example)
catalog for the vehicle model. Please refer to the catalog
3201
to check the part name.
3. Matters omitted from this manual Parts catalog
FIG number
(1) This manual omits descriptions of the following jobs, but
perform them in actual operation:
(a) Cleaning and washing of removed parts as required
(b) Visual inspection (partially described)
TERMINOLOGY
Caution:
Important matters, negligence of which may cause accidents. Be sure to observe them.
Note:
Important items, negligence of which may cause accidents, or matters in operating procedure which require
special attention.
Standard : Value showing the allowable range in inspection or adjustment.
Limit : The maximum or minimum value allowed in inspection or adjustment.
ABBREVIATIONS
Abbreviation Meaning Abbreviation Meaning
ASSY Assembly SAE Society of Automotive Engineers (USA)
LH Left hand SST Special service tool
L/ Less STD Standard
OPT Option T= Tightening torque
O/S Oversize {{T Number of teeth ({{T)
PS Power steering U/S Undersize
RH Right hand W/ With

0-7
OPERATING TIPS
GENERAL INSTRUCTIONS
1. Safe operation
(1) After jacking up, always support with wooden blocks or rigid stands.
(2) When hoisting the vehicle or its heavy component, use wire rope(s) with a sufficient reserve in load capacity.
(3) Always disconnect the battery plug before the inspection or servicing of electrical parts.
2. Skillful operation
(1) Prepare the tools, necessary measuring instruments (circuit tester, megohmmeter, oil pressure gauge, etc.)
and SSTs before starting operation.
(2) Check the cable color and wiring state before disconnecting any wiring.
(3) When overhauling functional parts, complicated sections or related mechanisms, arrange the parts neatly
to prevent confusion.
(4) When disassembling and inspecting a precision part such as a control valve, use clean tools and operate
in a clean location.
(5) Follow the specified procedures for disassembly, inspection and reassembly.
(6) Always replace gaskets, packings, O-rings, self-locking nuts and cotter pins with new ones each time they
are disassembled.
(7) Use genuine Toyota parts for replacement.
(8) Use specified bolts and nuts and observe the specified tightening torque when reassembling. (Tighten to
the medium value of the specified tightening torque range.) If no tightening torque is specified, use the value
given in the “standard tightening torque table”.
3. Protection of functional parts (battery operated vehicles)
(1) Before connecting the battery plug after vehicle inspection or maintenance, thoroughly check each
connector for any faulty or imperfect connection.
Faulty or imperfect connection of connectors related to controllers, especially, may damage elements inside
the controllers.
4. Defect status check
Do not start disassembly and/or replacement immediately, but first check that disassembly and/or replacement
is necessary for the defect.
5. Waste fluid disposal
Always use a proper container when draining waste fluid from the vehicle.
Careless discharge of oil, fuel, coolant, oil filter, battery or other harmful substance may adversely affect human
health and the environment. Always collect and sort well, and ask specialized companies for appropriate
disposal.
0-8
JACKING UP
Always observe the following instructions when jacking up the vehicle:
• Remove any loads, towed or loaded, and halt the vehicle on a flat surface. Be sure to avoid an inclined or rough
surface.
• Use a jack with ample capacity and jack up the vehicle at the specified jack-up point. Jacking up at any other
point is dangerous.
• Always support the load of jacked-up vehicle with wooden blocks at specified points. Supporting the vehicle with
the jack only is very dangerous.
• Never, under any circumstances, put any part of the body (including hands and feet) under the jacked-up vehicle.
Wooden block point
Jack-up point
Wooden
block
Jack
Front section of frame Rear section of frame

0-9
HOISTING THE VEHICLE

Always hoist the vehicle by the specified attachment sections and in accordance with specified instructions. Never
hoist by any other attachment section as it is very dangerous.
4CBT2R·3R·4CBTK4R
4CBTY2R·4CBTYK4R
Remove the toe board before hoisting the vehicle.

When the battery is loaded, the center of gravity is located in roughly the same place as the loaded battery. When
no battery is loaded, the center of gravity is towards the front of the battery hood.
0-10
WIRE ROPE SUSPENSION ANGLE LIST

Suspension Suspension Suspension Suspension
Tension Compression Tension Compression
angle method angle method
1 tf
0° 1.00 time 0 time 90° 1.41 time 1.00 time 90°
tf
41
2t
1.
2t
30°
30° 1.04 time 0.27 time 120° 2.00 time 1.73 time
tf
120°
1.04
f
2t
2t 2t
60° 1.16 time 0.58 time 60°

tf
6
1.1
2t
SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE

Unit: N (tf) [lbf]
Single-rope
Rope Cutting Two-rope suspension Four-rope suspension
suspension
diameter load
0° 0° 30° 60° 90° 0° 30° 60° 90°
21380 3040 6080 5880 5200 4310 12160 11770 10400 8630
6 mm
(2.18) (0.31) (0.62) (0.60) (0.53) (0.44) (1.24) (1.20) (1.06) (0.88)
(0.24 in.)
[4807] [683.6] [1367] [1323] [1169] [970] [2734] [2646] [2337] [1940]
31480 4410 8830 8530 7650 6280 17650 17060 15300 12550
8 mm
(3.21) (0.45) (0.90) (0.87) (0.78) (0.64) (1.80) (1.74) (1.56) (1.28)
(0.32 in.)
[7078] [992.3] [1985] [1918] [1720] [1411] [3969] [3937] [3440] [2322]
49230 6960 14020 13440 11770 9810 27460 26480 23540 19610
10 mm
(5.02) (0.71) (1.43) (1.37) (1.20) (1.00) (2.80) (2.70) (2.40) (2.00)
(0.4 in.)
[11690] [1565.6] [3153] [3021] [2646] [2205] [6174] [5954] [5292] [4410]
76880 10980 21570 21280 18630 14710 43150 41190 37270 29420
12.5 mm
(7.84) (1.12) (2.20) (2.10) (1.90) (1.50) (4.40) (4.20) (3.80) (3.00)
(0.5 in.)
[17387] [2469.5] [4851] [4631] [4190] [3308] [9702] [9261] [8379] [6615]
96400 13730 27460 26480 23540 18630 54920 52960 47070 37270
14 mm
(9.83) (1.40) (2.80) (2.70) (2.40) (1.90) (5.60) (5.40) (4.80) (3.80)
(0.56 in.)
[21675] [3087] [6174] [5954] [5292] [4190] [12348] [11907] [10584] [8379]
0-11
TOWING THE VEHICLE

The cautions below should be observed when towing the
vehicle.
1. Always tow the vehicle with the front wheel raised.
2. The traveling speed when towing must not exceed the
maximum traveling speed of the forklift.
3. Before starting towing, always set the key switch to OFF and
the direction switch to the neutral position.
4. Be sure to disconnect the battery plug.
GRADIENT AND TOW CAPACITY

Conditions (Concrete covered road) µ=0.025
Slope road (Slope start)

Flat road
1° 2° 3° 4°
Tow capacity
(60 minute 2.0 0.8 0.3 Å\ Å\
4CBT2R rating)
4CBTY2R Tow capacity
(3 minute 2.0 1.5 1.1 0.9 0.7
rating)
Tow capacity
(60 minute 3.0 1.3 0.7 0.3 0.1
rating)
4CBT3R
Tow capacity
(3 minute 3.0 2.6 2.0 1.6 1.3
rating)
Tow capacity
(60 minute 4.0 1.9 1.1 0.6 0.3
4CBT4R rating)
4CBTY4R Tow capacity
(3 minute 4.0 3.6 2.9 2.4 2.0
rating)
0-12
ELECTRICAL PARTS INSPECTION

1. Always disconnect the battery plug before inspecting or servicing electrical parts.
2. Pay sufficient attention when handling electronic parts.
(1) Never subject electronic parts, such as computers and
relays, to impact.
(2) Never expose electronic parts to high temperature or
moisture.
(3) Do not touch connector terminals, as they may be
deformed or damaged due to static electricity.
3. Use a circuit tester that matches the object and purpose of measurement.
Analog type : This type is convenient for observing movement during operation and the operating condition.
Measured value should be used for reference only.
Digital type : A fairly accurate reading is possible. However, it is difficult to observe operation or movement.
(1) Difference between results of measurement with analog and digital types
Note:
The results of measurements using the analog type and the digital type may be different.
Differences between the polarities of the analog type and the digital type are described below.
(a) Analog circuit tester
Example of measurement result
Forward Reverse Tester range: kΩ range
Analog type
Continuity
Forward
11 kΩ
No continuity
Reverse
∞
(b) Digital circuit tester

Example of measurement result
Tester range: 2 MΩ range
Forward Reverse
Digital type
No continuity
Forward
1
Continuity
Reverse
2 MΩ
0-13
BOLT & NUT TIGHTENING TORQUES

Standard Bolt & Nut Tightening Torque
Tightening torques of standard bolts and nuts are not indicated throughout the manual.
Use the charts and table below to judge the standard tightening torque.
1. Judge the tightening torque for the hexagon head bolt, welded bolt or stud bolt having the standard bearing
surface according to the tightening torque table by identifying the bolt strength class from the table below.
2. Judge the tightening torque for the hexagon flange bolt based on the threading diameter.
3. The nut tightening torque can be judged from its corresponding bolt type.
BOLT STRENGTH CLASS IDENTIFICATION METHOD AND

TIGHTENING TORQUE
Identification by Actual Part
Type Shape and class Class
4 = 4T
5 = 5T
Number in relief or hallmark on the head 6 = 6T
7 = 7T
8 = 8T
No mark 4T
Hexagon head bolt

(standard) 5T
Bolt with two raised lines on head
Bolt with three raised lines on head 7T
Bolt with four raised lines on head 8T
Welded bolt 4T
No mark 4T
Stud bolt
2 mm groove(s) on one/both edge(s) 6T

0-14
Identification by Part No.
Type Part No. Shape
91611-40625
Nominal
Nominal length diameter
Hexagon bolt Nominal diameter
Class
Nominal length
92132-40614
Nominal length (mm) Nominal
diameter
Stud bolt Nominal diameter
Class
Nominal length
Tightening Torque Table
Nominal diameter Pitch Standard tightening torque

Class
mm mm N·m kgf·cm ft·lbf
6 1.0 5.4 55 48 in·lbf

8 1.25 13 130 9
10 1.25 25 260 19
4T
12 1.25 47 480 35
14 1.5 75 760 55
16 1.5 113 1150 83
6 1.0 6.5 65 56 in·lbf

8 1.25 16 160 12
10 1.25 32 330 24
5T
12 1.25 59 600 43
14 1.5 91 930 67
16 1.5 137 1400 101
6 1.0 7.8 80 69 in·lbf

8 1.25 19 195 14
10 1.25 39 400 29
6T
12 1.25 72 730 53
14 1.5 108 1100 80
16 1.5 172 1750 127
6 1.0 11 110 8
8 1.25 25 260 19
10 1.25 52 530 38
7T
12 1.25 95 970 70
14 1.5 147 1500 108
16 1.5 226 2300 166
6 1.0 12 125 9
8 1.25 29 300 22
10 1.25 61 620 45
8T
12 1.25 108 1100 80
14 1.5 172 1750 127
16 1.5 265 2700 195
0-15
HEXAGON FLANGE BOLT TIGHTENING TORQUE
Nominal diameter Pitch Standard tightening torque

Remarks
mm mm N·m (kgf·cm) [ft·lbf]
7.5 (76.5) [5.5]

5 0.8
Built-in washer
12.5 (128) [9.2]

6 1.0
13 (133) [9.6] Built-in washer
31 (316) [22.9]
8 1.25
64 (653) [47.2]
10 1.25
115 (1173) [84.9]

12 1.25
115 (1173) [84.9] Built-in washer
180 (1837) [133]

14 1.5
180 (1837) [133] Built-in washer
280 (2857) [207]

16 1.5
275 (2806) [203] Built-in washer
PRECOATED BOLTS
(BOLTS WITH SEAL LOCK AGENT COATING ON THREADS)
1. Do not reuse a precoated bolt without using appropriate proce-
dures as it is in the following cases:
(1) After it has been removed.
(2) When it has been moved by tightness check, etc.
(loosened or tightened)
Note:
For torque check, tighten the bolt at the lower limit of the
allowable tightening torque range; if the bolt moves,
Seal lock agent
retighten it according to the steps below.
2. How to reuse precoated bolts
(1) Wash the bolt and threaded hole.
(The threaded hole must be washed even when replacing
the bolt with a new one.)
(2) Completely dry the washed parts by blowing with air.
(3) Apply the specified seal lock agent on the bolt threaded
portion.
0-16
HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE

1. When connecting a high pressure hose, wipe the hose fitting and corresponding nipple contact surfaces with a
clean cloth to remove foreign matter and dirt. Also check that there are no dents or other damage on the contact
surfaces before installation.
2. When installing a high-pressure hose, align the hose metal joint with the nipple and tighten the bolt so as to
maintain alignment.
3. The maximum tightening torque must not exceed twice the standard tightening torque.
Standard tightening torque N·m (kgf·cm) [ft·lbf]

Nominal diameter of Hose inside diameter
screw mm (in.)
Standard Tightening range
7/16-20 UNF 25 (50) [18.1] 24 to 26 (240 to 270) [17.4 to 19.5] 6 (0.24)
9/16-18 UNF 49 (500) [36.2] 47 to 52 (480 to 530) [34.7 to 38.3] 9 (0.35)
3/4-16 UNF 59 (600) [43.4] 56 to 62 (570 to 630) [41.2 to 45.6] 12 (0.47)
7/8-14 UNF 59 (600) [43.4] 56 to 62 (570 to 630) [41.2 to 45.6] 12 (0.47), 15 (0.59)
1·1/16-12 UNF 118 (1200) [86.8] 112 to 123 (1140 to 1250) [82.5 to 90.4] 19 (0.75)
1·5/16-12 UNF 137 (1400) [101.3] 130 to 144 (1330 to 1470) [96.2 to 106.4] 25 (0.98)
PF1/4 25 (250) [18.1] 24 to 26 (240 to 270) [17.4 to 19.5] 6 (0.24)
PF3/8 49 (500) [36.2] 47 to 52 (480 to 530) [34.7 to 38.3] 9 (0.35)
PF1/2 59 (600) [43.4] 56 to 62 (570 to 630) [41.2 to 45.6] 12 (0.47)
PF3/4 118 (1200) [86.8] 112 to 123 (1140 to 1250) [82.5 to 90.4] 19 (0.75)
PF1 137 (1400) [101.3] 130 to 144 (1330 to 1470) [96.2 to 106.4] 25 (0.98)
RECOMMENDED LUBRICANT QUANTITY AND TYPES

Applicable portion Type Quantity
Rear axle Castle hypoid gear oil W (SAE 85W-90) Approx. 1.9 l (0.5 USgal)
Brake line Toyota brake fluid SH-H Approx. 0.16 l (0.04 USgal)
Chassis parts Toyota genuine MP grease Appropriate amount

0-17
LUBRICATION
4CBT2R·3R·4CBTK4R
II
III
4CBTY2R·4CBTYK4R
II
III
{: Inspection & addition I. Inspection every 8 hours (daily)

z: Replacement II. Inspection every 1000 hours (6-monthly)
A : MP grease III. Inspection every 2000 hours (annually)
B : Hypoid gear oil W (SAE 85W-90)
C : Toyota brake fluid SH-H 1. Front wheel bearing
2. Brake fluid reservoir tank
3. Rear axle
4. Steering chain
0-18
PERIODIC MAINTENANCE
INSPECTION METHOD
I : Inspection, repair or replacement if required.
M: Measurement, repair or adjustment if required.
T : Retightening C: Cleaning L: Lubrication
* : For new vehicle *1: Flaw detector
Every Every Every
Inspection Period 3 months 6 months 12 months
Item Every Every Every

500 hours 1000 hours 2000 hours
ELECTRICAL SYSTEM
Rotation sound I ← ←
Looseness in the connecting parts I ← ←

Motor
Insulation resistance M ← ←
Commutator contamination, damage I ←

Charge level I ← ←
Electrolyte level I ← ←
Electrolyte specific gravity M ← ←
Battery Terminal looseness I ← ←
Abnormality in the upper portion of the battery case I ← ←
Insulation resistance M ← ←
Voltage measurement of each battery cell after charging M
Contact looseness, damage, abrasion I ← ←
Operating condition of the auxiliary contact, contamination, I ← ←

abrasion
Magnet Mounting condition of the arc shooter I
contactor
Operating condition and timings I
Looseness of the coil mounting parts I
Mounting condition of the main circuit lead wire, looseness I
Operating condition and timings I ← ←

Microswitch
Damage and looseness of installing parts I ← ←
Direstion Operation condition, damage I ← ←

switch or
accelerator
lever
Operation condition I ← ←
Controller Interior contamination, damage C ← ←
Motor input voltage M
Fuse Looseness I ← ←
0-19
Every Every Every


Harness deterioration, clamp damage and looseness I ← ←
Wiring
(including Looseness in connecting parts, taping condition I ← ←
charging cord)
Connecting condition and damage of the battery connector I ← ←
POWER TRANSFER SYSTEM
Oil leakage I ← ←
Drive unit Oil level I ← ←
Bolt or nut looseness T
DRIVING SYSTEM
Tire inflation pressure M ← ←
Tire cuts, damage and abnormal wear I ← ←
Rim and hub nuts looseness T ← ←
Tire groove depth M ← ←

Wheels Metal chips, pebbles and other foreign matter trapped in I ← ←
tire grooves
Rim and disc wheel damage I ← ←
Abnormal sound and looseness of front wheel bearing I ← ←
Abnormal sound and looseness of rear wheel bearing I ← ←
Cracks, damage and deformation of beam I

Front axle
Looseness of axle beam in vehicle longitudinal direction M* M
Rear axle Cracks, damage and deformation of housing I
STEERING SYSTEM
Play and looseness I ← ←

Steering wheel
Function I ← ←
BRAKING SYSTEM
Play and depressed pedal clearance from the floor plate M ← ←

Brake pedal
Braking effect I ← ←
Operating force I ← ←
Parking brake Braking effect I ← ←
Rod and cable looseness and damage I ← ←
Brake pipe Leak, damage and mounting condition I ← ←
Reservoir tank Leak and fluid level I ← ←
Master Function, wear, damage, fluid leak and mounting I

cylinder and looseness
wheel cylinder
0-20
Every Every Every


Clearance between drum and lining M* ← ←
Wear of shoe sliding portion and lining I
Drum wear and damage I

Brake drum
and brake Shoe operating condition I
shoe
Anchor pin rusting I
Return spring fatigue M
Automatic adjuster function I
Deformation, cracks and damage I

Backing plate
Mounting looseness T
SAFETY DEVICE, ETC.
Lighting Function and mounting condition I ← ←

system
Horn Function and mounting condition I ← ←
Instruments Function I ← ←
Backup buzzer Function and mounting condition I ← ←
Rear-view Dirt, damage I ← ←

mirror Rear reflection status I ← ←
Seat Looseness and damage of mounting I ← ←
Towing device Looseness of draw bar mounting I ← ←
Damage and cracks of frame, cross members, etc. I

Body
Bolt looseness T
0-21
PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS

z: Replacement
Every Every Every
Replacement timing
3 months 6 months 12 months
Every Every Every

Item
500 hours 1,000 hours 2,000 hours
Rear axle gear oil z ←
Front wheel bearing grease z ←
Brake fluid z
Brake master cylinder rubber parts z
Wheel cylinder cup seals z
Brake fluid reservoir hose z Every 2 years

0-22
MASTER CONTROL
GENERAL
By using a transistor inverter in the main circuit, acceleration was made much smoother at the same time as lowering
power dissipation. The AC motor (alternating current induction motor is controlled).
COMPOSITION
Accelerator
Switch Display
potentiometer
Contactor
AC motor
48 V Controller
Electromagnetic
Contactor coil Thermo-sensor
brake coil
Rpm sensor
MAIN FUNCTIONS
1. Transistor inverter control
Drive control is smooth thanks to the use of a transistor as the power element of the AC inverter control system.
2. Return-to-neutral function
When the key switch or seat switch is turned ON with either the direction lever in the forward/reverse travel
position, or the accelerator pedal being depressed, the drive motor will not start until the accelerator pedal and
direction lever are returned to neutral.
0-23
3. Accelerator pedal
4CBT2R·3R·4CBTK4R
The resin-type accelerator pedal employed allows for much smoother starts.
Operability
(1) A greater linear element in operability was the goal behind increasing the sensor angle with respect to the
pedal operating angle and the enhancements made to the driving “feel” of operation.
(2) By widening the operating angle of pedal, greater ankle comfort was also realized.
e
gl
an
da g
p e ti n
of pera
l
°
21
O
Se
nso
r ang
le
4CBTY2R·4CBTYK4R
With the lever on the right grip, both forward and reverse traveling can be initiated and speed adjustments can
be made.
Reverse
30
° Neutral
45
°
Forward
0-24
4. Rear axle
(1) The drive unit was redesigned with the drive motor arranged vertically so that body dimensions could then
be made more compact and the rear field-of-view improved.
(2) For exceptional transmission efficiency, all gears used are helical-type.
4 Pinion differential
Vehicle center
0-25
OPS
GENERAL
4CBT2R·3R·4CBTK4R
The OPS system detects the presence of the operator using the seat switch and cuts driving power when the operator
is not in the normal driving position.
4CBTY2R·4CBTYK4R
The OPS system detects the presence of the operator using the floor switch and cuts driving power when the
operator is not in the normal driving position.
CONTROL SPECIFICATIONS
4CBT2R·3R·4CBTK4R
1. Drive OPS function
Even if the key switch is ON, if the operator is not sat in the seat, the driving power will be cut and the vehicle
will not move even if the accelerator pedal is depressed. Drive motor control will stop when the seat switch
remains OFF for 2 consecutive seconds. Turning the seat switch ON and returning the direction lever and
accelerator pedal to neutral will deactivate drive OPS.
2. OPS notification function
If the seat switch is OFF and the direction lever is set to either forward or reverse travel position, an error
indication will light up on the display to warn the operator that the OPS system is active. This error indication will
switch off when the seat is re-occupied.
When the seat is re-occupied with either the direction lever in the forward/reverse travel position or the
accelerator pedal being depressed and OPS is activated, the drive motor will not start until the accelerator pedal
and direction lever are returned to neutral.
4CBTY2R·4CBTYK4R
1. Drive OPS function
Even if the key switch is ON, if the floor switch is not being depressed (floor switch is OFF), the driving power
will be cut and the vehicle will not move even if the accelerator lever is operated. At speeds exceeding 1 km/h
(0.62 mil/h), drive motor control will stop after the floor switch has been OFF for 2 consecutive seconds. At
speeds of less than 1 km/h (0.62 mil/h), control will stop immediately after the switch is turned OFF. Drive OPS
can be deactivated by turning ON (i.e. depressing) the floor switch or by returning the accelerator lever to neutral
(the acceleration lever will automatically return to the neutral position when it is released).
When the floor switch has been turned from OFF to ON with the accelerator lever in the forward/reverse travel
and OPS activated, the drive motor will not start until the accelerator lever is returned to neutral.
0-26
VEHICLE DIMENSIONS
TOP/SIDE VIEW OF VEHICLE
4CBT2R·3R·4CBTK4R
B2
B1
R
h1
h4
h3
h2
L6
L4 L3 L5
L2
L1
0-27
4CBTY2R·4CBTYK4R
B2
B1
R
h1
h2
h3
h4
L6
L4 L3 L5
L2
L1
0-28
MAIN SPECIFICATIONS
4CBT2R·3R
4CBT2R 4CBT3R
Power Type Battery Battery
Vehicle mounting position seat seat
Non-puncture/ Non-puncture/
Tire Front/Rear
Non-puncture Non-puncture
Number of wheels Front/Rear 1/2x 1/2x
Maximum drawbar pull 3 minute rating N(kgf)[lbf] 2000(200)[450] 3000(300)[650]
Rated drawbar pull 60 minute rating N(kgf)[lbf] 500(50)[100] 750(75)[150]
Rated tow capacity 60 minute rating kg[lb] 2000[4400] 3000[6600]
When manned km/h[mph] 13[8.1] 13[8.1]

When manned
Maximum speed When loaded km/h[mph] 9[5.6] 9[5.6]
When operated by remote control km/h[mph] 3.6[2.2] 3.6[2.2]
3 minute rating When not loaded km/h[mph] 14[9] 14[9]

Climbing capacity
When manned When loaded km/h[mph] 5[3] 7[4]
L1 With hitch mm[in] 2045[80.5] 2045[80.5]

Overall length
L2 Without hitch mm[in] 2030[79.9] 2030[79.9]
L4 Front overhang mm[in] 545[21.5] 545[21.5]
L5 Rear overhang Without hitch mm[in] 345[13.6] 345[13.6]
L6 Hitch length mm[in] 145[5.7] 145[5.7]
B1 Overall width mm[in] 800[31.5] 800[31.5]
h1 Overall height mm[in] 1950[76.8] 1950[76.8]
R Minimum turning radius mm[in] 1940[76.4] 1940[76.4]
h2 Hitch height mm[in] 225[8.9] 225[8.9]
L3 Wheelbase mm[in] 1140[44.9] 1140[44.9]
B2 Front mm[in]
Tread
B3 Rear mm[in] 670[26.4] 670[26.4]
Ground At wheel base

h4 When manned mm[in] 80[3.1] 80[3.1]
clearance center
h3 Floor height mm[in] 330[13.0] 330[13.0]
With battery kg[lb] 770[1700] 770[1700]

Vehicle weight
Without battery kg[lb] 510[1120] 510[1120]
Front kg[lb] 290[640] 290[640]

Wheel load distribution
Rear kg[lb] 480[1060] 480[1060]
No. of wheels Front/Rear 1/2 1/2
Tire Front 3.50-5 3.50-5

Size
Rear 4.00-8 4.00-8
0-29
SERVICE BRAKE Hydraulic Hydraulic

BRAKE
Parking brake Mechanical Mechanical
Voltage/capacity (5 hour rate) V/Ah 48/129 48/129

Battery
Weight kg[lb] 260[570] 260[570]
Traveling motor kW AC 2.3 AC 2.3
Control Transistor inverter Transistor inverter
4CBTK4R
4CBTK4R
Power Type Battery
Vehicle mounting position seat
Non-puncture/
Tire Front/Rear
Non-puncture
Number of wheels Front/Rear 1/2x
Maximum drawbar pull 3 minute rating N(kgf)[lbf] 4000(400)[900]
Rated drawbar pull 60 minute rating N(kgf)[lbf] 1000(100)[200]
Rated tow capacity 60 minute rating kg[lb] 4000[8800]
When manned km/h[mph] 13[8.1]

When manned
Maximum speed When loaded km/h[mph] 8[5.0]
When operated by remote control km/h[mph] 3.6[2.2]
3 minute rating When not loaded km/h[mph] 14[9]

Climbing capacity
When manned When loaded km/h[mph] 8[5.0]
L1 With hitch mm[in] 2045[80.5]

Overall length
L2 Without hitch mm[in] 2030[79.9]
L4 Front overhang mm[in] 545[21.5]
L5 Rear overhang Without hitch mm[in] 345[13.6]
L6 Hitch length mm[in] 145[5.7]
B1 Overall width mm[in] 800[31.5]
h1 Overall height mm[in] 1950[76.8]
R Minimum turning radius mm[in] 1940[76.4]
h2 Hitch height mm[in] 225[8.9]
L3 Wheelbase mm[in] 1140[44.9]
B2 Front mm[in]
Tread
B3 Rear mm[in] 670[26.4]

h4 When manned mm[in] 80[3.1]
clearance center
h3 Floor height mm[in] 330[13.0]
With battery kg[lb] 880[1940]

Vehicle weight
Without battery kg[lb] 510[1120]
0-30
Front kg[lb] 340[750]

Rear kg[lb] 540[1190]
No. of wheels Front/Rear 1/2
Tire Front 3.50-5

Size
Rear 4.00-8
SERVICE BRAKE Hydraulic

BRAKE
Parking brake Mechanical
Voltage/capacity (5 hour rate) V/Ah 48/220

Battery
Weight kg[lb] 370[820]
Traveling motor kW AC 2.3
Control Transistor inverter
4CBTY2R·4CBTYK4R
4CBTY2R 4CBTYK4R
Power Type Battery Battery
Vehicle mounting position Upright Upright
Non-puncture/ Non-puncture/
Tire Front/Rear
Non-puncture Non-puncture
Number of wheels Front/Rear 1/2x 1/2x
Maximum drawbar pull 3 minute rating N(kgf)[lbf] 2000(200)[450] 4000(400)[900]
Rated drawbar pull 60 minute rating N(kgf)[lbf] 500(50)[100] 1000(100)[200]
Rated tow capacity 60 minute rating kg[lb] 2000[4400] 4000[8800]
When manned km/h[mph] 13[8.1] 13[8.1]

When manned
Maximum speed When loaded km/h[mph] 9[5.6] 8[5.0]
When operated by remote control km/h[mph] 3.6[2.2] 3.6[2.2]
3 minute rating When not loaded km/h[mph] 14[9] 14[9]

Climbing capacity
When manned When loaded km/h[mph] 5[3] 7[4]
L1 With hitch mm[in] 2045[80.5] 2045[80.5]

Overall length
L2 Without hitch mm[in] 2030[79.9] 2030[79.9]
L4 Front overhang mm[in] 545[21.5] 545[21.5]
L5 Rear overhang Without hitch mm[in] 345[13.6] 345[13.6]
L6 Hitch length mm[in] 145[5.7] 145[5.7]
B1 Overall width mm[in] 800[31.5] 800[31.5]
h1 Overall height mm[in] 1950[76.8] 1950[76.8]
R Minimum turning radius mm[in] 1940[76.4] 1940[76.4]
h2 Hitch height mm[in] 225[8.9] 225[8.9]
L3 Wheelbase mm[in] 1140[44.9] 1140[44.9]
B2 Front mm[in]
Tread
B3 Rear mm[in] 670[26.4] 670[26.4]
0-31

h4 When manned mm[in] 80[3.1] 80[3.1]
clearance center
h3 Floor height mm[in] 200[13.0] 200[13.0]
With battery kg[lb] 770[1700] 880[1940]

Vehicle weight
Without battery kg[lb] 510[1120] 510[1120]
Front kg[lb] 290[640] 340[750]

Rear kg[lb] 480[1060] 540[1190]
No. of wheels Front/Rear 1/2 1/2
Tire Front 3.50-5 3.50-5

Size
Rear 4.00-8 4.00-8
SERVICE BRAKE Hydraulic Hydraulic

BRAKE
Parking brake Mechanical Mechanical
Voltage/capacity (5 hour rate) V/Ah 48/129 48/220

Battery
Weight kg[lb] 260[570] 370[820]
Traveling motor kW AC 2.3 AC 2.3
Control Transistor inverter Transistor inverter

0-32
1-1
BATTERY
Page 0
LIST OF APPLICABLE BATTERIES................. 1-2
1
BATTERY COMPARTMENT.............................. 1-3
SERVICE STANDARDS..................................... 1-3
2
LED DISPLAY .................................................... 1-4 3
TROUBLESHOOTING ....................................... 1-5 4
BATTERY ASSY ................................................ 1-6
REMOVAL • INSTALLATION...................................... 1-6
5
INSPECTION............................................................... 1-7 6
REPLACING BATTERY PLUG TERMINAL............... 1-9
7
LEVER FOR EMERGENCY BATTERY PLUG
DISCONNECTING ................................................. 1-10 8
BATTERY ROLLER (ON THE VEHICLE) ................ 1-11
BATTERY STOPPER ............................................... 1-12
9
BATTERY CARRIER ................................................ 1-14 10
11
12
13
14
15
16
17
18
LIST OF APPLICABLE BATTERIES
1-2
Examples of batteries recommended for use in Europe

Cell
Voltage Capacity Height (incl. case) Weight (incl. case)
Standard Manufacturer Length Width
(V) (AH/5HR) Vehicle model (mm) [in] (kg) [lb]
(mm) [in] (mm) [in]
120 CHLORIDE IMF7H 61.5 [2.42] 158 [6.22] 542 [21.34] 240 [529.2]
CHLORIDE TLF7N 61.5 [2.42] 158 [6.22] ↑ 295 [650.48]

BRITISH 162
OLDHAM EXH3 61 [2.40] 159 [6.26] ↑ 305 [672.53]
STANDARD
CHLORIDE TLF7H 61.5 [2.42] 158 [6.22] ↑ 335 [738.68]
189
48 OLDHAM XH3 61 [2.40] 159 [6.26] ↑ 340 [749.7]
120 CHLORIDE 2PzS120H 47 [1.85] 198.5 [7.81] ↑ 240 [529.2]
DIN VARTA 2PzS160 47 [1.85] 198 [7.80] ↑ 325 [716.63]

160
STANDARD CHLORIDE 2PzS160 47 [1.85] 198.5 [7.81] ↑ 320 [705.6]
180 CHLORIDE 2PzS180H 47 [1.85] 198.5 [7.81] ↑ 325 [716.63]
Battery connector type: CONNECTEUR 160A FEMALE 50 mm2

1-3
BATTERY COMPARTMENT
Refer to the table below when procuring batteries locally.
Vehicle model Dimensions of battery compartment (mm) [in]
Depth X Width Y Height Z 0

ALL MODELS
350 [13.90] 763 [30.04] 548 [21.57]
1
2
3
X
pth
De
4
5
Z Height
6
7
8
Y
Width
9
10
11
SERVICE STANDARDS
12
13
Specific gravity when fully charged 1.280 [20°C (68°F)]
Specific gravity when fully charged 1.150 [20°C (68°F)]
Discharge end voltage 48 V 42.5 V 14

15
Electrolyte Refined dilute sulfuric acid
Fluid to be added Distilled (deionized) water
Insulation resistance 1 MΩ or more 16

17
18
1-4
Check LED (yellow) LED DISPLAY

The LED display shows all warning indications as well as the
amount of power remaining.
The 6 LEDs of the LED bar, together with the BATTERY LED,
indicate 8 levels of remaining power. As power is discharged the
LEDs will start to extinguish one by one, starting from the right-
hand side. The battery LED lights up when 80% has been
discharged. Charge the battery.
Battery LED (red) LED Bar (green)
Indication of Battery Power

Battery
Remaining capacity (%) ON OFF ON OFF
100 to 81
80 to 66
65 to 51
50 to 36
35 to 21
20 to 11
10 to 1
0 to
Caution:
Remaining capacity can be modified depending on the condition of the battery. (Refer to SECTION 2,
“CONTROLLER”)
Warning Indications
Refer to SECTION 3, “TROUBLESHOOTING”
1-5
TROUBLESHOOTING
Plate corrosion Sulfation Plate warpage and active substance freeing
Improper charging 0
Long storage Repeated
End of life Short circuit
without operation overdischarge/overcharge
1
between cells
2
Excessive charging
Defect of electrolyte
Insufficient current
Defective electrolyte
electrolyte
Excessive ambient
3
Overdischarge
Battery defect
4
temparture
5
Crack or
Damaged Improper chipping of cell
separator water supply Imperfect
Overcharge terminal connection
6
7
8
Deposition of freed Fouled terminal or
active substance connecting plug
at bottom of celll
Short circuit Electrolyte leakage and reduction Loosened or corroded connection 9

10
11
12
13
14
15
16
17
18
1-6
BATTERY ASSY
REMOVAL • INSTALLATION
Vehicle with Battery Roll-out Specifications
Press to apply brake. 5 4
Removal Procedure
1. Disconnect the battery plug. (Refer to SECTION 5, “FRONT AXLE”)
2. Open the battery hood.
3. Connect a battery carrier (option) to the vehicle. Always apply the battery carrier brake.
4. Unlock the battery stopper.
5. Move the battery ASSY to the battery carrier.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Battery stopper Lock the battery stopper on the battery carrier to prevent the
handle battery from falling out.
Battery stopper
1-7
INSPECTION
1. Electrolyte level inspection
Stopper Open the cap, and if the white line on the red float has
White line dropped, distilled water should be added.
Add water until the white line appears.
Stop adding water when the white line appears, since addition
is excessive when the tip end of the float comes into contact
with the stopper.
Float
As a level gauge is provided at the front of the battery case, the

electrolyte level can generally be checked at a glance, but
open the cap regularly to check the level.
The green light of the level gauge lights up to indicate
activation of the level gauge sensor, and the red light flashes
to indicate the necessity of adding water.
Red light Green light

Normal level OFF ON
Insufficient level Blinking ON
Note:
Never change the installation location of the vent caps on
which the sensor is installed.
Reference:
The consumption of electrolyte can be calculated using
the following equation:
Consumption (cc) = 5 hour capacity × 0.0336 × number of
cells × number of charges
Battery capacity
Vehicle model Number of cells
(AH/5HR)
4CBT2R·CBT3R·
24 129
4CBTY2R
4CBTK4R·
↑ 220
4CBTYK4R
2. Electrolyte inspection
Battery electrolyte is normal when it is transparent. Check for
turbidity when inspecting the specific gravity. If it cannot be
checked clearly, put the electrolyte in a beaker for inspection.4
1-8
3. Battery electrolyte specific gravity inspection

Use a hydrometer to measure the specific gravity of the
electrolyte.
Specific gravity when fully discharged:
1.280 [20°C] (68°F)
Specific gravity when fully discharged:
1.150 [20°C] (68°F)
The specific gravity of the electrolyte is expressed with 20°C

(68°F) as the standard.
Equation for converting specific gravity
S20 = St + 0.0007 (t – 20)
S20 : Specific gravity at 20°C (68°F)
St : Specific gravity at t°C
t : Electrolyte temperature upon measurement (°C)
How to use the hydrometer

(1) Insert the nozzle of the hydrometer into the electrolyte port
and allow the electrolyte to be sucked into its outer tube.
Hydrometer
(2) Let the hydrometer float correctly without making contact
Rubber bulb with the outer tube, top or bottom, and read the scale at
Out tube the highest point of the electrolyte surface as illustrated at
left when the bubbles in the electrolyte disappear.
(3) After the measurement, wash the inside and outside of
Nozzle the hydrometer well with clear water and store it after
wiping the water off with clean cloth.
4. Insulation resistance inspection
Measure the resistance between the battery and battery case
with an insulation resistance meter (megohmmeter).
Insulation resistance: More than 1 MΩ
Note:
When insulation resistance is less than 1 MΩ, remove the
battery from the vehicle and wet-clean.
Allow to dry completely after wet-clean, then measure the
insulation resistance again. If the result is 1 MΩ or more,
reinstall the battery onto the vehicle.
Battery maintenance sheet

Prepare a maintenance sheet for each battery to record and maintain the inspection results.
Specific Added electroly
Time Cell number gravity Temperature Notes Inspected by
(amount)
1-9
REPLACING BATTERY PLUG TERMINAL

1. Disconnect the battery plug cables one by one.
Caution:
Never disconnect more than one cable at the same time.
Fatal accidents may occur as a result of short circuit.
2. Insert a screwdriver from the terminal side, push down the

spring at the bottom of the terminal, at the same time, and pull
Terminal the cable to draw out the terminal.
Screwdriver
Spring Spring
3. Strip the tip of the cable for approx. 30 mm (1.18 in.), solder
sufficiently and insert it into the crimped portion of the new
terminal.
Note:
Be sure to prevent solder from running and adhering to
the contact surface of the terminal.
4. When crimping cables, use a crimping tool and make sure not
Crimping method to bend the terminal.
Crimping tool
Pad
(To prevent the contact piece
from bending)
5. Insert the terminal into the battery plug.

Check that the tip of the terminal goes over the tip of the spring
Case Terminal and is set securely.
Spring Cable
1-10
LEVER FOR EMERGENCY BATTERY PLUG DISCONNECTING

Flange bolt
Connector lever
Hook
Bolt
Nut
Nut
Pin Pin Spring pin
Plate
Washer Spring
Bracket
Bushing Lever
EEC specifications Bolt
Handle (mounted on battery hood)
Hook
Nut
Note:
After mounting the hook, check that turned the handle disconnects the plug.
Lever Operating Procedure

When the lever is turned towards the front of the vehicle the plug
on the battery side moves, breaking the connection with the plug on
the connector side.
1-11
BATTERY ROLLER (ON THE VEHICLE)
Assembled state
Roller Spacer
Bearing
Shaft
1-12
BATTERY STOPPER
Bolt
Panel
Washer
Stopper
Limit switch
Washer
Bracket
Washer
Panel Collar
Nut Flange bolt
Cushion
Flange bolt
Stopper
Limit switch harness
Limit switch
Flange bolt Catch
Note:
• Tighten the upper nut until dimension A is 0 mm (0 in.).
Secure the upper nut so that it does not turn and tighten
the lower nut to the specified amount of torque.
A
• Make sure the harness is connected in the correct

Switch positions.
No. Line color

1
1 Red - blue
2 Yellow - green
Harness
Note:
Apply MP grease to the rotating section after reassembling.
1-13
Adjustment Method
Limit switch for the Battery Stopper Limit Switch
Panel
Adjust until distance A is within the standard value range indicated
below.
Standard: 26 ± 0.5 mm (1.02 ± 0.02 in.)
Panel Mounting Method

After mounting the limit switch, push the panel in the direction of the
Bolt arrows and secure in place with 2 bolts.
Note:
• After reassembling, check that the limit switch is working
by moving the battery stopper up and down.
Bolt
• If the limit switch is not working, or the battery stopper is
catching against the limit switch, perform adjustment
again.
1-14
BATTERY CARRIER
Shaft
Steering wheel
Rod Hook
Return spring
Flange bolt
Pin
Plate washer
Stopper pin
Steering
Hook handle
Battery stopper handle
Roller
Return spring
Brake
Bearing
Flange bolt
Cushion rubber Spacer
Pin
Battery stopper
Hook Leg
Guide
Flange nut
Spherical nut
Rod
Wheels
Pin Washer
Plate washer Plate
Cotter pin Flange bolt
2-1
CONTROLLER
Page 0
CONTROLLER ................................................... 2-2
1
GENERAL ................................................................... 2-2
REMOVAL•INSTALLATION ...................................... 2-8 2
CONTACTOR ..................................................... 2-9 3
GENERAL ................................................................... 2-9
REMOVAL • INSTALLATION.................................... 2-11
4
ACCELERATOR PEDAL ................................. 2-12 5
COMPONENTS......................................................... 2-12 6
INSPECTION AND ADJUSTMENT OF
7
ACCELERATION SENSOR ................................... 2-13
8
ACCELERATOR .............................................. 2-14
COMPONENTS......................................................... 2-14 9
REMOVAL • INSTALLATION.................................... 2-14 10
ACCELERATOR INSPECTION ................................ 2-16
ACCELERATOR LEVER ADJUSTMENT ................ 2-17
11
FLOOR SWITCH .............................................. 2-18 12
COMPONENTS......................................................... 2-18
13
FLOOR SWITCH ADJUSTMENT METHOD............. 2-19 14
15
16
17
18
2-2
CONTROLLER
GENERAL
SYSTEM CONFIGURATION
Accelerator
Switch Display
potentiometer
Contactor
AC motor
48 V Controller
Electromagnetic
Contactor coil Thermo-sensor
brake coil
Rpm sensor
2-3
EXTERIOR VIEW OF CONTROLLER
✽ Nameplate
✽
✽ DIP switch function label
0
✽
1
✽ 2
CN1
3
DSW2
4
DSW1 5
CN3
CN2 6
7
DIP switch function label in detail
8
9
10
11
12
13
14
15
Note:
The tightening torque when mounting terminals is T=9.8 ± 2.0 N·m (100 ± 20 kgf·cm) [7.24 ± 1.45 ft·lbf]
16
Note:
17
When replacing the controller, always use a controller with the same part number as that written on the
nameplate. A vehicle cannot be operated, or cannot be operated to 100% efficiency when the controller part
number does not match the vehicle.
18
2-4
CONTROLLER SPECIFICATIONS
No. Item Specifications
1 Name Driving AC controller
4CBT2R 4CBTK4R
2 Model type 4CBT3R
4CBTY2R 4CBTYK4R
3 Control method MOSFET inverter
4 Voltage rating 48 V
5 Operating voltage range 20 to 65 V
6 Operating temperature range –40 to 80°C (–40 to 176°F)
7 Storage temperature range –40 to 80°C (–40 to 176°F)
8 Operating humidity range 30% to 95% RH
9 Amperage rating (3 mins.) 100 Arms 132 Arms 164 Arms
10 Amperage rating (60 mins.) 50 Arms 60 Arms 70 Arms
11 Dielectric strength 500 VAC (50/60 Hz) for 1 min.
12 Insulation resistance 10 MΩ or more at 500 VDC
13 Weight 2.8 ± 0.32 kg [6.17 ± 0.71 lb]
14 External dimensions 250 × 132 × 95 mm [9.84 × 5.20 × 3.74 in.]
15 Cooling system Natural cooling
16 Tightening torque for connecting terminals M8, 9.8 ± 2.0 N·m (100 ± 20 kgf·cm) [7.24 ± 1.45 ft·lbf]
18
17
Model selector 1
16
Model selector 2
Seat (floor)
15
Parking
14 Brake
Traveling speed limit
Error clear
13
Diagnosis indication
brake
Option input
Electromagnetic
12
Contactor panel
Destination selector 1
Destination selector 2
11
Acceleration
10
Shielded
9
Drive motor
Thermo-sensor
8
Shielded
7
(Drive motor)
sensor A
Traveling speed
Electromagnetic
Shielded
6
Electromagnetic
sensor B
(Drive motor)
Traveling speed
5
Electromagnetic brake
4
Option output
3
Remaining battery charge indicator
2
1 Remaining battery charge indicator

0
Controller
WIRING DIAGRAM
2-5
2-6
CN1 CN2
9 8 7 6 5 4 3 2 1 7 6 5 4 3 2 1
21 20 19 18 17 16 15 14 13 12 11 10 16 15 14 13 12 11 10 9 8
31 30 29 28 27 26 25 24 23 22 24 23 22 21 20 19 18 17
1 Model selector 2 1 —
2 Model selector 1 2 —
3 Contactor – 3 Option output
4 Contactor + 4 —
5 Display power supply + 5 —
6 Key switch 6 Electromagnetic brake
7 Battery 7 —
8 Resistor – 8 —
9 Resistor + 9 —
10 Display (BIBC) 10 Diagnosis indication
11 — 11 Error clear
12 Shielded (rpm sensor A) 12 Traveling speed limit
13 Rpm sensor A – 13 —
14 Rpm sensor A + 14 —
15 GND 15 Destination selector 2
16 Acceleration switch 16 —
17 Brake switch 17 GND
18 Parking switch 18 Direction forward
19 Seat (floor) switch 19 Direction reverse
20 Thermo-sensor 20 Option input
21 Accelerator potentiometer + 21 —
22 Display (BIBC) 22 —
23 Display power supply – 23 Destination selector 1
24 — 24 —
25 Shielded (Accelerator)
26
27
Shielded (rpm sensor B)
Rpm sensor B –
CN3
28 Rpm sensor B +
29 Thermo-sensor
30 GND — — — — — —
31 Accelerator potentiometer output
— — — — — —
— — — — —
Unused
SIGNAL INPUT TO CONTROLLER

No. Name Model type No. Name Mode type No. Name Model type
Error clearance
1 Key switch All models 7 Parking brake switch All models 13 All models
switch
Forward travel Destination select
2 All models 8 Brake switch All models 14* All models
switch switch 1
Reverse travel 4CBT2R·3R· Destination select
3 All models 9 Accelerator switch 15* All models
switch 4CBTK4R switch 2
4CBT2R·3R· Accelerator 4CBTY2R·
4 Seat switch 10* Model select switch 1 All models 16
4CBTK4R potentiometer switch 4CBTYK4R
4CBTY2R·
5 Floor switch 11* Model select switch 2 All models 17 Motor thermo-sensor All models
4CBTYK4R
Diagnosis display
6 Speed limit switch All models 12 All models 18 Motor rpm sensor All models
switch
*: Depending on the vehicle, this may be set automatically by the harness selected. When an unsuitable harness is installed,
the vehicle will move at an incredibly slow speed, or will not move at all.
2-7
SPEED LIMIT
Vehicle speed limit is 13 km/h (8 mph) when traveling forward. When traveling in reverse, the speed limit is 9 km/h
(5.6 mph) for sit-down type models and 6 km/h (3.7 mph) for standup models.
However, the speed limit setting for forward travel that is activated using the speed limit switch can be changed using
the controller DIP switch.
Switch position
Maximum speed
1 2 3
6 km/h ON ON ON
7 km/h ON ON OFF
8 km/h ON OFF OFF
9 km/h ← Factory setting OFF OFF OFF
10 km/h OFF OFF ON
Note:
Check DIP switch position on the plate attached to the
controller.
BATTERY CHARGE INDICATOR

When the power depletion level and remaining power indication on the display do not match, the indication on the
display can be corrected by operating the DIP switches.
Switch position
Indication level
1 2 3
Level 1 ON OFF ON
Level 2 ON ON ON
Level 3 ON ON OFF
Level 4 ON OFF OFF
Level 5 ← Factory setting OFF OFF OFF
Level 6 OFF OFF ON
Level 7 OFF ON ON
Level 8 OFF ON OFF
CHANGING ACCELERATOR RELEASE AND BRAKE REGENERATION
Switch position
Accelerator release and brake
DIP SW1 DIP SW2
regeneration
4 1
Level 1 (0.00G) ON ON
Level 2 (0.05G) ON OFF
Level 3 (0.10G) ← Factory setting OFF OFF
Level 4 (0.15G) OFF OFF

2-8
REMOVAL•INSTALLATION
Removal Procedure
1. Stop the vehicle somewhere flat and chock the wheels. (Apply
the parking brake)
2. Disconnect the battery plug. (Refer to SECTION 5, “FRONT
AXLE”)
4. Remove the 3 bolts and take the controller cover off.

Roll the controller cover backwards to remove.
Controller cover
5. Remove the 5 bolts and disconnect the cables from the

controller.
Note:
• Record the cable and harness positions before
starting removal/installation. Always check harness
position when mounting.
• When connecting, match up symbols on cables with
those on the controller.
• Check the plate attached to the controller.
6. Remove the 4 bolts then remove the controller.

Weight of controller: Approx. 3 kg [6.62 lb]
Controller
7. Disconnect the 2 connectors from the controller.
Connector
2-9
CONTACTOR
GENERAL
EXTERIOR VIEW OF CONNECTORS mm [in.]
105 [4.13] 37.8 [1.49]
100 [3.94]
105 [4.13]
8 [0.31]
89 [3.50]
106 [4.17]
2-10
LOCATION OF CONNECTORS
Resistor
Contactor
Connector cable N1 Connector cable P1
Detail A portion View B

Fuse 175A
Red
Purple
Check line color and connection position

when mounting.
P3 cable
2-11
Removal Procedure
1. Disconnect the P3 cable from the controller.
2. Disconnect the P1 cable and P1 harness from the contactor.
3. Disconnect the connector.
Note:
Record position and order for mounting before removing
harness and cables.
4. Disconnect the 2 connectors from the contactor.
Connector
5. Remove the 2 bolts then remove the contactor.
P3 cable Removing fuses

Note:
Make sure the fuse is straight when mounting.
Fuses Copper plate

2-12
ACCELERATOR PEDAL
COMPONENTS
4CBT2R·3R·4CBTK4R
Accelerator pedal
Bracket
Accelerator arm
Flange bolt
Pin
Bushing
Spring
Flange bolt
Accelerator bracket
Bushing
Sensor lever
Washer
Nut
Screw
Acceleration sensor Harness

2-13
Removal Procedure
Front toeboard
1. Remove the toe board. (Refer to SECTION 9, “BODY • FRAME”)
2. Remove the accelerator harness from the inner side of the
Bolt front toe board.
Accelerator
pedal Accelerator 3. Remove the 2 bolts.
harness
4. Remove the 2 bolts then remove the accelerator link.

Bolt
Front toe board
Accelerator link
INSPECTION AND ADJUSTMENT OF ACCELERATION SENSOR

1. Check that operation of the accelerator pedal turns the switch
ON and OFF.
Measurement terminals 51 - 64
Pedal not operated ∞Ω

Standard
51 Pedal operated Continuity
64
Accelerator link 2. Adjustment of Accelerator Potentiometer Installation

Sensor (1) Temporarily assemble the accelerator sensor on the
bracket sensor bracket.
(2) Insert 1.5 mm [0.06 in.] thickness gauge in the gap
between the accelerator link and accelerator bracket.
(3) Adjust the acceleration sensor by rotating until the
accelerator switch turns ON.
Thickness gauge
(4) When adjustment is complete, screw the acceleration
Acceleration sensor sensor in place and remove the thickness gauge.
Note:
• Apply 08833-76002-71 to the threaded portion of the
screw.
• Insert 1 mm [0.04 in.] thickness gauge and check that
the acceleration sensor is OFF.
2-14
ACCELERATOR
COMPONENTS
4CBTY2R·4CBTYK4R
Bolt
Accelerator
Bolt
Plate washer
Accelerator lever
Bushing
Removal Procedure
1. Stop the vehicle somewhere flat and chock the wheels. (Apply
Console cover
the parking brake)
2. Disconnect the battery plug. (Refer to SECTION 5, “FRONT
AXLE”)
3. Remove the 2 bolts.
Bolt
2-15
Console cover 4. Half-open the console cover and disconnect the connectors for
Horn switch the horn switch and turn signal switch.
5. Remove the console cover.
Turn signal
switch
6. Disconnect the accelerator connector.

7. Remove the 2 bolts then remove the accelerator.
Bolt
Accelerator
8. Remove the accelerator lever set bolt.

Plate washer
Bolt
Bushing
9. Rotate the accelerator lever when removing.

2-16
ACCELERATOR INSPECTION
mm [in.]
100 [3.93]
60 [2.36]
94 [3.70]
81 [3.19]
Reverse traveling Forward traveling
46° 46° 75 [2.95]
80 [3.15]
70 [2.76]
64 [2.52]
Inspection method
Check the resistance between accelerator terminals.
5 4 3 2 1
Standard
10 9 8 7 6 No.
Neutral Forward traveling Reverse traveling
2-4 ∞Ω 0Ω 0Ω
NO P C J 4-1 ∞Ω 0Ω 0Ω
1 N2 R-L LSA
2 45 G LSAR 1-10 2.5 kΩ 2.5 kΩ 2.5 kΩ
3
4 45 W LSAF 1-9 Change of 0 to 2.5 kΩ depending on operation angle of lever
5 70 R-Y LSCOM
6 120 Y-R LSFO 10-9 ↑
7 103 R-W LSBU
8 52 GR AC
9 N2 L-R AC-
10 53 R-B AC+
2-17
ACCELERATOR LEVER ADJUSTMENT

1. Accelerator lever position
Reverse traveling Adjust the accelerator lever until the gap created between the
Lever box lever and the lever box notch is uniform throughout the entire
movement of the lever from forward to reverse travel positions.
Accelerator Once adjustment is complete, secure the lever in place with a
lever bolt.
Standard gap distance: Approx. 2.5 mm [0.1 in.]
Accelerator Note:
lever
After mounting is complete, check that the accelerator
Forward traveling lever is working smoothly by moving it 2 or 3 times.
Accelerator lever 2. Horizontal position of accelerator

When mounting the accelerator lever, adjust the accelerator
Accelerator until the pin sticks out 3 to 4 mm [0.12 to 0.16 in.].
3 to 4 mm
[0.12 to 0.16 in.]
Pin
3. Lengthwise position of accelerator

Adjust the position of the accelerator so that the accelerator
lever notch does not come into contact with the accelerator
pin.
Pin
Notch
2-18
FLOOR SWITCH
COMPONENTS
4CBTY2R·4CBTYK4R
Pedal
Screw
Spring
Nut
Plate washer
Bolt
Limit switch
2-19
Floor switch pedal Removal Procedure
1. Remove the toe board. (Refer to SECTION 9, “BODY • FRAME”)
2. Remove the 2 bolts from the inner side of the front toe board
then remove the floor switch pedal.
Bolt
3. Unscrew the nut from the underside of the toe board and
Plate washer
remove the screw and spring from the upper side.
Screw
Spring
Nut
Cautions for installing springs

• Set the plate washer on the first coil of the spring and hold in
Plate washer Spring place with the screw.
• The plate is threaded.
• The spring should be installed in as perpendicular a position as
possible.
Boss Screw • After fixing the spring in place, make sure that the spring and
boss are not touching.
(0.04 in.)
Approx.
Plate • After securing the screw in place with the nut, tighten the screw
1 mm
until it protrudes approx. 1 mm [0.04 in.] from the nut.

Nut
FLOOR SWITCH ADJUSTMENT METHOD

Adjust the floor switch nut until the floor switch protrudes by A.
Nut
A = 25 mm [0.98 in.]
Note:
Mount the floor switch so that the harness faces aft.
3-1
TROUBLESHOOTING
Page 0
BEFORE TROUBLESHOOTING ....................... 3-2
1
GENERAL .......................................................... 3-4
TROUBLESHOOTING ....................................... 3-5
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
3-2
BEFORE TROUBLESHOOTING
CONNECTOR HANDLING
1. Disconnect the battery plug before connecting or
disconnecting each connector or terminal.
2. When unplugging a connector, first remove the lock then,
without pulling the harness, pull out the connector while
holding the main unit.
To connect, push the connector fully until it is locked in
position.
3. When applying tester probes, always do so from the rear of the

connector (harness side).
4. When this is not possible, such as with waterproof tester
probes, make sure that inserting will not deform the connector
terminal.
5. Do not touch connector terminals directly with your hand.
6. When bringing tester probes into contact with live terminals,
prevent two tester probes from coming into contact with each
other.
WIRE HARNESS AND CONNECTOR INSPECTION

PROCEDURE
When a problem occurs, first check the connector and wire harness
for the related electrical circuit using the method described below.
Continuity check
1. Disconnect the connectors at both ends of the relevant
harness.
2. Measure the resistance between corresponding terminals of
the connectors at both ends.
Standard: less than 10 Ω
Note:
Move the wire harness slightly from side to side and up
and down while measuring.
Reference:
The cause of disconnections is almost always the
connector as disconnections in the vehicle’s central
wiring are rare. Inspect especially the sensor connectors
with sufficient care.
3-3
Short circuit check

1. Disconnect the connectors at both ends of the relevant
harness.
2. Measure the resistance between the corresponding connector
terminal and N1. Always inspect the connectors at both ends. 0
Standard: 1 MΩ or more
Note:
Move the wire harness slightly from side to side and up
1
and down while measuring.
2
3. Measure the resistance between the corresponding connector
terminal and another terminal of the same connector. Always
inspect the connectors at both ends.
3
Standard: 1 MΩ or more
Note:
4
5
The wiring may short-circuit due to being pinched by the
body or defective clamping.
6
Visual and contact pressure checks
• Disconnect the connectors at both ends of the relevant
7
harness.
• Perform a visual check to make sure that there is no rust or
foreign matter contaminating the connector terminal.
8
9
• Check that the caulking is not loose or damaged, and, after
checking that there is no damage, gently tug the connector or
wire harness to make sure that it cannot be pulled out.
10
• Insert a male terminal same as that of the terminal to a female
11
terminal and check the extracting force.
Defective contact may exist at a terminal where the extracting
force is less than that of other terminals.
12
Note:
If a problem, such as rust or foreign matter on the
13
terminal, or a drop in the contact pressure of male/female
terminals occurs, simply disconnecting and reconnecting
the connected connector may change the contact
14
conditions and the problem may be solved. Try
disconnecting and re-connecting several times. If such a
defect is recognized, it is likely that there is a defective
15
terminal contact.
16
17
18
3-4
GENERAL
When an electrical fault occurs, the remaining power indicator LED
LED
(light emitting lights up or blinks and details regarding the fault are displayed.
diode) Moreover, by fitting SST (09561-40590-71) to the error memory
display connector located in the rear of the vehicle, the most recent
10 errors can be displayed in order.
Follow the troubleshooting instructions to solve the current
problem.
Remaining power
indicator
Error memory display connector
Black tube
Error memory clear connector
PROCEDURE FOR CLEARING ERROR MEMORY

1. Attach SST to the connector.
2. Turn the key switch to ON.
PROCEDURE FOR DISPLAYING ERROR MEMORY

1. Attach SST to the connector.
2. Turn the key switch to ON.
3. The error memory displays the details of the fault that has occurred most recently.
4CBT2R • 3R • 4CBTK4R
Move the shift lever to the forward travel position to display the details of the next most recent fault.
Return the shift lever to neutral every time the display switches.
4CBTY2R • 4CBTYK4R
Move the accelerator lever to the forward travel position to display the details of the next most recent fault.
MULTIPLE FAULTS
When multiple faults occurred simultaneously, the details of the fault detected last are displayed. Remedy the current
fault then turn the key switch OFF → ON to display the next fault.
If no fault is displayed after turning the key switch OFF → ON, the vehicle is in normal working order.
Note:
In the event that movement is disabled as a result of a fault, always disconnect the battery plug before towing
the vehicle.
3-5
TROUBLESHOOTING
Error indication Cause Vehicle condition Memory
• Controller temperature abnormality

Traveling disabled Yes
0
* • Motor temperature abnormality
On 1
* lamp was flashing before lighting
Was flashing Open the battery hood in a well- 2
ventilated area and cool the controller
Was not flashing and motor
3
Outside
Perform motor voltage check between
CN101-21 to 32
standard
range Disappears 4
Replace motor
Standard:
0.15 V to 4.95 V
Within standard
Does not Normal operation is possible
5
disappear
6
range Error indication
Perform motor thermo-sensor Disappears

resistance/voltage check
Standard:
0.3 kΩ/0.3 V (±10%)
Outside
Normal operation is possible 7
standard
Within standard
range
range
Replace thermo-sensor 8
Perform motor thermo-sensor continuity
Does not
disappear 9
Error indication
check between CN101-21 to 32
Continuity No continuity
Disappears 10
Normal operation is possible
11
Replace harness
12
Replace controller
Does not disappear
Error indication 13
Disappears

14
Caution:
15
• Check part number before replacing the controller.
The vehicle cannot be operated to 100% efficiency when an unsuitable controller is installed.
• Check DIP switch settings.
16
17
18
3-6
• Controller temperature rise

Output limited None
* • Motor temperature rise
Flashing
Open the battery hood in a well-

ventilated area and cool the controller
and motor
Disappears
Charger incorrectly connected Contactor OFF None
Connected
Connection of charger plug to battery
Not connected
Connect charging plug into device
P-N is 68 V or less when the key switch

is ON
Replace controller
3-7
Controller high voltage Traveling disabled None
Error indication after disconnecting and Does not disappear

re-connecting the battery plug
Disappears
Battery plug disconnected while the

vehicle was traveling
Disconnected Still connected
Re-connect the plug
Yes Error indication frequently displayed

while the vehicle is traveling
No
Battery inspection
Further tighten the controller’s P terminal and N terminal

bolts.
Standard tightening torque:
T=7.8 to 11.8 N·m (80 to 120 kgf·cm) [5.8 to 8.7 ft·lbf]
Perform P terminal-N terminal voltage Outside standard

check range
Replace controller
Standard:
Less than 72 V
Within standard range
Perform continuity and visual checks for Abnormal

Replace cable
battery connector cable
Normal
Replace controller
3-8
• Traveling disabled
Main circuit abnormality Yes
• Contactor OFF
Key switch OFF → ON
Error indication disappears Error indication does

not disappear
Normal operation is possible • Check for loose

contactor cable Abnormal Replace contactor and controller and
• Check for loose U, V, tighten terminal bolts further
W, P, and N terminals
Normal
Does not disappear
Perform controller resistance check Error indication
Measurement Tester polarity
Standard Disappears
terminals + –
P U 1 kΩ to 4 kΩ
P-U Normal operation is possible
U P Changes from 2 kΩ to 10 kΩ to ∞
U N 1 kΩ to 5 kΩ
U-N
N U Changes from 2 kΩ to 11 kΩ to ∞
P V 1 kΩ to 6 kΩ
P-V
V P Changes from 2 kΩ to 12 kΩ to ∞
V N 1 kΩ to 7 kΩ
V-N
N V Changes from 2 kΩ to 13 kΩ to ∞
P W 1 kΩ to 8 kΩ
P-W
W P Changes from 2 kΩ to 14 kΩ to ∞
W N 1 kΩ to 9 kΩ
W-N
N W Changes from 2 kΩ to 15 kΩ to ∞
Notes regarding measurement

• Disconnect motor cable when measuring
• Use an analog tester
• Use 1 kΩ measurement range
• Check that all controller terminals are tightened to the specified torque
Within standard range Outside standard range
Check resistance value between

Within standard
controller resistor and CN101-9 and
range
CN101-10 Replace controller
Standard:
25°C (77°F) 39 Ω ± 10%
Outside standard range
Replace harness
Note:
Tightening torque for contactor terminals:
T=7.8 to 11.8 N·m (80 to 120 kgf·cm) [5.8 to 8.7 ft·lbf]
3-9
• Acceleration sensor abnormality

Traveling disabled Yes
• Accelerator abnormality
Perform acceleration sensor check Abnormal

Refer to SECTION 2, “CONTROLLER” Replace acceleration sensor
Normal
Does not disappear

Error indication
Disappears
Perform harness check between
controller and acceleration sensor Normal operation is possible
Normal Abnormal
Replace harness
Does not disappear

Replace controller Error indication
Disappears
Perform accelerator check Abnormal

Refer to SECTION 2, “CONTROLLER” Replace accelerator
Normal
Does not disappear

Error indication
Disappears
Perform harness check between
controller and acceleration sensor Normal operation is possible
Normal Abnormal
Replace harness
Does not disappear

Disappears

3-10
Direction switch abnormality Traveling disabled Yes
Error indication
Direction switch inspection disappears
Disconnect CN9 Replace direction switch
Error indication
does not disappear
Does not disappear
Error indication
Disappears
Perform harness continuity check
Perform continuity check for CN102-18 Continuity
to CN102-19 and for CN102-18 to
CN102-20 with direction lever in neutral
No continuity Replace harness
Does not disappear

Disappears

Note:
Refer to the table of “CONNECTOR DIAGRAM” in SECTION 10, “APPENDIX” for connectors.
Error indication
Accelerator inspection disappears
Disconnect CN9 Replace accelerator
Error indication
does not disappear
Does not disappear
Error indication
Disappears
Perform continuity check for CN102-18 Continuity
to CN102-19 and for CN102-18 to
CN102-20 with acceleration lever in
neutral
Replace accelerator
No continuity
Does not disappear

Disappears

Note:
3-11
Seat switch abnormality Display only Yes
Error indication
Deadman seat switch check disappears Seat switch individual inspection
Disconnect CN42 (seat switch) Seat switch OFF (seat not occupied)
No continuity
Error indication Seat switch ON (seat occupied)
does not disappear Continuity exists
Abnormal Normal
(Vehicle w/ battery
roll-out spec)
Replace seat
Does not
Does not disappear disappear
Error indication
Disappears
Roll-out spec

Battery stopper switch inspection
Standard: Normal Abnormal
Standard:
CN43-2 to CN42-2 No continuity
Switch OFF No continuity
CN43-1 to CN101-16 No continuity
Switch ON Continuity exists
CN42-1 to CN101-20 Continuity exists
Normal Abnormal
Replace switch
Replace controller Replace harness
Note:
• Use genuine Toyota parts when replacing the seat.
• Refer to the table of “CONNECTOR DIAGRAM” in SECTION 10, “APPENDIX” for connectors.
3-12
Floor switch abnormality Display only Yes
Error indication
Floor switch inspection disappears Seat switch individual inspection
Disconnect CN42 (floor switch) Seat switch OFF (seat not occupied)
No continuity
Error indication Seat switch ON (seat occupied)
does not disappear Continuity exists
Abnormal Normal
(Vehicle w/ battery
roll-out spec)
Replace floor switch
Does not
Does not disappear disappear
Error indication
Disappears
Roll-out spec
Perform harness continuity check Battery stopper switch inspection

Standard: Normal Standard: Abnormal
CN101-20 to CN42-2 Continuity exists Switch OFF No continuity
CN101-16 to CN43-1 Continuity exists Switch ON Continuity exists
Normal Abnormal
Replace switch
Replace controller Replace harness
Note:
3-13
• Parking brake not applied • Display only

• Return-to-neutral function • Traveling disabled None
• OPS • Traveling disabled
Put the direction lever in neutral, Error indication does not disappear
release the accelerator, then release
the parking brake while
Was occupying the
not flashing
seat
Perform parking brake switch check Abnormal

Standard:
Switch OFF No continuity Parking brake switch
Error indication disappears Switch ON Continuity exists
Normal
Does not disappear
Error indication
Normal operation is possible Sit in the seat and operate the direction Disappears
lever in the forward/reverse directions
several times, then put into neutral Normal operation is possible
Does not Seat switch individual inspection

disappear Standard: Abnormal
Error indication Replace seat
Seat occupied Continuity exists
Disappears Seat not occupied No continuity
Does not disappear
Error indication
Disappears
See P3-11 Troubleshooting
Note:
Use genuine Toyota parts when replacing the seat.
Release the parking brake with the floor Error indication does not disappear
switch depressed and the acceleration
lever in neutral Was not flashing
Perform parking brake switch check

Standard:
Error indication disappears Switch OFF No continuity
Switch ON Continuity exists
Normal operation is possible Does not

Error indication disappear See P3-12
Troubleshooting
Disappears

3-14
Contactor abnormality Traveling disabled Yes
Error indication disappears Error indication does not disappear
Normal operation is possible Perform contactor check Abnormal

• Foreign matter on contact points? Replace parts
• Fusion?
• Snagged parts?
Normal Does not disappear
Error indication
Disappears
Perform cable check between
contactor and controller Normal operation is possible
• Loose bolt(s)?
Standard:
T=7.8 to 11.8 N·m (80 to 120 kgf·cm) Abnormal
[5.8 to 8.7 ft·lbf] Tighten bolts further or
• Perform continuity check replace cable
CN101-4 to CN136-2
CN101-5 to CN136-1
Normal
Does not disappear
Error indication
Disappears
Fuse inspection Abnormal

Standard: Replace fuse
Resistance is not ∞
Normal
Does not disappear

Disappears

3-15
Voltage drop Traveling disabled Yes
Normal operation is possible Perform cable check between battery Abnormal

Tighten bolts further or
and controller replace cable
• Loose bolt(s)?
• Perform cable continuity check
Normal
Does not disappear
Error indication
Disappears
Charge battery
Error indication
Does not disappear
Disappears
Replace controller Normal operation is possible

3-16
Drive current sensor abnormality Traveling disabled Yes
Normal operation is possible Replace controller
Motor thermo-sensor abnormality Traveling disabled Yes
Perform harness continuity between No continuity

motor thermo-sensor and CN101-21 Replace harness
and CN101-32
Continuity
Perform motor thermo-sensor check

CN101-21 to CN101-32 Outside standard range
Standard: Replace motor
Thermo-sensor voltage
Less than 0.15 V or more than 4.95 V
Replace controller
3-17
Controller thermo-sensor abnormality Display only Yes
Controller abnormality Display only Yes

3-18
Motor rpm sensor abnormality Display only Yes
Perform motor rpm sensor voltage check with the key switch
turned ON and the vehicle stopped
Within standard range
rpm sensor A CN101-14 to CN101-15 Replace controller
Standard range
1.2 V to 3.2 V
rpm sensor B CN101-29 to CN101-30
CN53 (rpm sensor A) Standard switches

CN54 (rpm sensor B) between and
Switch sensors around, then perform Rpm sensor abnormality
voltage check again
Remains unchanged
outside standard range
Replace motor
Replace harness
4-1
MOTOR
Page 0
DRIVE MOTOR .................................................. 4-2
1
GENERAL ................................................................... 4-2
SPECIFICATIONS ...................................................... 4-2 2
COMPONENTS........................................................... 4-3 3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
4-2
DRIVE MOTOR
GENERAL
40 mm
STD [1.6 in.]
277 mm [10.9 in.]
W
V
U
rpm sensor A
22 mm [0.9 in.]
3-M8 × 1.25
Rpm sensor B
Electromagnetic brake specifications 40 mm

275 mm [10.8 in.] [1.6 in.]
W
V
U
rpm sensor A
22 mm [0.9 in.]
3-M8 × 1.25
Rpm sensor B
SPECIFICATIONS
Vehicle model Voltage (V) Dimensions (mm) [in.] Output (kW) Motor type
4CBT2R
4CBT3R
Free ventilation
ø202 × 277
4CBTK4R 48 2.3 Flange-type
[ø7.95 × 10.90]
Cage-type
4CBTY2R
4CBTYK4R
4-3
COMPONENTS
STD
Bolt, Washer
Bearing
Screw Plate
0
Bushing
Bracket
Collar
Stator
Bracket
1
Sensor Washer
Gear 2
Nut
Center cap
Bearing
3
4
5
Oil seal
Flange bolt Rotor

6
7
Electromagnetic brake specifications
Bolt, Washer
Bearing 8
Screw
Bushing
Bracket
Plate
Collar 9
Stator
Bracket
10
Washer
Sensor
Flange
Gear
Bearing 11
12
Oil seal
13
Nut
Flange bolt
14
Rotor
15
16
17
18
4-4
Removal Procedure
1. Stop the vehicle somewhere flat and chock the wheels.
2. Disconnect the battery plug.
(Refer to SECTION 5, “FRONT AXLE”)
3. Remove the battery hood.
(Refer to SECTION 9, “BODY • FRAME”)
4. Disconnect the harness from the motor. (3 places)
5. Disconnect the motor cable from the controller.

Boot
(1) Remove the controller cover.
(2) Turn the boot up to reveal the terminal.
Motor (3) Remove the bolts and disconnect the motor terminals
from the controller.
Terminal
Controller
6. Remove the electromagnetic brakes (for relevant vehicles).

Note:
Remember to disconnect the electromagnetic brake
connectors.
7. Disconnect the motor from the rear axle.

(1) Remove the 4 mounting bolts for the motor.
Tightening torque for bolts N·m (kgf·cm) [ft·lbf]:
T=68.6 to 88.2 (700 to 900) [50.6 to 65.1]
(2) Fix eyebolts into threaded holes (M8 × 1.25) on upper
face of the motor.
(3) Set the shackle and wire then hook up to the hoist.
4-5
8. Raise the motor.

Note:
• Work slowly and with care to prevent the harnesses
and cables from interfering with other parts and
thereby causing damage.
0
1
2
3
4
5
• When reassembling, use a brush to apply grease to
6
7
the spline section of the motor shaft.
8
9
Splined portion
10
Sealing agent
• When reassembling, the sealing agent should be
applied to the rear axle housing in a seamless,
unbroken line. 11
12
13
14
• Cautions for connecting the rpm sensor
15
Rpm sensor B
Blue tape is attached to the wire for the connector
Rpm sensor A
(connector NO.CN53) linked to rpm sensor A to allow
for verification when making connections.
16
17
Blue tape attached 18
5-1
FRONT AXLE
Page 0
GENERAL .......................................................... 5-2
1
SPECIFICATIONS.............................................. 5-2
STRUCTURAL SCHEME ................................... 5-3
2
COMPONENTS .................................................. 5-6 3
FRONT AXLE.............................................................. 5-6
4
FRONT WHEEL .......................................................... 5-7
FRONT AXLE HUB ............................................ 5-8 5
REMOVAL • INSTALLATION...................................... 5-8 6
FRONT AXLE SHAFT ...................................... 5-11
7
ADJUSTMENT METHOD FOR 8
FRONT AXLE HUB STARTING FORCE....... 5-14
9
10
11
12
13
14
15
16
17
18
5-2
GENERAL
SPECIFICATIONS
FRONT AXLE
Vehicle model
Item 4CBT2R, 3R, 4CBTK4R 4CBTY2R, 4CBTYK4R
Minimum turning radius mm (in.) 1600 (64.0) 1600 (64.0)
FRONT WHEEL
Type Tire size Rim size Tire pressure kPa (kgf/cm2) [psi]
Pneumatic 3.50-5-6PR 3.00SP 700 (7.0) [99.5]
Ribbed self-sealing tire (option) 3.50-5 3.00SP —

5-3
STRUCTURAL SCHEME
3°
0
1
2
3
4
5
6
7
8
9
10
11
The front axle is installed at a tilt of 3° in a rearward direction. 12
13
14
15
16
17
18
5-4
4CBT2R·3R·4CBTK4R
Steering shaft
Connects to the steering wheel
Universal joint
Seal bearing
Seal bearing
Steering stopper pin
Steering chain
Sprocket gear 1: 4
Steering stopper
Divided rim
5-5
4CBTY2R·4CBTYK4R (for standup models)
0
Connects to the steering handle
1
2
Steering shaft
3
4
Seal bearing
5
6
7
8
9
10
11
12
Steering stopper
13
14
15
Divided rim
16
17
18
5-6
COMPONENTS
FRONT AXLE
4CBT2R·3R·4CBTK4R
Snap ring
Bearing
Wheel cap
Cotter pin
Bearing
Castle nut
Front axle shaft

Plate washer
Bearing
Front axle hub
Bearing
Dust seal
4CBTY2R·4CBTYK4R
Snap ring
Bearing
Bearing
Wheel cap
Cotter pin
Castle nut
Front axle shaft

Plate washer
Bearing
Front axle hub
Bearing
Dust seal
5-7
FRONT WHEEL
Nut
Spring washer
Divided rim
Tire
Bolt
Nut
Spring washer
Bolt
5-8
FRONT AXLE HUB

Note:
The front axle hub can be removed and installed even with the front axle ASSY mounted on the vehicle. This
manual describes operations performed with a mounted front axle ASSY.
Removal Procedure
2. Remove the front wheels.

(1) Loosen the hub nuts on the front wheels.
(2) Set jack at specified jacking position and raise the
vehicle.
(3) Support frame with wooden blocks.
Note:
• Place blocks at specified positions on both the
Wooden left and right.
block • Wooden blocks should be at least 90 mm [3.5 in.]
in height.
(4) Remove hub nuts and spring washers. (4)
Spring washer
Tightening torque for hub nuts N·m (kgf·cm) [ft·lbf]:
T=34.3 to 68.6 (350 to 700) [25 to 51]
Hub nut
(5) Remove the front wheels.

5-9
3. Remove the front axle hub.

(1) Remove the wheel cap.
Remove the cap by setting the tip of a pointed tool
Tool between the cap and the main section and tapping lightly
with a hammer.
Wheel cap
(2) Take out the cotter pin then remove the castle nut and
Plate washer
plate washer.
Cotter pin
Cap
Castle nut
(3) Remove the front axle hub and bearing using the SST.
Front axle hub
SST 09950-76013-71
(09950-40010)
SST
Bearing
(4) Remove the bearing outer race from the front axle hub
using a hammer or bar. This outer race should be
Bar
Outer race removed from the outer (wheel) side.
Use the SSTs when mounting the outer race.

SST 09950-76020-71......(1)
(09950-70010)
SST 09950-76018-71......(2)
(09950-60010)
SST(1) SST(1)
SST(2) SST(2)
Inner side Outer side

5-10
(5) Remove the inner race and the dust seal of the bearing
from the front axle shaft.
SST 09950-76013-71
(09950-40010)
SST
When installing bearings, inject grease into the gaps

between the bearing roller section, the inner bearing, and
the outer bearing. Apply spray grease to the knuckle tip,
Knuckle tip
castle nuts, cotter pin, and the inner surface of the wheel
cap.
Wheel cap
When installing the dust seal, set it on the knuckle and,

while holding in place with your hand, drive into place by
tapping the shaded area with a plastic hammer.
Note:
Always use brand-new dust seals when replacing.
5-11
FRONT AXLE SHAFT

Removal Procedure
4CBT2R·3R·4CBTK4R
Cover 1. Disconnect the battery plug.
2. Apply wheel blocks to the rear wheels.
3. Jack up the front of the vehicle and support with wooden
blocks. (Wooden blocks should be at least 90 mm [3.5 in.] in
height.)
4. Remove front wheels.
5. Remove the cover.
6. Remove the toe board.
7. Remove the steering chain.
Note:
Clip Set the steering straight ahead then remove the clip.
Plate
Spacer
Ring
8. Remove the snap ring.
Snap ring
9. Stand the bar on the front axle shaft and strike with a hammer.
Weight of front axle shaft : Approx. 12 kg [26.5 lb]
Distance shaft must be driven : Approx. 20 mm [0.9 in.]
Bar
Note:
Place cushioning on the floor to prevent damage caused
by the front axle shaft falling.
5-12
10. Remove the front axle shaft.
11. If the lower bearing remains attached to the frame side,

Bar
remove it using a bar and hammer.
Lower bearing
12. Remove the upper bearing using the SST.

SST 09950-76020-71......(1)
(09950-70010)
SST 09950-76018-71......(2)
SST(2) (09950-60010)
SST(1)
4CBTY2R·4CBTYK4R
Cover 2. Apply wheel blocks to the rear tires.
3. Raise the front of the vehicle and support with wooden blocks.
(Wooden blocks should be at least 90 mm [3.5 in.] in height.)
4. Remove the front wheels.
5. Remove the cover. (4 bolts)
Side cover Side cover 7. Remove the column covers. (Refer to SECTION 7,
“STEERING”)
Screw
Column
cover
(front)
Column cover
Screw (rear)
5-13
8. Loop the fiber rope around the handles.

Fiber rope
Note:
Turn signal switch
The rope should not loop around either the turn signal
Accelerator switch (located on the left of the lever box) or the
lever accelerator lever (located on the right of the lever box).
9. Disconnect the steering shaft and the front axle shaft.

Operate the handles in order to move them to the position
Bolt Nut most convenient for subsequent tasks.
When bolts are difficult to remove, tap with the plastic hammer.
10. Perform steps 9 to 12 on Page 5-11.
5-14
ADJUSTMENT METHOD FOR FRONT AXLE HUB STARTING FORCE

The diagram shows 4CBT2R·3R but the adjustment method described is identical for all vehicle types.
Adjustment Procedure
1. Tighten castle nuts to 29.4 to 49 N·m (300 to 500 kgf·cm) [21.7 to 36.2 ft·lbf].
2. Loosen castle nut tightening torque to 0 N·m (0 kgf·cm) [0 ft·lbf].
3. Retighten to 29.4 to 49 N·m (300 to 500 kgf·cm) [21.7 to 36.2 ft·lbf] then rotate the hub several times in both the
left and right direction.
4. Hang the hub bolt on the spring balance and measure the starting force.
Standard: 14.7 to 34.3 N (1.5 to 3.5 kgf) [3.3 to 7.7 lbf]
5. Tighten the castle nut within the specified torque range until the starting force of the front axle hub reaches the
standard value.
6-1
REAR AXLE
Page 0
GENERAL .......................................................... 6-2
1
SPECIFICATIONS.............................................. 6-2
COMPONENTS .................................................. 6-3
2
REAR AXLE ASSY ..................................................... 6-3 3
DRIVE UNIT AND DIFFERENTIAL ASSY.................. 6-4
4
DRIVE UNIT AND REAR AXLE ASSY .............. 6-5
REMOVAL • INSTALLATION...................................... 6-5 5
REAR AXLE SHAFT .......................................... 6-8 6
7
DRIVE UNIT AND REAR AXLE ASSY .............. 6-9
DISASSEMBLY • INSPECTION • REASSEMBLY....... 6-9 8
DIFFERENTIAL CASE ASSY .......................... 6-19 9
DISASSEMBLY • INSPECTION • REASSEMBLY..... 6-19
10
11
12
13
14
15
16
17
18
6-2
GENERAL
A
A A-A
Oil hole plug
Drain plug
Level plug
Hub nut
T=88.2 to 156.8 N·m
(900 to 1600 kgf·cm)
[5.1 to 115.7 ft·lbf]
SPECIFICATIONS
REAR AXLE
Vehicle model
Item All models
Rear axle Semifloating type
Suspension type Fixed to frame type
Weight 70.0kg[154.4lb]
REAR WHEEL ASSY

Vehicle model Tire Tire size Rim size Tire pressure KPa (kgf/cm2) [psi]
Pneumatic 4.00-8-6PR 8 × 3.00D 700 (7) [102]

All models
Non-puncture (OPT) 4.00-8 ↑ —
DRIVE UNIT
Vehicle model
Item All models
Reduction ratio 24.71
Differential oil amount l [US gal] 2.1 [0.55]

Rear axle bracket (LH)
O-ring
Oil seal
Brake ASSY
COMPONENTS
REAR AXLE ASSY
Rear axle housing end T=50 to 70 N·m

(510 to 714 kgf·cm) Brake drum
[37 to 52 ft·lbf]
Bearing
Rear axle case
Rear axle shaft
Bearing cap plate
T=88 to 108 N·m
(897 to 1101 kgf·cm) Bearing cap plate
[65 to 80 ft·lbf]
Snap ring Snap ring
T=59 to 79 N·m
(602 to 806 kgf·cm) Rear axle bracket (RH) T=59 to 79 N·m
[44 to 58 ft·lbf] (602 to 806 kgf·cm)
[44 to 58 ft·lbf]
Rear axle shaft Bearing
Brake drum
Rear axle housing end
Brake ASSY
Oil seal
T=88 to 108 N·m

O-ring
(897 to 1101 kgf·cm)
Shims [65 to 80 ft·lbf]
T=50 to 70 N·m
(510 to 714 kgf·cm)
[37 to 52 ft·lbf]
6-3
9
8
7
6
5
4
3
2
1
0
18
17
16
15
14
13
12
11
10
6-4
DRIVE UNIT AND DIFFERENTIAL ASSY
Joint
T=30 to 40 N·m Pin
(306 to 408 kgf·cm) Adjusting nut
[22 to 30 ft·lbf]
Bearing T=30 to 40 N·m
(306 to 408 kgf·cm)
[22 to 30 ft·lbf]
Drive pinion bearing retainer
Bearing
Pinion gear
Front cover
T=20 to 30 N·m
Shims
(204 to 306 kgf·cm)
[15 to 22 ft·lbf]
O-ring
Breather
Drive shaft adjuster
Bearing
Bearing Oil drop plate
Drive shaft adjuster
O-ring T=20 to 30 N·m

Lock plate Bearing (204 to 306
Drive shaft kgf·cm)
Differential
case [15 to 22 ft·lbf]
Ring gear
Rear cover
T=78 to 88 N·m
(795 to 897 kgf·cm)
[58 to 65 ft·lbf]
Bearing
Pinion thrust washer
Pinion shaft
Bearing
Pinion gear
Side gear
Bearing Counter gear

Note: Pinion shaft
Pay attention to the width of the bolt.
6-5
DRIVE UNIT AND REAR AXLE ASSY

Removal Procedure
1. Park the vehicle on a flat ground and chock the wheels.
0
Note:
• Put the front wheels in straight-ahead position.
1
• Disengage the parking brake.
2. Disconnect the battery plug. 2
Chock
(See SECTION 9, “BODY • FRAME”) 3
4. Remove the battery hood.
(See SECTION 9, “BODY • FRAME”)
4
5. Remove the battery. (See SECTION 1, “BATTERY”)
6. Remove the drive motor. (See SECTION 4, “MOTOR”) 5
7. Remove the drawbar and mud guards.
Drawbar
8. Loosen the hub nuts. (6 each side, left and right) 6
7
8
Mud guard 9
9. Jack up the center part of the rear end of the frame and prop
up the underside with wooden blocks.
10
10. Remove the rear wheels.
Note:
When removing only the rear wheels, follow steps 1, 2, 7,
11
8, 9, and 10, but engage the parking brake.
12
Wooden block
Wooden block 13
14
15
16
17
18
6-6
11. Remove the brake pipes from the brake ASSY.

LH Be sure to mop up any spilled brake fluid with a waste cloth.
Note:
After reassembling the brake pipe, be sure to air bleed the
brakes. (See SECTION 8, “BRAKE”)
RH
Bolt 12. Disconnect the parking brake wire.

(1) Remove the clamp.
Clamp
(2) Disconnect the parking brake wire from the hook.
Note:
Adjust the parking brake after reassembling.
Parking brake wire (See SECTION 8, “BRAKE”)
Hook
Brake pipe 13. Remove the 3-WAY for the brake pipe from the rear axle
housing.
Bolt
3-WAY
Rear axle
14. Support the lower side of the rear axle housing using wooden
blocks.
Note:
Adjust the height of the wooden blocks so that the
clearance between the wooden blocks and the rear axle
housing is 2 to 3 mm (0.08 to 0.12 in.) both front and back.
Wooden block
Wooden block Rear axle housing
6-7
15. Remove the 4 rear axle set bolts from above the vehicle.
Plate
Tightening torque for rear axle set bolts:
68.6 to 88.2 N·m (700 to 899 kgf·cm) [51 to 65 ft·lbf]
Note:
Be sure to attach the plate when installing.
Drive motor attachment hole
Drive motor attachment hole
Plate
Moving
Parking brake cable
16. Hoist the vehicle, remove it from the rear axle, move the vehicle forward, and let it down.
Note:
• Attach the drawbar to the drawbar bracket, and prevent the rope from falling off.
• When moving the vehicle, be careful that the parking brake cable does not catch on the frame and
get damaged.
• Be careful that the brake pipes do not get damaged.
• After moving the vehicle, place wooden blocks under the frame to stabilize it when lowering the
vehicle onto the floor.
• If any brake fluid is spilled onto the floor, be sure to mop it up with a waste cloth.
6-8
REAR AXLE SHAFT

Removal Procedure
1. Remove the rear wheels. (See P6-5.)
Brake drum 2. Remove the brake drum.
Note:
If the brake drum is difficult to remove, lightly tap the outer
Rear wheel circumference with a hammer while removing it.
3. Remove bearing cap plate set bolts (4 pcs.). Rotate the axel
Bearing cap plate shaft and work from the notched part of the axel shaft flange
part.
Rear axle shaft
T=59 to 79 N·m
(602 to 806 kgf·cm)
[44 to 58 ft·lbf]
Bearing cap plate

Bearing
Snap ring
Axle shaft
4. Remove the rear axle shaft.

Note:
When the rear axle shaft is removed, differential oil will pour out. To prevent the oil from getting on the
brakes, cover the brake ASSY with a waste cloth beforehand.
2
T=30 to 40 N·m
3
(306 to 408 kgf·cm)
11 [22 to 30 ft·lbf]
T=30 to 40 N·m
(306 to 408 kgf·cm) 4
[22 to 30 ft·lbf] 5
T=59 to 79 N·m
T=20 to 30 N·m
9 (602 to 806 kgf·cm)
(204 to 306 kgf·cm)
[44 to 58 ft·lbf]
[15 to 22 ft·lbf] 7
T=88 to 108 N·m

9 (897 to 1101 kgf·cm)
[65 to 80 ft·lbf]
DRIVE UNIT AND REAR AXLE ASSY
T=50 to 70 N·m
6 (510 to 714 kgf·cm)
[37 to 52 ft·lbf]
8 7
T=20 to 30 N·m
(204 to 306 kgf·cm)
3 6 [15 to 22 ft·lbf]
5 10
2
4 T=50 to 70 N·m
(510 to 714 kgf·cm)
T=88 to 108 N·m [37 to 52 ft·lbf]
T=59 to 79 N·m (897 to 1101 kgf·cm)

(602 to 806 kgf·cm) [65 to 80 ft·lbf]
[44 to 58 ft·lbf]
6-9
T=N·m (kgf·cm) [ft·lbf]

6-10
1. Drain the differential oil. [Point 1]
Note:
The oil will drain better if the oil hole plug is loosened.
2. Remove the brake drum.
3. Remove the rear axle shaft. [Point 2]
4. Remove the rear axle housing end.
5. Remove the brake ASSY.
7. Remove the rear axle bracket and oil seal. [Point 3]
8. Remove the differential ASSY outer bearing. [Point 4]
9. Remove the differential ASSY W/counter gear.
10. Remove the drive shaft adjuster. [Point 5]
11. Remove the drive shaft and ring gear. [Point 6]
12. Remove the drive pinion gear, drive pinion bearing retainer and joint. [Point 7]
13. Remove the oil drop plate. [Point 8]
Note:
• Apply 08833-76001-71 to the brake set nut and rear axle bracket set bolt.
• Apply 08826-76002-71 to the front and rear covers of the drive unit case, and to the contacting surfaces
of the brake ASSY and rear axle bracket.
• Apply 08826-76002-71 to the outer circumferences of the oil seals of the drive shaft and the drive pinion.
6-11
Point Operations
[Point 1]
Reassembly:
Remove the plug for the oil level, and slowly pour in hydraulic
oil until hydraulic oil spills from the threaded section.
A Pouring amount (approximately): 2.1l [0.55 US gal]
[Point 2]
Disassembly:
Use the SST to remove the real axle shaft bearing.
SST 09950-76014-71
(SST 09950-40011)
SST
Reassembly:
Use the SST to reassemble the rear axle shaft bearing.
SST 09410-40150-71
SST
[Point 3]
Disassembly:
Use the SST to remove the oil seal.
SST 09320-23000-71
SST
Reassembly:
Use the SST and reassemble the oil seal.
SST(1)
SST 09950-76018-71......(1)
(SST 09950-60010)
SST(2) SST 09950-76020-71......(2)
(SST 09950-70010)
6-12
Clearance
Rear axle case A mm [A in.]
Rear axle bracket (LH)
Rear axle bracket (RH)
Differential ASSY
Temporarily tighten.
Note:
Do not use a thread tightener.
Reassembly:
The procedure for reassembly of the rear axle bracket is according to the following points.
(1) Reassemble the outer bearing and oil seal to the rear axle bracket.
(2) Reassemble the differential ASSY, rear axle bracket (LH) and gasket into the rear axle case.
Note:
Apply ThreeBond #1360K to the attaching bolts.
(3) Lightly tap the differential ASSY with a copper hammer until there is no gap between the bearing and the
rear axle bracket (LH), and the bearing and the differential case.
(4) Reassemble the rear axle bracket (RH) to the rear axle case at the regulation tightening torque.
Note:
Do not apply thread locking agent to the attaching bolts.
(5) Measure the gap A between the rear axle bracket (RH) and rear axle case.
(6) Insert a shim of gap Amm+0.1mm[Ain+0.0039in], and reassemble the rear axle bracket (RH) to the rear
axle case at the regulation tightening torque.
Shims: 0.10mm, 0.15mm, 0.30mm, [0.0039in, 0.0059in, 0.0118in]

6-13
(7) Measure the end play B of the differential W/counter gear.
Standard: B=0 to 0.1mm [0 to 0.0039in]

(8) If the end play is within the criteria, apply ThreeBond #1360K
to the attaching bolts, then reassemble at the regulation
torque. If the end play does not meet the criteria, carry out
procedures 4 to 6 again.
[Point 4]
Use the SST and reassemble the bearing outer race.
SST 09320-23000-71
SST
Disassembly:
Use the SST and reassemble the bearing outer race.
SST(1) SST 09950-76018-71......(1)
(SST 09950-60010)
SST(2) SST 09950-76020-71......(2)
(SST 9950-70010)
[Point 5]
Disassembly:
Use the SST to remove the drive shaft bearing retainer.
SST 09340-10330-71
SST
6-14
Disassembly:
Use the SST to remove the bearing outer race.
SST 09320-23000-71
SST
Reassembly:
Use the SST to reassemble the bearing outer race.
SST 09950-76018-71......(1)
(SST 09950-60010)
SST(1) SST 09950-76020-71......(2)
(SST 09950-70010)
SST(2)
Inspection:
Check the ring gear starting force.
Standard: 0.49 to 0.99 N·m (5.0 to 10 kgf·cm)
[0.4 to 0.7 ft·lbf]
Inspection:
Adjust the drive retainer to adjust the tooth contact of the ring gear and the drive pinion gear.
Thinly apply tooth contact powder to 7 or 8 of the tooth faces of the ring gear, then engage the ring gear forward
and backward to inspect the tooth contact.
Note:
• Rotate the left and right adjusters by the same amount so that there is no change in the preload.
• The adjustment of the tooth contact status is to be carried out according to the following points.
6-15
Correct tooth contact status
Tooth contact Adjustment method
Correct tooth contact Adjust the tooth contact by increasing or

(At the time of no-load) decreasing the shims A of the drive pinion
• Length of tooth contact bearing retainer face.
About 50 to 70% of face width When adjusting the tooth contact, rotate the
• Width of tooth contact drive shaft bearing retainer each time and
About 50 to 70% of face height adjust the backlash.
• Center of tooth contact positioned
40% from the small end
Incorrect tooth contact status
Tooth contact Cause Corrective action
The drive pinion is too separated from 1. Decrease the drive pinion shims to bring
the ring gear. the drive pinion closer to the ring gear.
2. Bring the ring gear away from the drive
pinion and adjust the backlash.
The drive pinion is too close to the 1. Increase the drive pinion shims to bring
ring gear. the drive pinion away from the ring gear.
2. Bring the ring gear closer to the drive
pinion and adjust the backlash.
Inspection:
Adjust the backlash of the drive pinion and the ring gear by the
following procedure.
(1) Rotate the drive pinion and measure the backlash.
Standard: 0.10 to 0.15 mm (0.004 to 0.006 in.)
6-16
(2) If the backlash is outside the standard, adjust with the

drive shaft bearing retainer.
(3) After adjusting, lock with the lock plate.
Note:
To make the backlash larger, tighten the RH drive
shaft bearing retainer and loosen the LH. To make the
backlash smaller, tighten the LH drive shaft bearing
retainer and loosen the RH.
Lock plate
[Point 6]
SST(1)
Disassembly:
Use the SST to remove the bearing.
SST(2) SST 09950-76013-71......(1)
(SST 09950-40010)
SST 09430-40590-71......(2)
Reassembly:
Use the SST to reassemble the bearing.
SST 09950-76020-71......(1)
SST(1) (SST 09950-70010)
SST 09950-76018-71......(2)
(SST 09950-60010)
SST(2)
Disassembly• Reassembly:
Make match marks on the drive shaft and ring gear.
Match mark
Use a plastic hammer to lightly tap the outer circumference of
the ring gear when dissassembling and reassembling it.
[Point 7]
Disassembly:
Make match marks before removing the adjusting nut.
Reassembly:
Match mark Align match marks when reassembling.
6-17
Use the SST to remove the adjusting nut.
SST 09310-10330-71
SST
SST
Reassembly:
Reassemble the drive pinion gear and drive pinion bearing
retainer with the following procedure.
(1) Reassemble the lower nut so that the starting force of the
drive pinion gear becomes A.
A=0.49 to 0.99 N·m (5.0 to 10.0 kgf·cm) [0.4 to 0.7 ft·lbf]
Measure the starting force using the SST.
SST 09420-40590-71
(2) Reassemble the upper nut after the lower nut has been
assembled, so that the tightening torque becomes B.
Tightening torque of the upper nut:
B=30 to 40 N·m (306.0 to 408 kgf·cm) [22 to 30 ft·lbf]
Disassembly:
Use the SST to remove the lower bearing inner race.
SST 09950-76013-71
(SST 09950-40010)
Reassembly:
Use the SST to reassemble the lower bearing inner race.
SST SST SST 09700-30200-71
Disassembly:
Use the SST to remove the bearing outer race.
SST 09700-30200-71
SST
SST
6-18
Reassembly:
Use the SST to reassemble the bearing outer race.
SST 09950-76019-71......(1)
(SST 09950-60020)
SST(1) SST 09950-76020-71......(2)
SST(1)
(SST 09950-70010)
SST(2)
SST(2)
Reassembly:
Use the SST to reassemble the upper bearing inner race.
SST 09700-30200-71
SST
[Point 8]
A Oil drop plate Reassemble so that the oil drop plate does not come into
contact with the counter gear.
A-A
A
Counter gear
6-19
DIFFERENTIAL CASE ASSY

T=N·m (kgf·cm) [ft·lbf]
T=78 to 88 2
(795 to 897)
[58 to 65]
4
3
1. Remove the counter gear. [Point 1]
2. Disassemble the differential cover.
3. Remove the pinion shaft, pinion gear, pinion thrust washer and side gear.
4. Remove the side bearings. [Point 2]
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
• When reassembling the thrust washer, side gear and pinion, check to make sure that no dirt or shavings
have adhered to them.
• Apply sufficient hypoid gear oil to all moving and rotating parts.
• Apply ThreeBond # 1360K to the counter gear set bolt.
6-20
[Point 1]
Match mark Make match marks on the differential case and counter gear.
Use a plastic hammer to lightly tap the outer circumference of
the counter gear when dissassembling and reassembling it.
[Point 2]
Disassembly:
Use the SST to remove the bearing.
SST 09950-76013-71......(1)
(SST 09950-40010)
SST(1) SST 09950-76018-71......(2)
SST(1) (SST 09950-60010)
SST(2)
SST(2)
Reassembly:
Use the SST and reassemble the bearing.
SST 09950-76020-71......(1)
SST(1)
(SST 09950-70010)
SST(1) SST 09950-76018-71......(2)
(SST 09950-60010)
SST(2) SST(2)
7-1
STEERING
Page 0
GENERAL .......................................................... 7-2
1
STRUCTURAL SCHEME ...................................... 7-5
COMPONENTS .................................................. 7-6 2
STEERING WHEEL•MAST JACKET ................ 7-8 3
REMOVAL•INSTALLATION .................................. 7-8
4
STEERING SHAFT........................................... 7-13
REMOVAL•INSTALLATION ................................ 7-13 5
6
7
8
9
10
11
12
13
14
15
16
17
18
7-2
GENERAL
4CBT2R•3R•4CBTK4R
Steering wheel
Attaching bolt
Steering shaft
(UPPER side)
Universal joint
Steering shaft
(LOWER side)
Steering chain
Sprocket (Small) Front axle shaft
Sprocket (Large)
• The steering wheel and front axle shaft are linked by the steering shaft, universal joint, and steering chain with
a ratio of 1:4.
• The sprocket (large) is integrated with the front axle shaft (LOWER side).
• The sprocket (small) is integrated with the steering shaft.
7-3
4CBT2R•3R•4CBTK4R With Steering Tilt Mechanism
0
1
2
3
4
5
6
7
8
9
Steering tilt lever
10
11
12
13
14
15
16
17
18
7-4
4CBTY2R•4CBTYK4R
Steering
Steering installation part
Steering shaft
Universal joint
Front axle shaft
The steering and the front axle shaft are linked by the steering shaft and a universal joint.
7-5
STRUCTURAL SCHEME
4CBT2R •3R •4CBTK4R 4CBTY2R •4CBTYK4R
0
Steering stopper
1
Steering
stopper pin
2
Steering
stopper
3
4
5
6
• Steering lock angle: 60° both left and right
• The steering stopper is welded to the frame, and the position where the steering stopper pin contacts the
7
steering stopper is the steering end.
8
4CBT2R•3R•4CBTK4R 4CBTY2R•4CBTYK4R
9
5°
10
11
100 mm 12
(3.9 in.)
13
14
15
The position of the steering wheel can be
Steering can be optionally set at 100 mm (3.9 in.)
higher than the standard specification.
16
adjusted within a range of 5° on vehicles
fitted with a steering tilt mechanism.
17
18
7-6
COMPONENTS
*2 Details
Adjuster nut (RH)
Cap
Adjuster nut (LH)
Lock ring
Nut
Lock bolt
Steering wheel
Lever
Screws (for installing switch)
Forward, reverse and turn

signal and headlight switch
Column cover
(FR side)
Spacer *1
Nut *1
Column cover
Seal
(RR side)
Adjuster
(With tilt steering
mechanism *2)
Screws
Bolt *1 (for installing column cover)
Spacer *1
*3 Details
Mast jacket and
Steering shaft *3 Snap ring
Bearing
Bracket
Mast jacket
Bearing
Steering shaft
Steering chain
O-ring
Steering shaft
Universal joint
Bushing
Nut
Bolt
*1: Vehicles without tilt steering mechanism (STD)
7-7
4CBTY2R•4CBTYK4R
Console box (*1)
Snap ring
Bearing
Bolt Bracket
Plug
Column cover
Seal
Steering shaft
Screw
Nut
*1 Details Column cover

Bolt
Cover
Bolt
Universal joint
Steering handle
Console box
Flange bolt Flange nut
Steering shaft
7-8
STEERING WHEEL•MAST JACKET

Removal Procedure
1. Park the vehicle on flat ground and chock the wheels.
2. Disconnect the battery plug. (See SECTION 5, “FRONT
Cover AXLE”)
3. Remove the cover. (Four bolts)
4. Remove the steering wheel.

Steering wheel
Cap Tightening torque for the nut N·m (kgf·cm) [ft·lbf] :
T=25 to 45 (255 to 459) [18.4 to 33.2]
Nut
5. Remove the screw from the RR side, and remove the column
cover.
Column
cover
(FR)
Column
cover
(RR)
Screw
Note:
• The key switch is installed in the column cover (RR).
Therefore, disconnect the harness from the key
Column
switch.
cover
(RR)
Key switch
Connector
7-9
Mast jacket
• The column cover (RR) is attached to the mast jacket
with a pawl. Be careful not to damage the pawl.
• When reassembling the column cover (RR) after
Column attaching with screws, push it in slowly until the pawl
Cover engages with the mast jacket.
(RR)
Pawl
Screw 6. Remove the shift lever switch and turn signal switch.
(1) Disconnect the connectors from the switches. (In 3
places)
(2) Remove the screws.
7. Remove the harness clamp from the mast jacket. (In 2 places)
Harness clamp Harness clamp

8. Remove the nut and pull out the bolt. Disconnect the mast
Mast jacket jacket and the universal joint.
Note:
When reassembling the mast jacket and the universal
Nut Bolt joint, adjust the orientation of the mast jacket and
universal joint so that the bolt points straight ahead.
Universal
joint
9. Remove the adjuster bolt.
Spacer For a (STD) vehicle without a tilt mechanism:

Nut
(1) Remove the nut.
Bolt (2) Pull out the bolt.
Note:
• Do not drop the spacer.
• Take measures before the operation to make sure that
the mast jacket is not dropped.
7-10
Mast jacket • To install the adjusting bolt, first temporarily tighten

Spacer the bolt, then having matched the match marks,
Nut Spacer tighten the nut with the specified torque.
Vehicle Tightening torque for the nut N·m (kgf·cm) [ft·lbf] :

LH T=5 to 7 (50 to 70) [3.6 to 5.0]
side
Bolt
Front protector
Match marks
Mast jacket
Spacer
Adjusting nut (LH) For vehicles with a tilt mechanism:
Tilt steering handle (1) Remove the lock ring.

(2) Remove the lock bolt. (Bolt width 12 mm (0.47 in.))
Lock ring (3) Remove the adjusting nuts (LH, RH).
Lock bolt
Adjuster nut (RH)
Note:
Adjusting nut (RH) Mast jacket
• When removing the lock bolt, do not drop the
Adjusting nut (LH) adjusting nut.
• Take measures before the operation to make sure that
Left the mast jacket is not dropped.
side • When installing, apply MP grease to the parts shown
of with arrows before reassembling.
vehicle
Tightening torque for the lock bolt N·m (kgf·cm) [ft·lbf] :
Lock ring T=10 to 14 (102 to 142) [7.4 to 10.3]
Front protector Lock bolt
10. Remove the mast jacket.
7-11
4CBTY2R•4CBTYK4R
Removal Procedure
Cover
AXLE”)
3. Remove the cover. (Four bolts)
Plug 4. Remove the column cover.

Plug (1) Remove the left and right plugs.
Column
cover
(2) Remove the screws. (4 pcs.)
(FR)
Column
cover
(RR)
5. Disconnect the connectors (2 places) and clamps (2 places).
Clamp
Connector
Connector
Front Clamp
protector
6. Loop a fiber rope under the handle, and attach the rope to a
hoist.
Note:
• Push the axle lever forward before looping the rope
Fiber rope under the handle.
• Be careful not to loop the rope around the turn signal
switch.
7-12
7. Remove the bracket bolts (2 pcs.) and disconnect the front

protector and the steering shaft.
Bolt
Bracket
Bolt
8. Disconnect the steering shaft and universal joint (front axle).

If the bolt is difficult to pull out, remove it by tapping with a
plastic hammer.
When reassembling, make sure that the upper side bolt faces
Bolt Nut exactly to the side, and adjust the front axle so that the
underside bolt faces straight ahead before installing the bolts.
Tightening torque for the bolts N·m (kgf·cm) [ft·lbf] :

T=5 to 7 (50 to 70) [3.6 to 5.0]
9. Hoist the steering.

Note:
Perform this operation slowly, taking sufficient care that
the harness doesn’t get damaged by the front protector or
other parts.
7-13
STEERING SHAFT
Connector Removal Procedure

After chocking the wheels, release the parking brake.
AXLE”)
3. Remove the toe board. (See SECTION 9, “BODY • FRAME”)
4. Disconnect the wiring connector. (In 3 places)
5. Disconnect the harness clamp from the frame.
Clamp RH side
of
vehicle
6. Disconnect the parking brake cable.

Plate washer
Cotter pin
Hook
Pin
7. Remove the left and right rear-view mirrors.

Rear-view mirror
Spring washer
Nut
7-14
8. Disconnect the brake pipe.
Brake Pipe
9. Disconnect the steering shaft and universal joint.

Universal joint
Bolt
Nut
Steering shaft
10. Remove the steering chain. (See SECTION 5, “FRONT

Wire AXLE”)
11. Install a shackle and wire-rope to the rear-view mirror eyelets,
set the wire rope to a hoist crane, and raise the hoist crane until
there is no slack in the wire rope.
Shackle
12. Remove the front protector installation bolts. (4 pcs.)
13. Remove the front protector from the vehicle and place it on a
work bench.
7-15
Note:
Connector
Frame notched • Do not damage the brake pipes.
portion • When pulling the harness out of the frame, pass the
connectors through the hole one at a time.
Brake Pipe
• When pulling the parking brake cable out of the

Parking brake cable frame, ensure that it does not catch on the frame.
• When placing the front protector on the work bench,
ensure that the harness and cables etc. are not
pinched. Also, take measures to prevent it from
tipping over.
Frame notched portion
SST(2) 14. Use the SST to remove the steering shaft and bearing.
SST 09950-76020-71......(1)
SST(1) (09950-70010)
SST 09950-76018-71......(2)
(09950-60010)
Note:
Place something to act as a cushion underneath the
steering shaft to prevent it from getting damaged if it falls
off.
Steering shaft
Bearing
Bearing 15. From the under side of the vehicle, use the SST and tap with
a hammer to remove the bearing.
SST(2)
SST 09950-76020-71.......(1)
(09950-70010)
SST(1) SST 09950-76018-71.......(2)
(09950-60010)
7-16
Note:
• For adjustment of the parking brake cable, see SECTION 8, “BRAKE”.
• For instructions on how to air bleed the brakes, see SECTION 8, “BRAKE”.
Caution:
After adjusting the brakes, measure the controlled stopping distance and check that it is within the standard
value.
Without a speed limiter;

The vehicle should stop within 5 m [196.9 in.] when unloaded and driven at full speed (13 km/h
[8.07 mph]).
With a speed limiter;
Disable the speed limiter. The vehicle should stop within 5 m [196.9 in.] when unloaded and driven at full
speed (13 km/h [8.07 mph]).
If the vehicle does not stop within the standard value under the above conditions, repeat the bleeding
operation.
8-1
BRAKE
Page Page
0
GENERAL .............................. 8-2 ELECTROMAGNETIC 1
BRAKE ............................... 8-32
SPECIFICATIONS.................. 8-2 2
STRUCTURAL SCHEME ......... 8-32
COMPONENTS ...................... 8-5
SPECIFICATIONS .................... 8-32 3
SERVICE BRAKE ................ 8-13
REMOVAL • INSTALLATION.... 8-33
DISASSEMBLY • INSPECTION • 4
REASSEMBLY........................ 8-13 DISASSEMBLY • INSPECTION •
BRAKE AIR BLEEDING ...... 8-18

REASSEMBLY ....................... 8-35 5
MEASUREMENT AND
BRAKING FORCE ADJUSTMENT OF 6
INSPECTION • CLEARANCES
ADJUSTMENT ................... 8-19 (ON THE VEHICLE)................ 8-36 7
HOW TO MANUALLY
MASTER CYLINDER ........... 8-20 RELEASE THE BRAKE ......... 8-36 8
REMOVAL • INSTALLATION .... 8-20
DISASSEMBLY • INSPECTION •
9
REASSEMBLY........................ 8-22
10
PARKING BRAKE LEVER .. 8-25
REMOVAL • INSTALLATION .... 8-25
11
MAINTENANCE NOTES........... 8-27 12
ADJUSTMENT .......................... 8-27
13
BRAKE PEDAL
ADJUSTMENT ................... 8-28 14
REASSEMBLY AND
ADJUSTMENT GUIDE FOR 15
BRAKE SWITCH AND
STOP LIGHT SWITCH ....... 8-31
16
17
18
8-2
GENERAL
SERVICE BRAKE
T=4.21 to 6.17 N·m

43 to 63 kgf·cm
3.11 to 4.56 ft·lbf
T=19.6 to 28.4 N·m

200 to 290 kgf·cm
14.47 to 20.98 ft·lbf
Brake shoe expansion rotation direction
SPECIFICATIONS
Vehicle model
All models
Item
Foot brake type Hydraulic internal expansion duo servo brake
Parking brake type Internal expandison mechanical brake
Brake drum inside diameter mm (in.) 203.2 (8.00)
Brake lining material Resin mold (asbestos-free)
Brake lining dimensions (thickness × width × length) mm (in.) 4.0 × 34 × 195 (0.16 × 1.34 × 7.68)
Wheel cylinder bore mm (in.) 19.05 (0.75)
Master cylinder bore mm (in.) 15.87 (0.625)
Applicable oil Toyota brake fluid SH-H

8-3
PARKING BRAKE
0
1
2
3
4
5
6
Connect under toe board
Clamp under toe board

7
Clamp under battery
8
9
10
11
12
13
14
15
16
17
18
8-4
MASTER CYLINDER
4CBT2R• 3R • 4CBTK4R
8-5
COMPONENTS
PARKING BRAKE LEVER• CABLE
0
Parking brake lever
1
Return spring
Spring hook
2
3
Nut
Nut
4
Flange bolt
Parking brake cable 5

6
Flange bolt
7
Clamp
Cotter pin
8
Plate washer
Hook 9
Pin 10
Flange bolt
Clamp
Flange bolt
(Installed to front cover and bracket)
T=20 to 30 N·m
11
204 to 306 kgf·cm
15 to 22 ft·lbf 12
Bracket
13
Bracket
(Welded to frame)
14
15
16
17
18
8-6
BRAKE PEDAL
Switch cover Switch cover
Limit switch for brake (Black)

Limit switch bracket
Limit switch for stop light (Brown)
Limit switch bracket attachment bolts

Stopper bolt
Bracket
Bushing
Lock nuts
Spacer
Bracket set bolts
Cushion
Spring washer
Pad
Bolt
T=29.4 to 44.1 N·m
300 to 450 kgf·cm
Return spring 21.7 to 32.6 ft·lbf
Brake pedal
8-7
Master cylinder
Pad
Bushing Brake pedal

Return spring
Trim
Spacer
Bushing
Bracket
Brake switch
Trim
Cover Cushion
Spring washer
Bolt
Lock nut
Bolt
Stopper bolt T=29.4 to 44.1 N·m
300 to 450 kgf·cm
Stop light switch 21.7 to 32.6 ft·lbf
Brake switch detail
Limit switch (Black)

Grommet
Stop light switch detail

Limit switch (Brown)
Harness
Switch cover
Harness Bolt
Switch cover
Bolt
8-8
RESERVOIR TANK AND MASTER CYLINDER

Reservoir tank
Clamp
Reservoir hose
Clamp
Pin
Plate washer
Cotter pin
Flange bolt
Holder
Master cylinder
Flange nut
Cap
Strainer
Union
Union bolt
Plug
Gasket
Gasket Cap
Gasket Breather plug
Check valve
Spring
Plate
Snap ring
Union
Boot
Filter
Nut Piston
Clevis
Rod
8-9
Union bolt
Plug
Valve Gasket
Spring Union
Gasket
Gasket
Reservoir tank
Piston
Clevis Nut
Rod
Snap ring
Boot
Clamp
Cap
Holder
Strainer Flange bolt
Master Cylinder
Cotter pin
Plate washer
Pin
Reservoir hose Clamp
Clamp
8-10
BRAKE PIPING
To master cylinder
Front pipe
Bolt
Clamp
Center pipe
Clamp Joint
Rear pipe
Bolt
Joint
Breather
Bolt
To LH brake ASSY
3-WAY
(attached to rear axle)
To RH brake ASSY
Rear pipe LH
Rear pipe RH
8-11
Front pipe
Center pipe
To master cylinder
Joint
Breather
To LH brake
ASSY
Flange bolt
3-WAY To RH brake ASSY
Rear pipe LH
Rear pipe RH
8-12
SERVICE BRAKE
8-13
SERVICE BRAKE
13
6
7
14
4
9
10 5
8
1. Chock the front wheels.
2. Remove the rear wheels.
3. Remove the brake drum. [Point 1]
4. Remove the hold down spring. [Point 2]
5. Remove the link, actuator lever, actuator spring, and pawl lever. [Point 3]
6. Remove the shoe return spring. [Point 4]
7. Remove the strut lever. [Point 5]
8. Remove the adjuster spring and adjusting screw. [Point 6]
9. Remove the brake shoe. [Point 7]
10. Disconnect the parking brake cable.
11. Drain the brake fluid.
12. Disconnect the brake pipe.
13. Remove the wheel cylinder ASSY. [Point 8]
14. Remove the backing plate.
8-14
Note:
• Check that the brake lining and brake drum interior surface are free from grease or oil before
reassembly.
• Before installing the brake drum, screw in the adjusting screws and install the brake shoes so that the
outer diameter meets the dimensions below. (Set the outer diameter at about 1 mm [0.04 in.] smaller than
the inside diameter of the brake drum.)
Brake shoe installed outer diameter: 202.2 mm [7.961 in.]
• Apply thread tightener (loctite No.271 or equivalent) to the axle shaft set bolts before tightening.
• After reassembling, be sure to bleed air from the brakes. (See P8-18)
• After reassembly, adjust the braking effect performance. As a method for adjustment, move the vehicle
forwards and backwards repeatedly, depressing the brake pedal each time to stop.
• The tightening torques of each part are as follows.
Unit: N·m (kgf·cm) [ft·lbf]
Hub bolt set nut 88.2 to 157 (900 to 1600) [65.1 to 115.8]
Axle shaft set bolt 29.4 to 44.1 (300 to 450) [21.7 to 32.6]
Backing plate self lock nut 88.2 to 118 (900 to 1200) [65.1 to 86.8]
Wheel cylinder set bolt 4.22 to 6.18 (43 to 63) [3.1 to 4.6]
Point Operations
[Point 1]
Inspection:
Measure the brake drum inside diameter.
Standard : 203.2 mm (8.00 in.)
Limit : 205.0 mm (8.07 in.)
[Point 2]
Disassembly • Reassembly:
SST 09510-31960-71
SST
8-15
Inspection:
Measure the free length of the hold down spring.
Standard : 20 mm (0.79 in.)
Limit : 18 mm (0.71 in.)
[Point 3]
Inspection:
Measure the free length of the actuator spring.
Limit : 27 mm (1.06 in.)
Reassembly:
Apply grease to the contact surfaces of the brake shoe,
actuator lever and sleeve.
Grease
[Point 4]
SST
Disassembly:
SST 09717-76001-71
(SST 09717-20010)
Inspection:
Measure the free length of the shoe return spring.
Limit : Replace if there is a gap between the coils.
8-16
Reassembly:
SST 09718-76001-71
(SST 09718-20010)
SST
[Point 5]
Inspection:
Measure the free length of the strut to shoe spring.
Limit : 18 mm (0.71 in.)
[Point 6]
Inspection:
Measure the free length of the adjuster spring.
Limit : Replace if there is a gap between the coils.
Reassembly:
Apply grease to the adjusting screw threaded portion the cap.
[Point 7]
Inspection:
Measure the brake lining thickness.
Limit : 1.0 mm (0.04 in.)
8-17
Reassembly:
Before brake shoe installation, apply grease to the illustrated
sections of the backing plate (6 places in contact with the shoe
rim and the anchor pin).
[Point 8]
Inspection:
Measure the clearance between the wheel cylinder and piston.
Limit: 0.18 mm (0.007 in.)
8-18
BRAKE AIR BLEEDING

Note:
Add brake fluid to the reservoir tank during air bleeding to prevent it from becoming insufficient.
1. Bleed air from the brake master cylinder.
(1) Depress the brake pedal several times to compress the
air in the piping, and hold that state.
(2) Loosen the breather plug to discharge air in the piping
together with the brake fluid, then tighten it just before the
fluid stops running out.
(3) Repeat steps (1) and (2) above until no air bubbles can be
seen in the discharged brake fluid.
2. Bleed air from wheel cylinders RH and LH.
(1) Operate as described in step 1 above for the RH and LH
LH brake ASSY sides one at a time.
RH brake ASSY
3. Add brake fluid to the specified level.

(1) Add brake fluid through the filter provided in the reservoir
tank.
(2) Add brake fluid up to the staged section in the reservoir
tank.
Staged Filter
section
8-19
BRAKING FORCE INSPECTION • ADJUSTMENT

1. Inspect the braking force by means of a brake tester or traveling test.
Braking distance (without load)
All models
Initial speed of braking km/h (mph) 13 (8.1)
Braking distance m (ft) 5 (16.4)
Note:
When the speed limiter is provided, disable the limiter and perform a braking force inspection at the top
forward speed of 13 km/h.
2. Adjust the braking force.
(1) Repeat traveling in the forward and reverse directions to adjust the brake shoe clearance.
During reverse traveling, the adjusting screw will automatically adjust the clearance when the brake pedal
is stepped on.
(2) If the braking force is insufficient, adjuster malfunction, lining contact defect, foreign matter adhesion on the
lining, or brake fluid leakage can be assumed. Remove and inspect the brake drum.
(3) When the brake shoe is replaced with a new one, repeat traveling in the forward and reverse directions for
running in.
8-20
MASTER CYLINDER
Removal Procedure
4CBT2R • 3R • 4CBTY4R
1. Park the vehicle on flat ground and chock the rear wheels.
During this time, be sure to have the parking brake engaged.
Cover
3. Disconnect the reservoir hose from the master cylinder.
Clamp
Master
cylinder
Reservoir
hose
4. Disconnect the brake pipe from the master cylinder.

Note:
Mop up any spilled brake oil with a waste cloth.
Master cylinder
Brake pipe
Brake pedal
5. Disconnect the master cylinder and the brake pedal.
(1) Remove the cotter pin.
Pin (2) Remove the plate washer.
Cotter pin (3) Remove the pin.

Plate washer
8-21
6. Remove the master cylinder from the bracket.

(1) Remove the nuts (2 pcs.).
Nut (2) Draw the master cylinder out downwards and remove it.
Bracket Note:
Be careful not to allow the master cylinder to fall when
Master removing the nuts.
cylinder
Note:
• Adjust the brake pedal after reassembly. (See P8-28)
• Perform air bleeding after reassembly. (See P8-18)
Master cylinder Removal Procedure

Clamp 1. Park the vehicle on flat ground and chock the rear wheels.
During this time, be sure to have the parking brake engaged.
Reservoir
hose 2. Remove the toe board.
3. Disconnect the brake pipe and reservoir hose from the master
cylinder.
Brake pipe
4. Disconnect the master cylinder and the brake pedal.

(1) Remove the cotter pin.
Master cylinder
(2) Remove the plate washer.
Pin (3) Remove the pin.
Brake pedal
Note:
Plate washer
If the pin interferes with the bracket and cannot be
completely drawn out, leave it in the clevis part of the
master cylinder and remove it when the master cylinder is
removed.
Cotter pin
5. Remove the master cylinder from the bracket.

Pin Master cylinder (1) Remove flange bolts (2 pcs.).
(2) Remove the master cylinder.
Note:
In the case where the pin has not been completely drawn
out, remove it as it is.
Flange bolt
Bracket
Note:
• Adjust the brake pedal after reassembly. (See P8-28)
• Perform air bleeding after reassembly. (See P8-18)
8-22

T = N·m (kgf·cm) [ft·lbf]
T = 8.83 to 12.75
T = 34.32 to 53.94 (90 to 130)
(350 to 550) [6.51 to 9.41]
[25.32 to 39.79]
T = 51.98 to 82.38
(530 to 840)
[38.35 to 60.77]
2
1. Turn back the boot and remove the snap ring. Remove the push rod. [Point 1]
2. Remove the piston.
3. Remove the fluid inlet elbow. [Point 2]
4. Remove the outlet plug and valve.
Note:
Apply rubber grease to the piston cup and reassemble.
8-23
Point Operations
[Point 1]
107 mm (4.21 in.)

Installation:
Temporarilily set the push rod length to the illustrated
dimension, and readjust after installation.
Reference: 107 mm (4.21 in.)
[Point 2]
Inspection:
Inspect the filter for clogging.
Filter
8-24
T = 39.2 to 68.6
(300 to 700)
[21.71 to 50.65]
T = 107.87 to 176.52
(1100 to 1800)
[79.59 to 130.23]
1. Remove the master clevis.
2. Remove the push rod. [Point 1]
3. Draw out the piston, cylinder cup, return spring, and inlet valve as one piece.
4. Remove the outlet check valve.
Note:
Wash each of the parts in new brake fluid, and apply brake fluid to them before reassembling.
Point Operations
[Point 1]
Installation:
Temporarilily set the push rod length to the illustrated
dimension, and readjust after installation.
Reference: 85 mm (3.35 in.)
85 mm (3.35 in.)
8-25
PARKING BRAKE LEVER

Pen holder
Removal Procedure
Vehicles without tilt steering mechanism (STD)
1. Park the vehicle on flat ground and chock the rear wheels.
During this time, be sure to have the parking brake released.
2. Disconnect the connectors for the fuses.
Perform the operation from the underside of the LH instrument
panel. Furthermore, the operation can be performed easily if
the pen holder is removed.
Fuses This operation can also be performed from the top side during
the operation of step 3.
3. Remove the LH instrument panel. (3 bolts)
LH instrument panel
4. Remove the return spring.

Return spring 5. Remove the parking brake cable adjusting nut.
6. Remove the spring hook.
Spring hook
7. Remove the parking brake cable from the parking brake lever.
Nut
Parking brake wire
8. Remove the attaching bolts (2 pcs.), and remove the parking

brake lever.
Note:
Adjust the parking brake after reassembling. (See P8-27)
8-26
Removal Procedure
Pen holder
Vehicles with tilt steering mechanism (OPT)
1. Park the vehicle on flat ground and chock the rear wheels. At
this time, be sure to have the parking brake engaged.
2. Disengage the tilt steering lock, and incline the steering fully
forwards.
3. Disconnect the connectors for the fuses.
Fuses Perform the operation from the underside of the LH instrument
panel. Furthermore, the operation can be performed easily if
the pen holder is removed.
This operation can also be performed from the top side during
the operation of step 5.
4. Remove the LH instrument panel. (3 bolts)
LH instrument panel 5. Release the parking brake.
6. Lock the tilt steering.
7. Perform steps 4 to 8 on page 8-25.
Note:
Adjust the parking brake after reassembling. (See P8-27)
8-27
MAINTENANCE NOTES
B2
A
B1
C2
Parking brake cable
adjusting nut
C1
1. Adjust the parking brake cable adjusting nut so that the parking brake cable is tensioned when the parking brake
is in the returned position.
2. Apply MP grease to the parts labled A in the drawing.
3. Reassemble the parking brake cable so that the dimension of the threaded portion B1 shown in the drawing =B2,
and the dimension of C1 = C2.
4. After installing by the above procedure, check to ensure that there is no dragging of the brake.
Note:
Adjustment of the parking brake cable should be carried out with the LH instrument panel removed.
ADJUSTMENT
.]
50 mm
[2.0 in
Adjust the parking brake so that it traverses 3 to 5 notches with an

operating force of 147 N (15 kgf) [33 lbf] in the position shown in the
drawing.
8-28
BRAKE PEDAL ADJUSTMENT

Note:
Remove the RH instrument panel to adjust the brake pedal.
1. Adjust the length of the stopper bolt so that the height A of the
brake pedal corresponds to the value below.
A=128 to 133 mm (5.03 to 5.24 in.)
2. Adjust the length of the push rod of the master cylinder so that
B
the play B of the brake pedal corresponds to the value below.

A
B=5 to 10 mm (0.20 to 0.39 in.)
Stopper bolt
Cushion
PUSH ROD PLAY

1. Be sure there is play in the push rod.
C=1 to 2 mm (0.04 to 0.08 in.)
107 mm (4.2 in.)
C
8-29
Brake pedal Pad
Brake bracket
A
1. Adjust the length of the stopper bolt so that the heights A and B from the top face of the brake bracket to the
center of the brake pedal correspond to the values below.
A: With pad, B: Without pad
A=162 to 167 mm (6.38 to 6.57 in.)
B=157 to 162 mm (6.18 to 6.38 in.)
2. Adjust the length of the push rod of the master cylinder so that the play C of the brake pedal corresponds to the
value below.
C=5 to 10 mm (0.20 to 0.39 in.)
3. After adjustment, check the remaining depression margin D
with a stepping force of 600 N (61.2 kgf) [135 lb].
Where D is less than 10 mm (0.39 in.), adjust using the
procedure below.
(1) Adjust the clearance of the brake shoes by operating the
vehicle several times in repetition through the sequence
reverse - stop.
(2) Carry out air bleeding of the brakes. (See P8-18)
D
(3) After carrying out (1) or (2) or both, re-check the value of
D.
Note:
After completing adjustment, be sure to check that the
braking distance is within standard values. (See P8-19)
8-30
4. Apply MP grease to the indicated parts.
PUSH ROD PLAY

1. Be sure there is play in the push rod.
84.5 mm [3.33 in.]
E=1 to 2 mm (0.04 to 0.08 in.)

E
8-31
REASSEMBLY AND ADJUSTMENT GUIDE FOR BRAKE SWITCH

AND STOP LIGHT SWITCH
Couple with CN5
Brake switch (Black) Couple with CN6
• Install the brake switch (Black) on the left side with respect to
the forward side of the vehicle, and the stop light switch
Red - Blue (Brown) on the right side. Check the color of each switch and
the color of the harness, and take care not to get them mixed
up.
• When connecting the wiring, take good care not to mis-
Black - Yellow connect it.
Yellow - Green
Vehicle front side Yellow
Stop light switch

(Brown)
• Install the brake switch (Black) on the right side with respect to
Brake switch (Black) the forward side of the vehicle, and the stop light switch
(Brown) on the left side. Check the color of each switch and the
color of the harness, and take care not to get them mixed up.
Stop light switch (Brown)
• When connecting the wiring, take good care not to mis-
connect it.
Couple with CN5
Black - Yellow Adjustment Procedure

1. Stop light switch (Brown)
Adjust the switch so that it goes ON within the range of the play
of the brake pedal (5 to 10 mm [0.20 to 0.39 in.]).
Couple with CN6
Yellow 2. Brake switch (Black)
Yellow - Green Adjust the switch so that it goes ON at the position depressed
Red - Blue
3 to 8 mm (0.12 to 0.31 in.) further from the range of the play
of the brake pedal.
Vehicle front side
8-32
ELECTROMAGNETIC BRAKE
STRUCTURAL SCHEME
mm [in.]
70.2 [2.76] 2-M8 × 1.25 (For releasing brake)
A
165 [6.50]
55 [2.17]
47Ω
0.4 Distance between internal

[0.02] DC24 V SOL
and external pole
Detail A portion Connection circuit
SPECIFICATIONS
Rated voltage DCV 24
Rated current A 2.0
Power consumption W 48
Brake torque N·m (kgf·cm) [ft·lbf] 35 (357) [25.8]

8-33
Removal Procedure
1. Park the vehicle on flat ground and chock the rear wheels. At
this time, engage the parking brake.
4. Disconnect the connectors of the electromagnetic brake.
5. Remove the attaching bolts (3 pcs.) of the electromagnetic

brake.
6. Remove the electromagnetic brake.
Solenoid
brake
7. Remove the hub attachment bolts.

Bolt
Lock the hub with a wrench or other similar tool so that it does
Plate washer not rotate while you are working.
Width across flats of hub 27 mm (1.06 in.)
Hub
Plate
8-34
8. Remove the hub and plate.

Hub
Plate
Motor
8-35

T = 14.5 to 15.5
(148 to 153)
[10.71 to 11.07]
6
1. Remove the end plate. [Point 1]
2. Remove the inner disc. [Point 2]
3. Remove the armature plate.
4. Remove the spring.
5. Remove the magnet ASSY.
6. Remove the hub.
Note:
For reassembling the brake ASSY, temporarily tighten the end plate set nuts.
But only so as the shims cannot come out.
Final reassembly is done on the vehicle so that the reassembly position of the inner discs and so forth can
be determined.
8-36
Point Operations
[Point 1]
Removal:
Keep a record of the reassembly position, and the number of
inserted adjusting shims.
Keep any removed shims safe so that they are not lost.
Installation:
Insert the shims that were attached prior to disassembly.
[Point 2]
Inspection:
Inspect the thickness of the inner disc.
Limit : 7.8 mm (0.31 in.)
MEASUREMENT AND ADJUSTMENT OF CLEARANCES (ON THE VEHICLE)

1. Ensure that the key switch is OFF.
2. Keep the brake pedal depressed.
3. Insert the thickness gauge into the 3 places indicated with
arrows, and measure the clearance.
Limit : 0.6 mm (0.024 in.)
Note:
Thickness gauge • If the clearance exceeds the limit, pull out the adjusting
shims, and reinsert them into the upper part of the end
plate.
• In the case where the shims have already been pulled out,
replace the inner disc with a new part.
HOW TO MANUALLY RELEASE THE BRAKE

In the event of trouble occuring with the electrical system, such that
Service bolt hole (M8 × P1.25)
the brake cannot be released, the brake can be released following
the method below.
1. Screw the service bolts into the service holes on the end plate
(M8 × P1.25) and set the clearance between the armature and
the magnet ASSY to zero, to release the brake.
Caution:
When the repairs on the brake are complete, be sure to remove
the service bolts and return to the original condition.
Service bolt hole
9-1
BODY • FRAME
Page 0
VEHICLE EXTERIOR VIEW............................... 9-2
1
DRAWING SHOWING THE LAYOUT
FROM THE OPERATOR’S SEAT ................... 9-4 2
SEAT .................................................................. 9-6 3
DRAWBAR AND DRAWBAR LEVER (OPT) .... 9-7
COMPONENTS........................................................... 9-7
4
BATTERY HOOD ............................................... 9-8 5
COMPONENTS........................................................... 9-8
6
BATTERY CHARGE INDICATOR AND 7
HOUR METER ............................................... 9-11
8
HOUR METER CONNECTION
PROCEDURE ................................................ 9-11 9
HAZARD SWITCH CONNECTION
PROCEDURE ................................................ 9-12
10
FUSES .............................................................. 9-12 11
TOE BOARD .................................................... 9-13 12
TOE BOARD REMOVAL • REATTACHMENT.......... 9-13
STROBO LAMP ............................................... 9-15
13
FRONT COMBINATION LIGHT ....................... 9-16 14
REAR COMBINATION LIGHT ......................... 9-16 15
ELECTRICAL PARTS ARRANGEMENT
PLAN.............................................................. 9-17 16
17
18
9-2
VEHICLE EXTERIOR VIEW

9-3
This drawing shows the battery roll-out specification vehicle.
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
9-4
DRAWING SHOWING THE LAYOUT FROM THE OPERATOR’S SEAT

Steering wheel
Battery charge indicator
Direction switch
Pen holder
Parking brake lever
Rear-view mirror Light and turn signal switch
Hour meter
Brake pedal
Fuses Accelerator pedal
Brake oil reservoir tank Brake master cylinder
OPT: Keyless start switch
ON
OPT OPT
Key switch OFF

Hazard light switch
Speed limit switch
Hazard light switch
9-5
Rear-view mirror
Turn signal switch

0
Horn switch
1
2
3
Accelerater lever
Steering handle
4
Parking brake lever Battery charge indicator
Hour meter
5
Hazard light switch
6
7
Lighting switch
8
9
10
11
Pen holder
Fuses Key switch
Brake oil reservoir tank
Speed limit switch
12
13
14
OPT: Keyless start switch
Vehicle
front
side
ON ON
15
Righthand Lefthand
(RH) (LH)
OFF OFF
16
Hazard light switch
17
Turn signal switch Lighting switch
18
9-6
SEAT
A A A A
Standard With a hip support Long leg type Long leg type with a hip
support
Adjustment
seat height
range for
E
Lowest position of seat height
B
D
C
Seat height at the time of shipping
Long leg type with a hip

Standard With a hip support Long leg type
support
A (mm) [in.] 452 [17.8] ← ← ←
B (mm) [in.] 446 [17.6] ← 526 [20.7] ←
C (mm) [in.] — 225 [8.9] — 305 [12.0]
D (mm) [in.] 405 [15.9] ← 485 [19.1] ←
E (mm) [in.] 100 [3.94] ← ← ←
HOW TO ADJUST THE SEAT HEIGHT

Boss 1. Support the seat back part with your hand.
2. Turn the left and right side knobs to unlock them.
3. Move the seat back up or down to the desired height.
4. Turn the left and right side knobs to secure the seat.
Note:
Knob The seat height should be within the adjustment range.
9-7
DRAWBAR AND DRAWBAR LEVER (OPT)

COMPONENTS
Knob
Lever (4CBTY2R • 4CBTYK4R)

Lever (4CBT2R • 3R • 4CBTK4R)
Bolt
Bushing
Spacer
Bracket (LH)
Bolt Bracket (RH)
Flange nut
Flange nut
Pin
Link Assy
Link
Cotter pin
Washer
Drawbar
Drawbar lever DRAWBAR LEVER ADJUSTMENT PROCEDURE

Drawbar
Adjust the lock nut so that when the drawbar has been operated,
the tapered section at the tip of the drawbar comes to the position
shown in the drawing, then tighten the lock nut.
Stopper bolt
Standard: A=16 mm (0.63 in.)
Drawbar bracket
9-8
BATTERY HOOD
COMPONENTS
Plug
Plug
Battery hood Catch
(Attach to frame)
Flange bolt
Cap
Bushing Screw
(Attach to battery hood)
Grip
Cotter pin
Seal
Collar Cushion
(Attach to battery hood)
Flange bolt
Bracket
Washer
Rubber cushion Bolt

(Attach to frame) Damper
Note:
Removal and re-installation of the battery hood should be performed by 2 people.
Removal Procedure
1. Park the vehicle on flat ground, and chock the wheels.
AXLE”)
3. Disengage the catch that locks the battery hood, and open the
battery hood.
9-9
4. On vehicles fitted with a drawbar lever, remove the nuts (4

pcs.) and remove the drawbar lever from the battery hood.
LH side Rear combination 5. Remove the bolts (2pcs.) and remove the rear combination
light cover light cover.
Note:
To remove the cover, close the battery hood after the bolts
have been removed, and remove the cover from the rear
of the vehicle.
RH side
Rear
combination
light cover
6. Remove the bolts (one each on the right and left sides) from
the rear side of the battery hood bracket.
Bolt
7. Disconnect the damper stay from the battery hood.

Note:
• Hold the battery hood open when the damper is
disconnected so that it does not close.
• Lay the disconnected damper down towards the front
of the vehicle, or disconnect it from the frame side
and remove it from the vehicle.
Damper stay
9-10
8. Close the battery hood.

9. Loosen the bolts on the front side of the battery hood (one
each on the right and left sides).
Bolt
Note:
The bolts cannot be removed in this state, so ensure that
the threaded part is completely withdrawn.
10. Remove the battery hood from the vehicle.

9-11
BATTERY CHARGE INDICATOR AND HOUR METER

BATTERY CHARGE INDICATOR
The charge remaining in the battery is displayed in 8 stages by the
combination of the 6 LED lights on the LED bar and the battery
LED. As the battery discharges, the LEDs go out in order from the
right side. At about 80 % discharge, the battery LED flashes. When
this level is reached, recharge the battery.
HOUR METER
4CBT2R • 3R • 4CBTK4R (Seat switch type)
This meter operates when an operator is sitting in the seat, and the
key switch is ON. It accumulates in units of 1/10 (every 6 mins).
The meter operates when the key switch is ON, and accumulates
in units of 1/10 (every 6 mins).
HOUR METER CONNECTION PROCEDURE

Note:
Match the numbers on the hour meter with the numbers on the harness side, and attach the hour meter.
No. Wiring color
1 1 Yellow
2 2 White
3 Orange
3
9-12
HAZARD SWITCH CONNECTION PROCEDURE

1
No. Wiring color
2 4
1 Blue
3
5
2 —
6 3 Green
4 Green-Yellow
5 —
6 Green
FUSES
Red Connecting destination
Quantity
Sit-down type vehicle Standup type vehicle
Black
F4 10 A Turn signal light relay ←
F5 10 A Tail light relay Stop light switch

Yellow F4
Black
F5
9-13
TOE BOARD
TOE BOARD REMOVAL • REATTACHMENT
Removal Procedure
4CBT2R • 3R • CBTK4
1. Remove the rear toe board.
Rear toe
board
Front toe
board
2. Disconnect the connectors of the harness for the accelerator

sensor.
3. Remove the bolt from the RH side of the vehicle.
Flange bolt
4. Remove the bolt from the LH side of the vehicle.
Flange bolt
9-14
5. Remove the accelerator pedal and the front toe board.
Accelerator
pedal
Rear toe
board 1. Remove the rear toe board.
Front toe
board
2. Lift the front toe board slightly, and disconnect the connector
for the floor switch.
3. Remove the front toe board. (Remove the floor switch together
with the front toe board).
9-15
STROBO LAMP
When the strobo lamp (option) is installed, the installation position of the rear combination light changes.
Strobo lamp
Rear combination light (LH) Rear combination light (RH)
Harness guard
Harness guard
Strobo lamp bracket
Battery hood stopper
Cover
(Install in the place of the rear
combination light instead of the
rear combination light)
Install on the rear

end of the frame
9-16
FRONT COMBINATION LIGHT

When the front combination light is not installed, a cover is installed on the front protector.
Cover
REAR COMBINATION LIGHT

When the rear combination light is not installed, the cover changes.
Rear combination light (LH)
Rear combination light (RH)
Cover
Cover
Turn signal relay
Tail light relay
Head light relay
Roll-out
specification vehicle
Standard specification vehicle (Short connector)
Rotary lamp
ELECTRICAL PARTS ARRANGEMENT PLAN
Connect with
contactor
To the seat switch
Connect Electromagnetic
with brake
To the battery
controller Chime
Acceleration
sensor
Accelerator
sensor harness
Horn
Main harness Front protector harness
Buzzer
Rear combination light
Fuses
Ground
Parking brake switch

9-17
Floor switch
Roll-out
specification vehicle
Standard specification vehicle (Short connector)
Horn switch Accelerator
Indicator light switch
Flasher unit
9-18
10-1
REMOTE CONTROLLER SPECIFICATION

Page Page
0
Overview.............................. 10-2 System Configuration 1
Overview .............................. 10-53
Sales points.............................. 10-2
External input and output..... 10-54
2
Handling ................................... 10-3
Bumper .............................. 10-18
COMPONENTS....................... 10-62 3
Error detection....................... 10-64
BUMPER REMOVAL- 4
INSTALLATION .................... 10-20 TROUBLESHOOTING ....... 10-66
Bumper adjustment Trouble shooting table.......... 10-66 5
procedure ............................. 10-23
Bumper Bracket Removal
TROUBLESHOOTING............ 10-67 6
Procedure............................. 10-26 Sensors.............................. 10-89
Guide sensor ......................... 10-89
7
Retractable device ............ 10-28
GENERAL ............................... 10-28
Address sensor ..................... 10-99 8
Setting addresses for
COMPONENTS ....................... 10-29
stopping at multiple 9
REMOVAL-INSTALLATION ... 10-31 set points ........................... 10-105
Adjustment procedure .......... 10-34 Stop sensor.......................... 10-109
10
Steering motor .................. 10-37 Signal horn........................... 10-112 11
Switches and Lamps ...... 10-116
GENERAL ............................... 10-37 12
SPECIFICATIONS................... 10-40 Rear tower ....................... 10-119
COMPONENTS ....................... 10-42 GENERAL............................. 10-119
13
REMOVAL-INSTALLATION ... 10-43 REMOVAL- 14
INSTALLATION.................. 10-122
Controller........................... 10-50
Procedure for setting 15
GENERAL ............................... 10-50
receiver frequency
SPECIFICATIONS................... 10-51 and code ........................ 10-125 16
As for items which are not covered in this section, see sections 0 to 9 and appendix tables.
17
18
10-2
Overview
Sales points
1. Excellent traveling performance
(1) AC motor drive provides constant speed in remote control travel regardless of the size of the tow capacity,
allowing stable traveling at all times.
(2) Remote controlled braking combines regenerative brakes and electromagnetic brakes to achieve improved
braking performance.
2. Excellent environmental performance
(1) Waterproof construction is used for the sensors to improve water resistance, thereby allowing traveling in
the rain under manned operation.
3. Safety functions
(1) In infra-red obstacle sensor and safety bumper are fitted so that the vehicle will reduce speed and stop on
encountering an obstacle.
(2) Emergency stop switches are provided on all four corners of the vehicle.
(3) Operator presence sensing function allows remote control operation to be prohibited when a mounted
operator is detected.
(4) If the battery lock is off when the brake is operated, remote control operation is prohibited.
(5) The vehicle stops when it has gone out of the course.
4. Operability
(1) A course detection lamp makes it easier to determine the position of the magnetic tape.
(2) LED display lamps are fitted to make it easy to check the remote controlled operation status.
10-3
Handling
GENERAL
Remote controlled operation functions have been added to the Tugnova standard vehicle, so that the vehicle can
now be started and stopped from a remote position, thereby reducing line supply time and other operation losses.
Conventional manned travel is also possible by operating the levers in the driver’s seat. 0
1
Remote Controller
2
3
Stopping and starting by operation
4
5
of the remote controller
6
7
The vehicle travels along magnetic tape on
the floor during remote controlled operation
8
9
10
Operation patterns for remote control
11
Remote control operation allows selection of three types of traveling pattern.
Inching function (standard)
Traveling between two points function (OPT)
12
Stopping at multiple set points function (OPT)
13
14
15
16
17
18
10-4
1. Inching function
The vehicle moves forward only when the inching switch on the remote controller is being pressed, and slows
to a stop when the switch is released.
Practical example:
(a) Move the vehicle forward by remote control operation and align with the position of the parts shelf while
working.
(b) When aligning the position, the vehicle can be advanced by remote control, without returning to the
driver’s seat enabling a good work efficiency.
(c) The vehicle can be moved quickly between operations by manned travel.
Manned Travel Inching travel by remote controlled operation
High speed movement to the target line by

manned travel
Production line
Work while inching by remote controlled

operation
Dolly
Move by manned travel from

the previous operation
Magnetic tape stuck to the floor

Traction
vehicle
Parts rack
10-5
2. Traveling between two points function (OPT)

The vehicle starts traveling by operation of the start switch on either the remote controller or the vehicle, then,
the vehicle travels automatically to the position of a stop marker, then, after reading the stop marker, the vehicle
slows to a stop.
(Start switch on the remote controller is OPT: Remote unmanned start device*)
(For five seconds on starting the vehicle travels at 1 km/h).
0
Practical example:
(a) Travel unmanned between operations, advance the vehicle by remote control at the side of the line to
align it with the parts while working.
1
2
Inching travel by remote controlled Unmanned traveling between
operation two points
3
• Stop at stop marker • Send off using the start switch 4
5
Parts line 6
7
• Stop at stop marker
8
9
10
11
12
13
Assembly line
14
• Send off using the start switch • Work while inching by remote controlled
operation 15
*: When the OPT remote unmanned start device is selected, the vehicle can be started using the start switch on the
remote controller.
16
Please note that in this case there is no start switch set on the vehicle.
17
18
10-6
3. Stop at multiple set points function [with speed reduction function] (OPT)
(1) The vehicle starts traveling by operation of the start switch on either the remote controller or the vehicle,
then, the vehicle travels automatically to the position of a set address marker, then, after reading the
address marker, the vehicle slows to a stop.
(Start switch on the remote controller is OPT: Remote unmanned start device*)
(For five seconds on starting the vehicle travels at 1 km/h).
(2) The setting of the stop address is performed with the address selection switch on the vehicle (max. 10
places)
Practical example:
(a) Travel unmanned between operations to set address, advance the vehicle by remote control at each
operation to align it with the parts rack while working.
10-7
Inching travel by remote controlled Unmanned traveling between

operation multiple set points
Vehicle address selection switch

Set the places to stop with the switch
• Send off using the start switch

• Stop at the address
marker
• Work while inching by remote

controlled operation
• Stop at the address marker
Stop at the address marker
• Send off using the

start switch
• Work while inching by remote

controlled operation
• Stop at the address marker • Stop at the address marker
*: When the OPT remote unmanned start device is selected, the vehicle can be started using the start switch on the
remote controller.
Please note that in this case there is no start switch set on the vehicle.
10-8
Speed Reduction Function

This function raises stopping accuracy by beginning to reduce speed from before the selected stop address
marker, thereby shortening the stop braking distance.
The vehicle reduces speed to 1 km/h by reading a speed reduction marker. Thereafter, it stops by reading the
selected stop address marker.
When a non-selected address marker is read, the vehicle determines that it is not a stop address marker, and
does not stop, accelerating to a speed of (3.6 km/h) to continue traveling.
If an address marker is not read within 10 seconds of beginning to reduce speed, the vehicle determines an error
has occurred and sounds an error warning and stops.
Speed reduction marker Selected: Address marker
3.6 km/h
Speed
reduction
Stop
1 km/h
Speed reduction marker Non-selected: Address marker
3.6 km/h Speed Acceler 3.6 km/h

reduction ation
Error stop
1 km/h
10 seconds
10-9
Remote Controller
Power light Start switch (Option)
Transmitting lamp Horn switch
Low Battery Warning Lamp Inching switch
Emergency stop switch Standby switch
When the vehicle is ready for unmanned traveling, the vehicle can be operated remotely by its remote controller.
Note:
• Always operate switches with your fingertips.
• Always check the safety of the vehicle periphery before operating the remote control.
• Do not perform remote control operations while mounted on the vehicle.
• Do not perform remote control travel outside of flat areas as there is a risk of damage being caused
to the guide sensor by surface irregularities on the course.
• Do not perform remote control operation close to facilities that emit noise that is close to radio
frequencies, such as high frequency electric furnaces, as this may cause malfunction.
• Do not perform remote control operation close to facilities that block electromagnetic waves, such
as iron partitions, as this may cause malfunction.
• Never perform remote control operations while the battery hood is open.
1. Power lamp (Red)
This lamp turns on for 3 seconds when the standby switch has
been pressed. (Ready to send traveling commands)
10-10
2. Transmission lamp (Red)

This lamp turns on during transmission of electromagnetic
waves.
3. Low Battery Warning Lamp (Red)

This lamp turns on when the remaining battery power in the
transmitter is low.
Note:
As operation during low remaining battery power can cause
malfunction, replace the battery promptly when the warning
lamp has turned on.
4. Emergency stop switch

This switch can be pressed to stop the vehicle in the event of
unexpected trouble occurring during remote control traveling.
Note:
To restart the vehicle, press the reset switch to unlock
abnormal stop mode, then press the standby switch to put the
vehicle into ready mode and allow remote control operation
again.
5. Start switch (Option)

When a remote unmanned start device (option) is set on a
vehicle with traveling between 2 points function (option) or a
vehicle with stopping at multiple set stops function (option), the
vehicle can be started by this switch.
Vehicles that do not have a remote unmanned start device
(option) set do not have a start switch on the remote controller,
so the start switch on the vehicle is used.
Note:
• Please note that if the vehicle is not operated within 3
seconds of pressing the standby switch, travel
commands will not be able to be transmitted.
• Always check the safety of the vehicle periphery before
starting the vehicle.
10-11
6. Horn switch
7. Inching switch
The vehicle can be advanced only while pressing this switch.
(Inching function)
When the switch is released, the vehicle slows to a stop.
Note:
• Please note that if the vehicle is not operated within 3
seconds of pressing the standby switch, travel
commands will not be able to be transmitted.
• Always check the safety of the vehicle periphery before
starting the vehicle.
8. Standby switch
When the switch is pressed, traveling commands can be
transmitted for an interval of 3 seconds during which the power
lamp turns on.
LED Display Lamp

LED Display Lamp These lamps turn on or off during remote control travel to inform the
operator of the vehicle status.
Refer to the table below for the display and meaning of each LED.
LED Display Description
• Blinking with 0.2 second cycle
Performing remote control travel
• Blinking with 1 second cycle
Yellow blinking Vehicle is stopped (ready mode)
Performing remote control reduced speed
travel
• Blinking with 0.2 second cycle
Abnormal stop such as emergency stop or
Red blinking stop due to contact with safety bumper
Vehicle is stopped (ready mode)
Turns on white Key switch on
10-12
Signal horn
Signal horn The signal horn sounds various warnings during remote control
travel.
Refer to the table below for the sound and meaning of each
warning.
Warning sound Description
Sounds when the obstacle sensor, safety
Beep (slow
bumper or some other safety function detects
intermittent horn)
an error.
Stutter (rapid
Warning horn prior to starting.
intermittent horn)
Bell (clear high-
Warning during traveling and after stopping
pitched bell)
Signal of arriving at a station
Yelp**** (rapid (Vehicles with travel between 2 points function
siren) and vehicles with stopping at multiple set stops
function: Option)
* Over the continuous travel time limit (120 seconds), out of the
course, accelerator lever, parking brake, OPS switch battery
stopper, emergency stop switch emergency stop switch
operation
10-13
VEHICLE EXTERIOR VIEW

Start switch (OPT)
Receiver and antenna
LED Display Lamp
Emergency stop switch
Address selection switch (OPT)

Start switch (OPT)
Obstacle sensor
Retractable device (built in)
Bumper
Signal horn
10-14
Start switch (OPT)
Receiver and antenna
LED Display Lamp
Emergency stop
switch
Start switch
Address selection (OPT)
switch (OPT)
Emergency stop switch Emergency stop

switch
Obstacle sensor
Retractable device (built in)
Signal horn
Bumper
10-15
Drawing showing the layout from the operator’s seat

Ready switch
Bumper error lamp
Course detection lamp
Steering error lamp
Emergency stop lamp
Ready switch
Reset switch Manned/Unmanned Selection Lever
10-16
Ready switch
Course detection lamp

Bumper error lamp
Steering error lamp

Emergency stop lamp
Ready switch
Manned/Unmanned Selection Lever

Reset switch
10-17
Name function
Manned/Unmanned
Switches between “Manned travel” and “Unmanned travel”.
Selection Lever
This lamp turns on when the vehicle has gone out of the course, or when an error occurs in the
Steering error lamp (Red)
automatic steering system. In such cases, the vehicle stops and unmanned travel is disabled.
Bumper error lamp (Red) This lamp turns on when the safety bumper encounters an obstacle and the vehicle stops.
In the following cases the lamp turns on or blinks, and unmanned travel is disabled.
Emergency stop lamp Turns on: When the emergency stop switch has been pressed to stop the vehicle
(Red) Blinks: When the emergency stop switch on the remote controller has been pressed to stop the
vehicle
Turns on: When the guide sensor has detected the course in unmanned travel mode
Turns off: When the vehicle enters one of the following states during unmanned travel mode,
Course detection lamp the lamp turns off and unmanned travel is disabled.
(White) • When the guide sensor does not detect the course
• When the vehicle goes out of the course while traveling
• When an error occurs with the retractable device
When the switch is pressed the lamp turns on and the vehicle becomes ready for unmanned
Ready switch
travel.
When the vehicle has stopped with one of the above abnormal situations, press the reset
Reset switch
switch before repairing the place with the error.
10-18
Bumper
GENERAL
Bumper bracket
Obstacle sensor
Front cover
Signal horn
Upper cover
Bumper
Urethane rubber
Bumper arm
10-19
COMPONENTS
Bumper arm
Set plate
Bolt Screw
Nut plate
Limit switch
Bolt
Snap ring Washer
Bushing
Roller
Spacer
Bumper arm
Hook
Stopper bolt Bushing Edge rubber
Lock nut Spacer
Thrust washer
Tension spring
10-20
Bolt
BUMPER REMOVAL-INSTALLATION
Removal Procedure
1. Remove the upper cover. (Three bolts)
Upper cover
Bolt 2. Remove the front cover attachment bolts.

(Four bolts)
3. Move the front cover aside slightly and disconnect the signal
horn connector.
4. Remove the front cover.
Front
cover
Signal horn
Disconnect the
connector.
5. Remove the left and right tension springs following the

Bolt procedure below.
(1) Loosen the hook attachment bolts.
Hook
(2) Loosen the adjustment bolts.
Note:
Do not remove the hook attachment bolts and adjustment
bolts.
6. After loosening the lock nut, tighten the stopper bolt and
Stopper bolt
loosen the tension of the tension spring.
Lock nut
Bumper arm
10-21
7. Remove the tension spring.

Tension spring
Large hook Note:
Attach the large hook of the tension spring to the hook
side, and the small hook to the bumper arm side.
Hook
Small hook
Bumper arm
Stopper bolt 8. Disconnect the connector of the limit switch.

9. Remove the bumper arm attachment bolts.
Bolt
Washer
Limit
switch
Bumper arm
Detail of bumper arm attachment section
Bolt
Washer
Bushing
Bumper arm
Tension spring
Thrust washer Washer
10. Remove the bumper W/bumper arm.

Note:
1 • Be careful of the bush falling off.
• Be careful not to touch the limit switch.
2
10-22
11. Remove the bumper arm attachment bolts, then remove the
Bolt nut plate.
Nut plate
12. Remove the bumper arm from the bumper.
Bumper arm
10-23
Bumper adjustment procedure

Bumper attachment and adjustment
Nut plate Bumper
Bumper bracket
Bumper bracket
Tension spring
Attach the bumper so that the dimension of the step A between the bumper and the bumper bracket is within 2 mm
[0.079 in] to the left or right****, then fasten the nut plate.
A = 10 mm [0.39 in]
10-24
Tension spring tension adjustment
Bumper
Bumper arm A
Hook attachment bolt
Hook
Small hook Large hook
Bumper bracket
Adjustment bolt
Tension spring
1. Hook up the spring between the bumper arm and the hook.
Note:
Attach the large hook of the tension spring to the hook side, and the small hook to the bumper arm side.
2. Tighten the adjustment bolt until the dimension A reaches the standard.
A = 46 to 47 mm [1.81 to 1.85 in]

3. Fasten the hook with the hook attachment bolt.
10-25
Adjust the limit switch
Bumper arm
Tension spring
Limit switch
1. Loosen the limit switch attachment screws.

2. After adjusting the spring, press the bumper arm fully in, then press the limit switch until it clicks on the bumper
arm side.****
3. Fasten the limit switch attachment screws.
10-26
Bumper Bracket Removal Procedure

Obstacle sensor 1. Disconnect the connector of the obstacle sensor.
Bumper bracket
Bumper bracket
attachment bolt
Wooden block
Wooden block
2. Place a wooden block under the bumper bracket.

3. Remove the bumper bracket attachment bolts.
10-27
Move
4. Remove the bumper bracket from the vehicle.
Bumper bracket adjustment procedure
Bumper attachment and adjustment
Bumper
Bumper bracket
A
Frame
1. Attach the bumper so that the dimension of the step A between the bumper and the bumper bracket is within 2
mm [0.079 in] to the left or right****, then fasten the nut plate.
A = 10 mm [0.39 in]
10-28
Retractable device
GENERAL
The following sensors needed for unmanned traveling are attached to the retractable device.
• Guide sensor
• Stop sensor
• Address sensor
• Manned/Unmanned selection switch
The retractable device is operated by the manned/unmanned selection lever in the driver’s seat.
When the manned/unmanned selection lever is operated, the retractable device moves up and down, and manned
or unmanned travel can be selected.
The retractable device is attached to the front axle bracket.
Bumper
Frame
Retractable device
Bumper bracket
Retractable wire
Manned/Unmanned
selection switch
Retractable device
Guide sensor Address sensor
Stop sensor
10-29
COMPONENTS
Knob
Retractable wire
mount
Spring mount
Manned/Unmanned Selection Lever

Shaft mount
Pin
Pin Bushing
Screw
Snap ring Flat washer
Flat washer
shaft
Pin
Lever
Flat washer
Damper Cotter pin
Spacer Bolt
Flat washer
Bushing
Flat washer Spring

nut
nut
Spacer
Retractable wire Clamp
10-30
Limit switch
mm [in]
(Movement until
operation)
1.5 max
(Operation position)
Mounting hole 4.2 +0.1 [0.165 +0.004

[1.472± 0.031]
0 0
]
37.4±0.8
Connector
33±0.15
[1.30± 0.006]
10-31
Pin
REMOVAL-INSTALLATION
Removal Procedure
1. Remove the bumper and the bumper bracket.
2. Disconnect the retractable wire.
Flat washer Cotter pin
3. Remove the bolt and nut that fastens the retractable wire.
nut Washer
Note:
Remove the clamp attaching bolt, then remove the clamp
from the retractable wire.
4. Disconnect the connector of the guide sensor.

Note:
Where a stop sensor and address sensor are fitted,
remove the connectors for each sensor.
Connector
5. Remove the harness clamp from the retractable device. (In 2

Bolt places)
Harness clamp
10-32
6. Remove the under cover.
Under cover
Bolt
7. Remove the attaching bolts of the retractable device (2 pcs).

Note:
Lower the retractable device, being careful not to contact
and damage the sensors.
8. Remove the retractable device from the vehicle.
Bolt 9. Remove the toe board and remove the retractable wire clamp.
(In 3 places)
Retractable wire
Note:
from the retractable wire.
Clamp
10-33
10. Remove the retractable wire clamp on the left hand side of the
front protector. (In 1 place)
Parking brake wire Retractable wire
Note:
Clamp from the retractable wire.
Bolt
Grommet
11. Remove the emergency stop switch from the left hand side of
Bolt the front protector.
Emergency Note:
stop switch Fasten the emergency stop switch to the front side of the
front protector.
12. Remove the retractable wire together with the instrument

panel (LH) from the vehicle.
(1) With the manned/unmanned selection lever, fuse and
warning lamp attached to the instrument panel (LH),
remove the attachment bolt.
(2) With the instrument panel lifted slightly, disconnect all the
connectors.
(3) Remove the retractable wire together with the instrument
panel (LH) without pulling excessively.
10-34
Adjustment procedure
Adjust the guide sensor
1. Press the manned/unmanned selection lever down, and put the retractable device in the lowered position.
2. Adjust the distance A from the guide sensor to the floor to the standard.
Standard A = 25 to 30 mm [0.98 to 1.18 in]
At this time the distance B becomes 8mm [0.315 in]. (Reference)

10-35
3. Adjust the dimension C so that the guide sensor and the floor surface become parallel to each other. (The degree
of parallel may be determined visually)
Reference C = 31 mm [1.22 in]

Note:
After adjustment, be sure to apply a lock nut to prevent the bolt from loosening.
10-36
Adjust the retractable wire
Manned/Unmanned
Selection Lever Clamp nut
1. Operate the manned/unmanned selection lever into the fully pressed down position.
2. Move the wire clamp and tighten the nut to fasten the wire clamp in the position where there is no play left in the
wire.
Note:
After adjustment, be sure to apply a lock nut to prevent the bolt from loosening.
10-37
Steering motor
GENERAL
Steering wheel
Steering motor
View from perspective A
• During manned travel

Operate the steering wheel to change the direction of travel.
• During unmanned travel
The signal from the guide tape enters the controller, and the motor is driven by a signal from the controller to
change the direction of travel.
10-38
Steering wheel
Steering motor
View from perspective A
• During manned travel

Operate the steering wheel to change the direction of travel.
• During unmanned travel
The signal from the guide tape enters the controller, and the motor is driven by a signal from the controller to
change the direction of travel.
10-39
Unit: mm [in]
M6 tap,
depth 15
4-M6 × 90
Position to affix part
1 2
(Black) (Red)
Connector pin
arrangement
Connection diagram
The direction of rotation is the clockwise direction viewed from the
output axle side when the red wire (2nd pin) is connected to the +
Red (2nd pin) side.
(The motor unit also rotates in the clockwise direction)****
Black (1st pin)

10-40
SPECIFICATIONS
Specification with speed reducer
Item Standard:
Rated output W 154
Rated speed r/min 60
Rated torque N • m (kgf • cm)[ft • lbf] 24.5 (250) [18.1]
Rated voltage V 48
Rated current A 6.5
Instantaneous maximum allowable

A 20
current
Continuous rating 60 minutes
Insulation type Type F
Withstand voltage AC 500 V, 50 Hz, 1 minute
Insulation resistance 10MÉ¹ or more at DC 500 Megavolt
Weight kg[lb] 4.5 [9.9]
Exterior coating Yoke: plated, Gears: Black paint, Other: untreated
Speed reducer specification

Item Standard:
Gear ratio 1/50
Efficiency 0.66
Motor unit
Item Standard:
Motor unit rated output W 233
Motor unit rated torque N • m (kgf • cm)[ft • lbf] 0.74 (7.5) [0.55]
Motor unit rated speed r/min 3000
Continuous rated torque during

N(kgf) [lbf] • min 0.81 (0.08) [0.18]
speed reduction
Actual continuous rated current

A 6.5
at reduced speed****
Counter electromagnetic force

V/kr/min 13.0
constant
Torque constant N • m (kgf • cm)[ft • lbf]/A 0.123 (1.254) [0.091]
Armature inertia kg-m2(GD2/4) 2.45 × 10-4
Armature resistance Ω 0.91
Armature inductance mH 3.5
Frictional torque N • m (kgf • cm)[ft • lbf] 0.03 (0.306) [0.02]
Maximum allowable speed r/min 5500
Instantaneous maximum torque N • m (kgf • cm)[ft • lbf] 2.5 (25.5) [1.84]

10-41
Item Standard:
Maximum theoretical
acceleration rad/s2 10200
Mechanical time constant ms 14.5
Electrical time constant ms 3.85
Thermal elevation limit of coil °C [°F] 155 [311]

10-42
COMPONENTS
Steering motor
Key
(Steering motor accessory)
Bolt
Flat washer
Adjustment bolt
Adjuster
nut
Lock nut
Plug
Sprocket
Spacer
Bolt
Steering motor chain
Sprocket
Plug
(Front axle)
Key
10-43
Front cover
Removal Procedure
Bolt
2. Loosen the 4 attachment bolts for the adjuster.

Steering motor
Note:
Do not remove the bolts.
Adjuster
Bolt
3. Move the steering motor W/adjuster to the center of the

vehicle.
(1) Loosen the lock nut.
(2) Loosen the adjustment bolt to its limit.
Adjustment bolt
(3) Move the steering motor W/adjuster to the center.
Lock nut
Adjuster
4. Disconnect the steering chain link.

Note:
Operate the steering wheel so that the clip comes to just
in front of you.
Clip
Plate
link
Steering chain
10-44

Note:
Apply MP grease to the sprockets on the motor side and
axle side, and attach the steering chain.
6. Disconnect the retractable wire from the front protector.

Retractable wire
7. Disconnect the connector of the steering motor.
Clamp
Connector
Bolt
8. Remove the instrument panel (LH).

(Refer to 10-33)
10-45
9. Remove the steering motor.

Steering motor
(1) Remove the loosened bolts.
(2) Remove the adjuster, sprocket, and adjustment bolt
together.
Adjuster
Adjustment bolt Sprocket
10. Remove the plug from the sprocket.
Sprocket
11. Remove the sprocket from the front axle side.
Note:
When reassembling the plug, be sure to apply Three Bond
1401-B or an equivalent product.
Plug
12. Use the SST and remove the sprocket.

SST SST 09950-76013-71
(09950-40010)
10-46
Removal Procedure
Front
Bolt
cover
Bolt
Bolt
2. Loosen the 4 attachment bolts for the adjuster.

Steering motor
Note:
Do not remove the bolts.
Bolt
Adjuster
3. Move the steering motor W/adjuster to the center of the

vehicle.
(1) Loosen the lock nut.
(2) Loosen the adjustment bolt to its limit.
Lock nut
(3) Move the steering motor W/adjuster to the center.
Adjuster
Adjustment bolt
10-47
4. Disconnect the steering chain link.

Note:
Operate the steering wheel so that the clip comes to just
Clip
in front of you.
Plate
Steering chain
link

Note:
Apply MP grease to the sprockets on the motor side and
axle side, and attach the steering chain.
6. Disconnect the retractable wire from the front protector.

Retractable wire
7. Disconnect the connector of the steering motor.
Clamp
Connector
Bolt
10-48
8. Remove the steering motor.

Steering motor (1) Remove the loosened bolts.
(2) Remove the adjuster, sprocket, and adjustment bolt
together.
Adjuster
Adjustment
bolt Sprocket
9. Remove the plug from the sprocket.

10. Remove the sprocket from the front axle side.
Sprocket Note:
When reassembling the plug, be sure to apply Three Bond
1401-B or an equivalent product.
Plug
11. Use the SST and remove the sprocket.

SST 09950-76013-71
(09950-40010)
SST
10-49
Steering chain adjustment procedure

1. Tighten the adjustment bolt by hand until it comes into contact
Lock nut with the frame.
2. From the status in 1., tighten the adjustment bolt a further one
turn (to tension the steering chain).
3. Fasten with a lock nut.
Adjuster
Adjustment bolt
10-50
Controller
GENERAL
Emergency stop relay
Drive contactor
Drive controller
Remote control contactor
Remote control controller

10-51
1. Manned travel mode

Even when the controller has been used, the manned travel functions of the vehicle can be retained by selecting
manned travel mode.
2. Remote inching function
In this mode, the vehicle travels along the magnetic tape route only while the inching button on the remote
controller is being pressed.
3. Traveling between two points ST
In this mode, traveling is initiated by pressing the continuous start button on either the remote controller or the
vehicle, then the vehicle stops automatically when it detects a station stop marker.
4. Stop at multiple set points ST traveling (with speed reduction function)
In this mode, the number of the destination station is pre-selected, then traveling is initiated by operation of the
continuous start button on either the remote controller or the vehicle.The vehicle stops when it detects an
address marker corresponding to the selected station.
5. During remote control travel, the controller controls the travel start and travel stop commands to the AC inverter
on the vehicle.
6. The controller controls the safety equipment such as the emergency stop switch, obstacle sensor and bumper.
SPECIFICATIONS
Item SPECIFICATIONS
Ambient temperature 0 to 50°C [32 to 122°F]
Ambient humidity 30 to 85% RH
10 to 55 Hz, 1 sweep/1 minute,

Controller ambient Vibration resistance
Double amplitude 0.75 mm [0.03 in], 10 minutes in each direction X/Y/Z
environment
Shock resistance 98 m/s2, Each direction, 4 times
No corrosive gas
Atmosphere
No severe dust
DC 48 V Lead battery
Input power
Voltage range 40 to 52 VDC
DC 24 V (Created by DC/DC power source inside the controller)

Control power
(Excluding board-internal power supply)
1 to 4km/h [0.621 to 2.484 mph] (Set by variable resistor inside the

Travel speed during remote control operation
controller)
Compatible motor 48V 154W DC motor
Control method PWM method

Steering motor control
Overcurrent detection
14.8 ±1.5 A (emergency stop if continued for 10 seconds)
value
Guidance method Magnetic guidance

Guidance control
Minimum curve radius R1500 mm [59 in]
Unit: mm [in]
External connector (1)
10-52
A
External connector (2)
For attaching section a unit

3 pcs****-φ7 thickness 12.3
Slotted
hole
Name 7 x 12
plate
System Configuration Overview
Remote controller
Magnetic guide
sensor
Battery Contactor EPS controller
DC 48 V (Steering motor control)
DCM DC motor
MC
Emergency stop
switch
Safety
PLC Controller
(Programmable controller) Ready
DC/DC power switch
supply CPU I/O
24 V Unit 1
I/O Input device
Unit 1 Switch,
I/O sensor,
Relay circuit
Unit 2 etc.
(Isolation from
AC inverter for
manned
traveling
operation
devices)
48 Input points Input device
48 Output points Lamp,
horn,
etc.
Speed • Some devices are omitted from this diagram.

adjustment • The configuration may differ from the actual machine
(Variable resistor) depending on the specification.
• For details of connection, refer to the Controller Connection
Diagram.
• This product does not include devices other than the remote
system controller.
10-53
External input and output
10-54
Note:
• For details of connection, refer to the wiring diagram.
• LP.stands for lamp, while SW.stands for switch.
• There is no overcurrent protection on the I/O output terminal of the controller.
• Do not apply any voltage other than DC 24 V to the controller I/O terminals.
• When using the 24 V power supply of the controller externally, make sure that the total current in use does not exceed 2.8 A.
• When connecting an induced load, provide a protective diode on the external device side.
• There are several connectors with the same pole number as the external input output connector. There is no protection to prevent insertion of
the wrong connector.
• Have the power turned off when inserting or removing connectors.
Connector No. Wire No. Name IN/OUT Supplements
• DC 48 V positive side for control supply of controller

VBKY Controller control power + IN 48 V 5 A
• Linked with vehicle key switch
CN311 N1 Controller control power - IN 48 V • DC 48 V negative side for control supply of controller
P48 Controller drive power + IN 48 V 20 A • DC 48 V positive side for driving steering motor
N1 Controller drive power - IN 48 V • DC 48 V negative side for driving steering motor
• Connected with direction switch for manned operation

DIF1 Direction SW. Forward Device side IN 24 V • If ON for more than 2 seconds during remote control mode travel,
emergency stop
• During manned operation, outputs direction SW. signal

DIF2 Direction SW. Forward Controller side OUT 24 V 100 mA
• During remote control mode, output from controller when traveling starts
• Connected with direction switch for manned operation

DIR1 Direction SW. Reverse Device side IN 24 V • If ON for more than 2 seconds during remote control mode travel,
emergency stop
CN312 • During manned mode, outputs direction switch signal
DIR2 Direction SW. Reverse Controller side OUT 24 V 100 mA
• During remote control mode, OFF
AC1 Accelerator resistance middle terminal (IN) • Connected with accelerator signal for manned operation
• During manned mode, outputs accelerator signal

AC2 Accelerator voltage output OUT • During remote control mode, outputs voltage set by controller speed
adjustment VR
ACP1 Accelerator resistance + (OUT) • Positive side of accelerator resistance for manned operation
ACP2 Accelerator power supply + IN 5 V • Positive side of 5 V supply for accelerator resistance
ACS1 Accelerator SW. IN 24 V • Accelerator switch for manned operation
• In manned mode, outputs accelerator switch signal unchanged

ACS2 Accelerator SW. OUT 24 V 100 mA
CN312 • During remote control mode, continuously ON
ACN Accelerator power supply - IN • Negative side of 5 V supply for accelerator resistance
• (Empty)
• Vehicle electromagnetic brake
• In manned mode outputs electromagnetic brake input from controller
unchanged
BK1 Electromagnetic brake Device side OUT
• During remote control operation, even when the brake signal from vehicle
controller is ON (brake OFF), the signal will be OFF (brake ON) if an error is
detected by the remote system controller.
• Electromagnetic brake signal from the vehicle controller (brake release with
BK2 Electromagnetic brake Controller side IN
ON signal)
SEA1 Seat switch Device side IN 24 V • Seat (floor) switch (ON when a person is detected on the vehicle)
CN313 • In manned mode, outputs the signal from the seat (floor) switch unchanged
SEA2 Seat switch Controller side OUT 24 V 100 mA
• During remote control mode, continuously output ON
• Connection with foot brake contact point (OFF when foot brake is
X24 FOOT BRAKE IN
depressed)
• Connection with parking brake contact point (OFF when parking brake is
X25 Parking brake IN
applied)
• (Empty)
• For battery voltage monitoring and control power OFF processing

VB ––– IN 48 V 1 A
• Supplies battery voltage when connected to the vehicle battery
• ON for 3 seconds when error occurs

• In case of obstacle sensor operation, does not turn OFF with passage of
Y23 Signal horn 1 OUT 24 V 100 mA
time
• Priority level 1 (Priority High)*1
CN314 • ON for 2 seconds when travel starts (does not operate if re-starting within 3
Y24 Signal horn 2 OUT 24 V 100 mA seconds from stopping)
• Priority level 2 *1
• ON during traveling
Y25 Signal horn 3 OUT 24 V 100 mA
• Priority level 3 *1
10-55
10-56
• ON after stopping at a station when in either travel between 2 points ST

mode or stop at multiple set points ST mode
CN314 Y26 Signal horn 4 OUT 24 V 100 mA • OFF after 20 seconds has elapsed after arriving at a station or when travel is
re-commenced
• Priority level 4 (Priority Low)*1
M10 Steering motor (A) OUT 48 V 18 A

CN321 • Connection with steering motor of rated voltage DC 48 V
M11 Steering motor (B) OUT 48 V 18 A
P24 External device 24 V power supply + OUT 24 V 3.7 A

• DC 24 V power supply for control device
N1 External device 24 V power supply - OUT 0 V
MS1 Ready SW. (1) IN

• Connection with ready switch
MS2 Ready SW. (2) IN
• Connection with reset SW.

X06 Reset switch IN 24 V
• Unlocks error mode when input is ON
• Connection with contact “a” of emergency stop switch

X07 Emergency stop SW. contact “a” IN 24 V
• When signal is ON, ready goes to OFF and traveling stops
• When using travel between 2 points ST function and stop at multiple set
points ST function, connects with the start switch “a” contact point
• Used as travel start signal for travel between two points ST function and stop
X08 Continuous start SW. IN 24 V at multiple set points ST function
CN322 • When signal changes to ON during travel between 2 points ST function or
stop at multiple set points ST function, traveling stops
• Check input if ON continues for more than 2 seconds
• ON when course detection signal (X01) from the magnetic guide sensor is
Y00 Course detection LP. OUT 24 V 100 mA
ON
• ON when out of course error occurs

Y01 Steering error LP. OUT 24 V 100 mA
• Blinks with a 0.2 second cycle during a steering controller error
• ON on bumper operation or disconnection
Y02 Bumper error LP. OUT 24 V 100 mA
• ON with a 1 second cycle on width sensor operation
• ON when emergency stop (X07) is ON

Y03 Emergency stop LP. OUT 24 V 100 mA
• Blinks with 1 second cycle when remote control receiver 4 (X23) is ON
• Outputs operation ready mode

Y04 Operation ready LP. OUT 24 V 100 mA
• ON when operation ready circuit is complete
EM11 Emergency stop SW. 1 Contact “b” IN
• Connects 2 sets of the no voltage “b” contact point of the emergency stop
EM12 Emergency stop SW. 1 Contact “b” IN switch
EM21 Emergency stop SW. 2 Contact “b” IN • When the input if OFF (emergency stop SW. pressed), the operation ready
circuit switches OFF
EM22 Emergency stop SW. 2 Contact “b” IN
• Connects with the obstacle sensor distance detection signal

• The signal is ON when no obstacle is being detected, and OFF when one is
detected
X4B Obstacle sensor distance detection IN 24 V • If the signal changes to OFF during remote control traveling, the vehicle
stops and vehicle resumes travel after 2 seconds have elapsed after the
signal returns to ON
• A PNP open collector output sensor is used
• Connects with the obstacle sensor close detection signal

detected
OSSD1 Obstacle sensor close detection 1 IN 24 V
• If the signal changes to OFF during remote control traveling the vehicle
stops traveling
• A NPN open collector output sensor is used
CN322 • Connects with the obstacle sensor close detection signal

detected
• If the signal changes to OFF during remote control traveling the vehicle
Obstacle sensor close detection 2
OSSD2 IN 24 V stops traveling
(24320-40600-71 only)
• The signal is input with the same timing as OSSD1. If the timing becomes
different, a sensor fault is assumed and the power supply must be turned on
again, and therefore****
• a PNP open collector output sensor is used
• Connects with the obstacle sensor failure diagnosis signal

X4D Diagnose failure of the obstacle sensor IN 24 V
• ON when the obstacle sensor is normal, OFF when there is a failure
• Connects with the width sensor of the “b” contact

X0C Width Sensor IN 24 V • If the signal turns OFF during remote control traveling the sensor detects an
error
• If this signal turns ON during travel between 2 points ST traveling, reduced

speed travel is initiated
Speed reduction marker sensor (for travel • If stopping at multiple set points ST specification has been set, this input is
X02 IN 24 V
between 2 points ST) disabled
• Even when travel between 2 points ST function is being used, if reduced
speed travel function is not required then connection is not required
10-57
10-58
• If this signal turns ON during travel between 2 points ST traveling, it is

Stop marker sensor (for travel between 2 assumed that the vehicle has arrived at a station, and the vehicle stops
X03 IN 24 V
points ST) • If stopping at multiple set points ST specification has been set, this input is
CN323
disabled
• (Empty)
• The remote control mode selection signal is inputted at the “b” contact
X05 Remote control mode selection IN 24 V
• When this signal is OFF, remote control mode is selected
• Connects with the magnetic guide sensor course detection signal

X01 Magnetic guide sensor Course detection IN 24 V
• The signal is ON when the guide course is detected
• Connects with the magnetic guide sensor deviation output (position signal)
• The signal range is 2 to 8 V, and the sensor voltage is input at 5 V
GS1 Magnetic guide sensor Analog signal IN 2 to 8 V
• This signal voltage is used to check the amount of deviation from the guide
CN323 course and control the steering
Y06 Magnetic guide sensor Left branching OUT 24 V 100 mA • Connects with the magnetic guide sensor SEL input (branching signal)
Y07 Magnetic guide sensor Right branching OUT 24 V 100 mA • As the branching function is not used, Y06 and Y07 are both always ON
BM11 Bumper switch (1) IN 24 V

• Connects 4 wire bumper to BM11, BP12, BP13 and N1
BP12 Bumper switch (2) IN 24 V
• For details of connection, refer to the controller connection diagram.
BP13 Bumper switch (3) IN 24 V
P24 External device 24 Vpower supply + OUT 24 V 3.7 A

• DC 24 V power supply for control device
N1 External device 24 V power supply - OUT 0 V
• Connects with wireless receiver

X20 Wireless receiver 1 IN 24 V
• When ON a remote control inching travel command is determined

X21 Wireless receiver 2 IN 24 V • When ON, start command is determined for travel between 2 points ST
CN331 function/stop at multiple set points ST function
X22 Wireless receiver 3 IN 24 V
• When signal is ON, outputs signal horn 3 (Y25)

• When signal is ON emergency stop signal is determined
X23 Wireless receiver 4 IN 24 V This signal is inputted to PLC and is processed by software to become
a stop signal. It is not directly connected to the operation ready circuit.
Take care in treating it as safety equipment.
• Blinks with a 0.2 second cycle when an error occurs
Y20 Signal lamp 1 OUT 24 V 100 mA
• Blinks with a 1 second cycle when a warning occurs
• Blinks with 1 second cycle when remote control mode is selected and the
operation ready circuit is ON
Y21 Signal lamp 2 OUT 24 V 100 mA • Under normal remote control travel, blinks with a 0.2 second cycle
• When traveling at reduced speed in remote control mode, blinks 1 second
CN331 OFF and 2 seconds ON
Y22 Signal lamp 3 OUT 24 V 100 mA • ON during operation of remote system controller CPU (PLC)
Y27 Traveling stopped OUT 24 V 100 mA • ON when travel command output is OFF
• (Empty)
• (Empty)
X28 Address sensor Trigger IN 24 V
X29 Address sensor 1 IN 24 V
X2A Address sensor 2 IN 24 V • Connects with the multiple set point address sensor
• Used as a station stop condition during stop at multiple set points ST control
X2B Address sensor 3 IN 24 V
• The signal timing of the multiple set point address sensor complies with
X2C Address sensor 4 IN 24 V Macome Corporation specification SMR-300HR (as of May 2006) *2
CN341
X2D Address sensor 5 IN 24 V
X2E Address sensor 6 IN 24 V
• When this input is ON (connect to N1) the stop at multiple set points ST
Enable stop at multiple set points ST function is enabled, and the travel between 2 points ST function is disabled
X2F IN 24 V
control • When this input is OFF (open) the stop at multiple set points ST function is
disabled, and the travel between 2 points ST function is enabled
10-59
10-60
X40 ST01 selection SW. IN 24 V
X42 ST03 selection SW. IN 24 V • Connects the stop at multiple set points ST function setting switch
When the stop at multiple set points ST function is not used, the connection
CN342 is not required
X44 ST05 selection SW. IN 24 V • The switch uses the “a” contact point
The ST selection status is controlled at the remote system controller side
X45 ST06 selection SW. IN 24 V The switch selects momentary specification****
• When each input changes to ON when each ST is not selected, the ST is
selected, and when the input changes to ON when a ST is already selected,
X47 ST08 selection SW. IN 24 V the selected status is removed

CN343 • Connects with station selection reset switch for stop at multiple set points ST
function
X4A ST selection Reset SW. IN 24 V
The switch selects the “a” contact points specification
• Check input if ON continues for more than 2 seconds
Y40 ST01 selection LP. OUT 24 V 100 mA

• Connects with the ST display lamp for stop at multiple set points ST function
Y43 ST04 selection LP. OUT 24 V 100 mA • Each ST selection LP shows the selection setting status of the ST, and turns
CN342 ON when an ST has been selected
Y44 ST05 selection LP. OUT 24 V 100 mA For 20 seconds after arriving at an ST, the LP corresponding to that ST
Y45 ST06 selection LP. OUT 24 V 100 mA blinks with a 1 second cycle
Y46 ST07 selection LP. OUT 24 V 100 mA Y40 to Y47 output error display output in addition to error codes when
error display mode is selected

CN343
X4F Error display mode for maintenance IN 24 V

CN303 Error display mode for maintenance • While ON, displays error codes to Y40 to Y47
N1 0V
COM
*1: The output priority order in the case where several horn output conditions are met simultaneously, from highest to lowest priority, is 1. Y23, 2. Y24, 3. Y25,
4. Y26.
*2: The signal and relationship to the stop ST of each address sensor is shown in the chart below.
ST 1 (X29) 2 (X2A) 3 (X2B) 4 (X2C) 5 (X2D) 6 (X2E) Remarks
1 ON OFF OFF OFF ON OFF
2 OFF ON OFF OFF ON OFF
3 ON OFF ON OFF ON OFF
4 ON OFF OFF ON OFF ON
5 OFF ON OFF ON OFF ON
6 OFF ON OFF ON ON OFF
7 ON OFF OFF OFF OFF ON
8 OFF ON OFF OFF OFF ON
9 ON OFF ON OFF OFF ON
10 OFF ON ON OFF OFF ON
– ON OFF OFF ON ON OFF Used as a marker to begin speed reduction
10-61
COMPONENTS
10-62
Number of
No. Name Model Number Manufacturer Remarks
device points
01 CP1 Circuit protector CP31FM/20 Fuji Electric For drive power
02 CP2 Circuit protector CP31FM/5 Fuji Electric For control power
03 Regl 24 V DC Power supply NVD24SC8-U ETA Electric Control power supply 24 VDC, 5 A
04 PLC Unit 1 Programmable controller CPU FPO-C32T Matsushita Electric Works Input 16 points, output 16 points (100 mA NPN)
05 PLC Unit 2 Programmable controller I/O FPO-E32T Matsushita Electric Works Input 16 points, output 16 points (100 mA NPN)
relay MY4N-D2 DC 24 V Omron Mode switching 3A 4c contact points
07 RY1
Socket PYF-14A Omron
relay MY4N-D2 DC 24 V Omron Mode switching 3A 4c contact points
08 RY2
relay MY2N-D2 DC 24 V Omron Speed reduction switching 5A 2c contact points
09 RY3
relay RJ2S-CLD1 D24 Aidec Bumper 8A 2c contact points
10 RY4
Socket SJ2S-05B Aidec
relay RJ1S-CLD1 D24 Aidec Electromagnetic brake 12A 1c contact points
11 RY5
Socket SJ1S-05B Aidec
12 SRY1 Safety relay controller G9SB-2002-C Omron Operation ready circuit
13 SRY2 Safety relay controller G9SB-200-B Omron Obstacle sensor
Safety relay G7SA-2A2B DC 24 V Omron Travel order
14 SRY3
Socket P7SA-10F-ND Omron
15 MC1 Contactor CM2-A DC 24 V Kyoritsu Keiki Drive power supply
16 EPS Power steering unit N54F40495=1 Meidensha Steering drive
17 VR1 Variable resistor WA2W501 Japan Resistor MFG For speed adjustment 500 Ω 2 W
18 R10 Resistor MOS2C182G KOA For speed adjustment 1.8 kΩ 2 W
19 R11 Resistor MOS2C122G KOA For speed adjustment 1.2 kΩ 2 W
20 R12 Resistor MOS2C122G KOA Speed reduction speed 1.2 kΩ 2 W
21 R13 Resistor MOS2C681G KOA Speed reduction speed 680 kΩ 2 W
RY3 RY4 RY5
CP2
CP1
SRY3
VR1
PLC Unit 1 PLC Unit 2 PLC Unit 3

RY2
RY1
SRY1
CP1
MC1 SRY2
SRY3
CP1
VR1
CP2
EPC
Reg1 EPC
Reg1
RY3 RY4 RY5

10-63
Error detection
10-64
Error code list

Detection enabled period
({: Enabled, U: Display only, motion Indication
Error – : Disabled)
Description
code Stopped Stopped Ready Emerg Autom Horn Display
Manned Travelin Norma
(Ready (Ready cut* ency atic 1 Lamp 1 Others
mode g l stop
OFF) ON) ***** stop return (Error) (Error)
01 PLC error (Hardware error) – { { { { { {
02 PLC error (Setting error) – { { { { { {
Steering error LP.
03 Steering controller error – { { { { { {
0.2 second cycle ON
Emergency stop error LP.
10 Emergency stop switch operation – { { { { { {
ON
Emergency stop error LP.
11 Wireless emergency stop operation – { { { { { {
1 second cycle ON
Ready OFF
12 (Ready has turned OFF unrelated to – { { { { { {
control)
20 Bumper operation Break circuit – U U { { { { Bumper error LP. ON
Bumper error LP.
21 Width sensor Operation Break circuit – U U { { { {
1 second cycle ON
Out of course
22 (When course is not detected for 0.1 – – – { { { { Steering error LP. ON
seconds or more while traveling)
30 Obstacle sensor failure – { { { { { {
31 Obstacle sensor close detection – – – { { { { {
32 Obstacle sensor distance detection – – – { { { { {
Travel continues for 120 seconds or more
50 – – – { { { {
in inching mode
51 – – – { { { {
in travel between two points ST mode
52 – – – { { { {
in stop at multiple set points ST mode
Reduced speed travel continues for10
57 – – – { { { {
seconds or more
Detection enabled period
({: Enabled, U: Display only, motion Indication
Error – : Disabled)
Description
code Stopped Stopped Ready Emerg Autom Horn Display
Manned Travelin Norma
(Ready (Ready cut* ency atic 1 Lamp 1 Others
mode g l stop
OFF) ON) ***** stop return (Error) (Error)
Seat switch operation (A person has
60 – – U { { { {
mounted the vehicle)
61 Foot brake in operation – – U { { { {
62 Parking brake in operation – – U { { { {
Front direction (ON continuously for 2
63 – – U { { { {
seconds or more)
Rear direction (ON continuously for 2
64 – – U { { { {
seconds or more)
Battery voltage low (40 V or less)
A0 – { { { {
(Warning display only, no horn operation)
Travel command when ready is OFF
A1 – { – – { {
(Warning display only)
*: When ready off by abnormal operation occurs during traveling, an emergency stop is performed.
10-65
10-66
TROUBLESHOOTING
Trouble shooting table
No. Trouble description Described on
1 After pressing the ready switch, the vehicle cannot perform unmanned start Page 10-67
2 Even when the ready switch is pressed, it does not light up Page 10-69
3 The bumper error lamp continues to turn on or blink –
3-1 • The bumper error lamp continues to turn on Page 10-70
3-2 • The bumper error lamp continues to blink Page 10-71
4 Emergency stop lamps turns on Page 10-72
5 Obstacle sensor continues to detect Page 10-73
6 The steering error lamp continues to turn on or blink –
6-1 • The steering error lamp continues to turn on Page 10-75
6-2 • The steering error lamp continues to blink Page 10-76
7 The electromagnetic brake does not operate (does not stop the vehicle) Page 10-77
8 While not switched to unmanned mode, the power for the remote control comes on –
8-1 • Manned/unmanned selection switch inspection Page 10-78
8-2 • Power is not turned on. Page 10-79
9 The emergency stop lamp continues to blink Page 10-80
10 The vehicle will not change back to manned mode from unmanned mode Page 10-81
11 Manned mode travel speed is not appropriate Page 10-82
12 Vehicle does not stop at the correct address marker Page 10-83
13 Vehicle does not reduce speed at the speed reduction marker Page 10-84
14 The vehicle does not travel following the guide tape, and easily goes out of the course Page 10-85
15 Cannot travel in manned mode Page 10-86
16 Steering becomes heavy when traveling in manned mode Page 10-87
17 Receiver inspection Page 10-88

10-67
TROUBLESHOOTING
After pressing the ready switch, the vehicle cannot perform unmanned start
The situation recovers when

the key switch is turned back
off then turned on again
No
While the ready switch is lit up, While the ready switch is lit up, While the ready switch is lit
the LED display lamp is neither the error alarm sound up, the LED display lamp is
flashing red not the error lamp are active flashing red, and the warning
buzzer continues to beep
(slow intermittent horn)
Transmitter inspection
(Refer to 10-88)
5.Obstacle sensor inspection
(Refer to 10-73)
Vehicle is not detecting the YES Move the vehicle and allow it Does not
course to detect the course recover
No
*
B
Turn off the input from the
There is input from the OPS floor switch (standing)
YES
switch (Standing: Floor switch Turn off the input from the
Seated: Seat switch) seat switch (seated)
No
*
The direction switch (seated), Return the direction switch
YES (seated), or accelerator lever
or accelerator lever (standing)
are not in neutral state (standing) to neutral state
No
*
The battery stopper is not Lock the battery stopper
locked securely (battery YES securely, putting the battery
stopper switch is not being stopper switch into a pressed
pressed) state
No
OPS switch input state
Category ON OFF
Seat Standing up from
Seated in the seat
A (Seat switch) the seat
Upright Step on the floor Do not step on the
(Floor switch) switch floor switch
10-68
*
The parking brake is being YES Release the parking brake
pulled (return the lever)
No
*
The foot brake is being YES
stepped on (there is input to Release the foot brake
the foot brake)
No
The obstacle sensor is reacting YES Remove any obstacles from

to an obstacle the obstacle sensor detection
area
No
Stop at multiple set points

specification only:
YES Set the stop addresses with
Address selection switch is not
the address selection switch
pressed
No
Do the * parts function normally No Check the operation of the *

in manned travel mode? parts with the switch unit
YES B
Replace RY1 and RY2
With all of the emergency stop switches

turned off, perform a
continuity inspection:
CN322-3 Ù CN322-7
No continuity Continuity
Replace PLC unit Replace

No.1 emergency stop
relay RYEM
10-69
Even when the ready switch is pressed, it does not light up
The situation recovers when the key

switch is turned back off then turned on
again
No
The yellow and red lamps of the LED YES

display are blinking, and the emergency
stop lamp is turned on
No
One of the 4 emergency stop switches YES

is being pressed
No
4.Emergency stop switch Return the emergency stop

inspection switch to recover
(Refer to 10-72)
The yellow lamp of the LED display is YES

blinking
No
Ready switch inspection

Conductivity inspection of the connector
of the ready switch on the LH
instrument panel
Continuity inspection:
CN252-1 Ù CN252-2 Error
No continuity (When switch if off)
Conductivity inspection of the connector

of the ready switch on the RH
instrument panel
CN352-1 Ù CN352-2
No continuity (When switch if off)
Vehicle will not switch to unmanned
travel mode Normal:
Replace ready switch
8-1. Manned/unmanned selection Replace harness

switch inspection (Refer to 10-78)
10-70
The bumper error lamp continues to turn on

again
No
The safety bumper is being pressed by YES

Remove the obstacle
an obstacle
No
While the safety bumper is not being YES Defective adjustment of the attachment
pressed, the bumper switch is being position of the bumper switch
pressed
No
Safety bumper adjustment defect

The safety bumper cannot return all the YES
• Bumper roller sliding defect
way • Lack of grease etc.
No
Bumper switch circuit inspection

Resistance value inspection:
CN323-10 Ù CN323-11
CN323-9 Ù CN322-7
Error
Resistance 0.05Ω or less Harness defect
CN323-10 Ù CN323-9
CN323-11 Ù CN322-7
No continuity
OK
Bumper switch inspection

Bumper switch connector inspection
Continuity inspection: No
CN211-3 Ù CN211-1 continuity
Replace bumper switch
CN211-3 Ù CN211-2
CN211-3 Ù CN211-4
Continuity (When switch is off)
Continuity
Error
RY5 inspection Replace RY5
Normal:
Replace PLC unit No.1

10-71
The bumper error lamp continues to blink

again
No
The short circuit connector of CN221 or YES

Connect the short circuit connector
CN226 is disconnected
No
No
Circuit continuity check continuity
Continuity inspection: Harness defect
CN323-4 Ù CN322-7
Continuity

10-72
Emergency stop switch inspection
Emergency stop switch conductivity

inspection
Terminal Switch status

number ON OFF
Error
Replace emergency stop switch
11 to 12 × {
21 to 22 × {
31 to 32 × {
{ : Continuity × : No continuity
OK
Harness continuity check

(With key switch and emergency stop continuity
Harness defect
switch off)
CN322-9 Ù CN322-10
CN322-11 Ù CN322-12
Continuity
Replace PLC unit No.1****

Error
Replace safety relay unit

10-73
Obstacle sensor continues to detect
Obstacle sensor continues to

detect
Power lamp of the obstacle

sensor is not turned on
Check continuity of the

No
harness
continuity
CN249-1 Ù CN324-4
CN249-12 Ù N1
Continuity
RY2 defective
The obstacle sensor is
Remove any obstacles from
reacting to an obstacle YES
within the obstacle sensor
The output lamps 1, 2
detection area
(orange) are turned on
*
*: If a highly reflective obstacle (reflective
No board, mirror etc) is in the front of the
detection area, the sensor may react
even though the obstacle is outside of the
The power supply lamp of detection area
YES
the obstacle sensor (green) Obstacle sensor defect
is blinking
No
Obstacle sensor continuity

inspection No
Continuity inspection: continuity
(Output 1) Harness defect
CN249-2 Ù CN323-8
(Output 2) Obstacle sensor error display Sensor window
CN249-3 Ù CN323-7
Continuity
Display window Projector window
Output 1: Distance area obstacle

detection
Output 2: Close area obstacle
detection
Output 3: Not used
Power supply
Output 3 (green: blinks during a failure)
Output 2 Output 1
(Orange)
10-74
Continues to detect an obstacle (travel between 2 points, stop at multiple set points)
Obstacle sensor continues to

detect
The obstacle sensor display

lamp is turned on, or there is No
a display on the 7 seg
display
YES No Check continuity of the
continuity harness
Harness defect Continuity inspection:
CN249-9 Ù CN220-1
CN249-12 Ù CN220-2
The close area display lamp Remove any obstacles
YES Continuity
or the distance area display from within the
lamp is turned on obstacle sensor
Obstacle sensor defect
detection area*1
No
Remove the dirt from the *1: If a highly reflective obstacle (reflective board,
laser detection surface of mirror etc) is in the front of the detection area,
The laser detection surface YES the sensor may react even though the
the obstacle sensor.
dirt warning lamp is turned obstacle is outside of the detection area
Take measures to prevent
on *2: If the laser detection surface dirt warning lamp
reflection of an external
No light source to the is flashing at 1 second intervals, this is
sensor.*2 indicating that it is time to clean the laser
detection surface.
The situation recovers when
Also, if the laser detection surface becomes
the key switch is turned back YES Recovers
dirty then
off then turned on again
The sensor is being will display on the 7 seg display.
No
dazzled by a headlight,
strobe light, infra red light Table 1
The 7 seg display shows source or by sunlight or 7 Seg Display
either YES other external light Cause of Failure
Indication
source.
OR . Take measures to prevent Leak at CN249-2 and N1
No reflection of an external
light source to the sensor. Leak at CN249-2 and P42
Any one of the items in Table YES
Harness defect Leak at CN249-2 and N1
1 are shown on the 7 seg
display
Leak at CN249-3 and N1
No
Leak at CN249-3 and P24
Check continuity of the No
harness continuity Leak at CN249-3 and N1
Harness defect
CN249-10 Ù CN323-8 Leak at CN249-2 and CN249-3
Continuity Leak or broken circuit at
CN249-2 or CN249-31
Obstacle sensor
The 7 seg display shows
operating Close area Normal operation lamp
either YES
temperature error display lamp
. Use within the
operating
No
temperature range
of the vehicle
Obstacle sensor defect Distance area
display lamp
7 seg display Laser detection surface

dirt warning lamp
10-75
Steering error lamp display is on
The situation recovers when the key switch is

turned back off then turned on again
No
YES
The vehicle is not aligned with the guide tape Return the vehicle to the course
No
The magnetic field of the guide tape is

becoming weak YES
(Change the location and try guided travel to Replace the guide tape
see if the operation is normal or not)
No
A magnetic body is present on or under the

course (including a buried object) YES Change the course and lay a course that
(Change the location and try guided travel to is not affected by any magnetic bodies
see if the operation is normal or not)
No
A magnetic body is attached to the guide YES

sensor Remove the attached magnetic body
No
The guide sensor is not mounted at the YES

appropriate height Adjust the mounting height of the guide sensor
No
Continuity inspection of the gate output circuit

Harness defect
CN215-3 Ù CN323-15
Continuity
Guide sensor inspection

Measure the gate output voltage:
Measure with the guide sensor over the guide
Error
tape Guide sensor defect
CN323-15 Ù CN322-8
(Normal value between 23.5 V and 25.0 V
inclusive)
Normal:

10-76
The steering error lamp continues to blink

again
No
YES
The circuit protector CP1 is off Turn the circuit protector CP1 on
No
Less than
Battery low voltage error check
38 V Battery low voltage error
Check voltage across P - N
(Normal value 38 V and above)
Normal:
Steering motor overcurrent check

Measure current:
CN258-1 Ù CN321-2
13.3 A or more YES Eliminate the cause of the steering lock
The steering is locked (Inspect the steering motor)
(The tire is stuck in a groove, a foreign
object is stuck in the steering chain, or
the motor has a defect)
No
Steering motor circuit inspection

1. Check steering motor connectors
Check connectors CN258 and CN321 1. Connector connections
Error
2. Check for breaks in the circuit 2. Harness defect
CN258-1 Ù CN321-1
CN258-2 Ù CN321-2
OK
Over heat inspection

Let the vehicle sit for a short while
(approximately 30 minutes)
Does not recover
Replace the steering controller

10-77
The electromagnetic brake does not operate (does not stop the vehicle)
Travel in manned mode and check the Operates

Electromagnetic brake gap adjustment defective
operation of the electromagnetic brake.
Does not operate
Display shows electromagnetic brake

No
error, and the vehicle speed is limited to Replace RY4
5km/h
YES
Check voltage of terminal on

electromagnetic brake side
Measure voltage:
CN131-3 Ù N
Voltage 5 V or less
OK
Replace harness
10-78
Manned/unmanned selection switch inspection
Even when the manned/

unmanned selection lever is YES The retractable device does Error Retractable device height
pulled down, the retractable not lower sufficiently adjustment defective
device does not press the
Normal:
manned/unmanned selection
switch
No
The dog for pressing in the

manned/unmanned selection YES Dog adjustment defective
switch does not make
contact with the switch
Disconnect the connector of

When the manned/
the manned/unmanned
unmanned selection lever is
selection switch and check
moved to the unmanned
YES whether the vehicle goes into Error
side, the manned/unmanned Manned/unmanned selection
unmanned mode
selection switch is pressed, switch defective
(The switch circuit is open
but the mode does not switch
during unmanned mode and
to unmanned mode
closed during manned mode)
Normal:
Check for a discontinuity in

the harness No
CN226-2 Ù CN323-16
CN262-3 Ù N1
Continuity
*:
• When the manned/unmanned selection switch is not pressed when the
manned/unmanned selection lever is pressed to the unmanned side and
the retractable device is not lowered sufficiently, the vehicle will perform
manned travel.
• If the guide sensor detects a magnetic field for 3 seconds or more when
the manned/unmanned selection switch is not pressed, the course
detection lamp blinks. Check for adjustment defect.
10-79
Power is not turned on.
The remote system controller power

supply does not turn on
(Manned travel can be performed)
YES Return the circuit protector lever and

The circuit protector CP2 is off turn in on
No
Inspect battery voltage: YES

Charge the battery
Less than 38 V
No
Voltage inspection:
Across the +Vout and 0Vout terminals of No
Replace the DC-DC converter
the DC-DC converter Reg1
Between 23.5 V and 25 V inclusive
YES

10-80
The emergency stop lamp continues to blink
The emergency stop lamp continues to

blink
Transmitter stop switch failure

No
Error display continues even when the 17.Transmitter inspection
transmitter battery is removed (Refer to 10-88)
YES
Voltage inspection:
No
CN331-1 Ù CN331-6 Receiver defective
0.1 V or less
YES

10-81
The vehicle will not change back to manned mode from unmanned mode
Even when the manned/ Even when the manned/

unmanned selection lever is YES unmanned selection lever is YES
Retractable device
set to the manned side, the switched to the manned side,
adjustment defective
manned/unmanned selection the retractable device does
switch is pressed not go up
No Normal:
The dog for pressing in the

manned/unmanned selection YES
Dog adjustment defective
switch does not come away
from the switch
Check for a discontinuity in No

the harness continuity
CN226-2 Ù CN323-16
CN226-3 Ù N1
Continuity
The manned/unmanned YES

selection switch is stuck and Replace manned/unmanned
does not return selection switch
No
Inspect manned/unmanned
selection switch No
Replace PLC unit 1
CN226-2 Ù CN226-3
(When switch is on)
Continuity
Replace manned/unmanned
selection switch
10-82
Manned mode travel speed is not appropriate
Vehicle speed in unmanned

mode is abnormal
Adjust vehicle speed

adjustment dial
Adjust the vehicle speed
adjustment dial to make the
vehicle speed 3.6 km/h
Check vehicle speed in The vehicle speed in Replace vehicle speed

Slow No
unmanned mode unmanned mode is 1 km/h adjustment dial
(Variable resistor defective)
Fast YES
RY3 defective
Measure voltage of
accelerator circuit Within
Replace drive controller
CN101-30 Ù CN101-31
Standard: 3V or above
Replace vehicle speed

adjustment dial
(Variable resistor
defective)
10-83
Vehicle does not stop at the correct address marker
Vehicle does not stop at the correct

address marker
The vehicle mis-identifies a certain set No The vehicle does not stop at any of the
address marker, or skips reading it address markers
YES
No
continuity Check for breaks in the clock circuit
Harness defect Continuity inspection:
CN217-3 Ù CN341-4
Continuity
Replace address sensor

The address marker magnet has peeled YES Error
off Address marker defective
No Replace PLC unit No.3
A magnetic body is attached to the YES

address sensor Remove the attached
magnetic body
No
The attachment of the address sensor YES

deviates from regulation values Adjust the height of the
address sensor
No
Check harness continuity

CN217-2 Ù CN341-3 (A • N circuit) No
CN217-1Ù CN341-2 (A • S circuit) continuity
Harness defect
CN217-10 Ù CN341-1 (B • N circuit)
CN217-9 Ù CN341-8 (B • S circuit)
N pole: Yellow S pole: Green
CN217-8 Ù CN341-7 (C • N circuit)
Magnetic
Continuity
Marker type polarity
① ② ③
Replace address sensor Advancing direction
Address No. 1 N OFF N
Error
Address No. 2 S OFF N
Address No. 3 N N N
Address No. 4 N S S
Address Address No. 5 S S S
marker Address No. 6 S S N
Address No. 7 N OFF S
Address No. 8 S OFF S
Address No. 9 N N S
Address No. 10 S N S
Speed reduction marker N S N
10-84
Vehicle does not reduce speed at the speed reduction marker
The vehicle does not perform reduced

speed traveling correctly
The vehicle reduces speed at markers No The vehicle does not reduce speed at
other than speed reduction markers
all
YES
No Check for breaks in the clock circuit

Harness defect continuity Continuity inspection:
CN217-3 Ù CN341-4
Continuity
Replace RY3
YES
The address marker magnet has peeled Address marker defective Error
No
Replace address sensor
Error
A magnetic body is attached to the YES
Remove the attached
address sensor
magnetic body Replace PLC unit No.3
No
The attachment of the address sensor YES

Adjust the height of the address
deviates from regulation values
sensor
No
Check harness continuity No

Harness defect
CN217-2 Ù CN341-3 (A • N circuit)
CN217-1 Ù CN341-2 (A • S circuit)
CN217-10 Ù CN341-1 (B • N circuit)
CN217-9 Ù CN341-8 (B • S circuit) N pole: Yellow S pole: Green
CN217-8 Ù CN341-7 (C • N circuit)
CN217-7 Ù CN341-6 (C • N circuit) Magnetic
Marker type polarity
Continuity
① ② ③
Advancing direction
Address No. 1 N OFF N
Replace address sensor Address No. 2 S OFF N
Error
Address No. 3 N N N
Address No. 4 N S S
Address Address No. 5 S S S
marker Address No. 6 S S N
Address No. 7 N OFF S
Address No. 8 S OFF S
Address No. 9 N N S
Address No. 10 S N S
10-85
The vehicle does not travel following the guide tape, and easily goes out of the course
The vehicle does not travel following the

guide tape, and easily goes out of the
course
Check for any error of the guide tape

(Peeling off of the guide tape or Abnormal
Lay the guide tape correctly
inversion of the guide tape or magnetic
guide rod etc)
No error
Check for any buried magnetic body

Present Change the course so as not to be
(Lay the guide tape in a separate place
affected by any magnetic bodies
and check the operation)
None
The turning circle of the front wheel is

small than R1500 YES Re-lay the guide tape so that the
(The guide tape is laid with a left turn radius of turns exceeds the
tighter than R1590 or a right turn tighter regulation R
than R1410)
No
YES
The track surface is wet or has oil on it Remove water or oil
No
There is slack in the steering motor YES Adjust the tension of the steering
chain motor chain
No
The guide sensor is not mounted at the YES

Adjust the mounting height of the
appropriate height
guide sensor
No
The steering signal is not being

outputted properly Error
Guide sensor defect
Measure the output voltage:
Measure with the guide sensor over the
guide tape 0V
CN323-14 Ù N1 Harness defect
Normal value: 2 to 8 V
OK
Replace STC controller

10-86
Cannot travel in manned mode
Manned travel disabled
Cannot travel in either manned or

No unmanned mode
Unmanned travel is possible
(Electromagnetic brake does not
YES release)
YES
Error
Check operation of RY4 RY4
defective
OK
Error
Check operation of RY1 and RY2 RY1 and RY2 defective
OK

10-87
Steering becomes heavy when traveling in manned mode
Steering becomes heavy when traveling

in manned mode
Check for any error of the steering

Abnormal
motor Steering motor defective
(Abnormal noise or heat)
No error
Replace steering controller (main

circuit FET short)
10-88
Receiver inspection
Inspect remote system controller

Check whether the transmitter signal is
Horn sounds
reaching the remote system controller
with operation of the horn
*
Horn does not sound
Check the frequency and code Not Replace the transmitter

Check that the frequencies and codes matched and receiver with units
inscribed on the respective nameplates whose frequencies and
of the transmitter and receiver match codes match
Matched
Insufficient
Check the remaining battery power of Check the continuity of the harness on
power
the transmitter the vehicle
remaining Replace the batteries
Check whether the transmitter’s low Continuity inspection:
of the transmitter
battery warning lamp is on, and where CN274-1 Ù CN331-4 (Inching
No operation)
the power lamp is on continuity CN274-2 Ù CN331-3 (Transmission)
Harness defect
Sufficient power CN274-5 Ù CN331-1 (Stop)
remaining CN274-7 Ù CN331-6 (24 V)
CN274-8 Ù CN331-5 (0V)
Continuity
Does not
Check the transmission status of the
turn on:
transmitter Replace the receiver
Press the inching and continuous
switches of the transmitter and check
that the communication lamp turns on
Turns on
Check the reception status of the

receiver Does not Check the battery voltage of the
Press the inching and continuous turn on: receiver
switches of the transmitter, and check Check that the power supply voltage
that the receive lamp (LED) on the supplied to the receiver is 24 V
receiver board turns on
It is 24 V
Turns on
Check the signal from the receiver Replace the receiver

Check for the presence of a travel
command signal between the receiver
and the vehicle No signal
Replace the receiver
Current inspection:
CN331-1 Ù CN331-6 (Stop operation)
CN331-4 Ù CN331-6 (Inching *: When inspecting the transmitted and receiver, first operate the
operation) horn and check for transmission to the vehicle by whether or not
CN331-3 Ù CN331-6 (Start operation) the horn sounds.There is a high likelihood that other travel
Signal present command signals will be transmitted similarly, so this way allows
you to home in on the cause easily.

10-89
Sensors
Guide sensor
GENERAL
This sensor detects the magnetic field generated by the guide tape that is laid down on the floor for guidance, and
thereby guides the vehicle in unmanned travel.
In the guide sensor there are 28 magnetic detection elements arranged with a pitch of 5 mm [0.197 in] as shown in
the drawing below. By detecting the magnetic field generated by the guide tape, these magnetic detection elements
recognize it as an ON/OFF bit pattern.
Bit pattern
Magnetic field
Guide tape
Characteristics
• The sensor detects the magnetic field generated by the guide tape and outputs a voltage (deviation output) for
the position deviation between the guide sensor and the guide tape.
• A branching command (SEL1 and SEL2) changed the mode between straight ahead mode, right branching
mode and left branching mode, to handle a route that branches into two.
• The deviation output in straight ahead mode is not easily influenced even when the distance between the guide
sensor and the guide tape changes.
• A gate output is provided to determine that the guide sensor is within the detection range of the guide tape.
SPECIFICATIONS
Item SPECIFICATIONS
Power source voltage DC + 10.8 V + 30 V
Current consumption 30 mA Max.
-10 to +60°C [14° to 140°F]
When operating
Ambient temperature (However, no condensation or freezing)
range -20 to +70°C [-4° to 158°F]
During storage
(However, no condensation or freezing)
When operating 35 to 95% RH (However, no condensation)
Ambient humidity range
During storage 35 to 95% RH (However, no condensation)
10-90
Item SPECIFICATIONS
Detected magnet Guide tape (MGL-50 series to MGR-50 series)
Detected magnetic pole N pole (Also reacts to strong S pole of *6mT or greater)
Operating distance 5 to 40 mm [0.197 to 1.575 in]
Branching command input Branching mode is specified by input signal of SEL1 and SEL2
Branching mode SEL1 SEL2

Branching command
Straight ahead L: Short circuit across SEL1, SEL2 and

L L
mode 0V
Right branching H: SEL1 and SEL2 open circuit****
Mode specification L H
mode
When unselected: Deviation output = 5 V
Left branching
H L Gate output = OFF
mode
Non-selected H H
Input circuit Converter

Response circuit 5 ms
A voltage output for the deviation of the guide tape center and the guide
Deviation output
sensor center
Output characteristics and positional
relationship
Straight ahead
0.1878 V
mode
Right branching
Step voltage 0.375 V
mode
Characteristics
Left branching
Deviation output
0.375 V
mode
For any step voltage value ± 10 mV
Precision of output voltage
(At power supply voltage DC + 24 V, No load gate voltage, Ta = 23 °C)
Range of output voltage 2 to 8 V
Center voltage 5V
Output element Op-Amp
Allowable load resistance value 2 kΩ or more
Output circuit
Output impedance less than 6.5 Ω

Response time 5 ms
Short circuit protection Deviation output - 0 V
Gate output Output switching of guide tape detectable zone****

Left and right detection range ± 90 mm [± 3.543 in]
Zone
Operating distance 0 to 45 mm [0 to 1.772 in]

Gate output
Output logic Closed inside detection zone

Output circuit Transistor open collector output (Refer to 10-95)
Output capacity Withstand voltage: DC + 30 V max. Sink voltage****: 100 mA max.
Residual voltage 2 V Max. (At sink current 100 mA)
Response time 5 ms
10-91
Item SPECIFICATIONS
Protection structure IP67 (IEC compliant)
Insulation resistance 100 MΩ Min. (at DC 500 V Megavolts) across 0 V and the case****
Case material Aluminum
External dimensions Refer to Page 10-97
Connector 6 pin waterproof connector (Sumitomo Wiring Systems MT Waterproof series)
Weight Approx. 290 g [0.64 lb] Max. (including cord and connector)
Output cord and connections

1. Output cord
Cord used: 6 core cord
End processing: 6 pin waterproof connector
2. Connector specification
Sumitomo Wiring Systems MT Waterproof series
Housing : M(6189-6171)
Terminal : M(1500-0105)
Wire seal : (7160-8234)
Connector diagram Pin No. Wiring color Input and output signal
1 Red DC + 10.8 V to ± 30 V
2 White Deviation output
3 Brown Gate output
4 Blue SEL1 Input
5 Yellow SEL2 Input
6 Black 0V
10-92
Connection example for guide sensor
Control side, input output port etc
+V 1 Red
(DC + 10.8 to 30 V)
Withstand 30 V max
Load
voltage 100 mA max
2 White Sink current
Gate output
3 Brown
Deviation output DC +10.8
to 30 V
4 Blue
SEL1 Input
5 Yellow
SEL2 Input *Contact point input
possible
6 Black
0V
10-93
Description of operation
Deviation output
As shown in the drawing below, calculation of the ON/OFF bit pattern by the inbuilt pattern analysis circuit allows
computation of the right end position, left end position and center position of the magnetic field generated by the
guide tape.
DC + 10.8 to
V + 30 V Electrical
0V circuit Left end output Output
Deviation circuit
Center circuit circuit
SEL1 Input Right end circuit
SEL2 Input
Branching
command
Pattern analysis circuit Gate circuit
input
Switch circuit
Magnetic detection elements
Guide tape
1. Straight ahead mode

Straight ahead mode is specified on a guide route that has no branching routes. In straight ahead mode the
center is calculated from the left end position and right end position of the ON bit pattern of the magnetic
detection switch. The output voltage of the deviation output is determined based on this position.
The number of ON bit patterns detected by the magnetic switch varies depending on the operating distance of
the guide sensor to the guide tape and the magnetic environment of the guidance route.
As the magnetic field generated by the guide tape is not generated vertically straight, but has a balloon form as
shown in the bit pattern diagram (Refer to 10-89), the number of ON bits changes as the operating distance
between the guide sensor and the guide tape becomes closer or more distant.
However, if the generated magnetic field has lateral symmetry then the center position is the same regardless
of the number of ON bits.
In other words, the center position can be detected regardless of the operation distance.
2. Right branching mode
The device switches into right branching mode directly before a branching route. The deviation output is
determined by the right end position of the ON bit pattern.
However, the output is not along the right end position of the guide tape, but the position at 1/2 way to the
center**** of the width of the guide tape.
Also, because in right branching mode only the right end of the ON bit pattern is monitored, if there is a change
in the operation distance as with the straight ahead mode, some displacement may occur.
10-94
3. Left branching mode

The device switches into left branching mode directly before a branching route. The deviation output is
determined by the left end position of the ON bit pattern.
However, the output is not along the left end position of the guide tape, but the position at 1/2 way to the
center**** of the width of the guide tape.
Also, because in left branching mode only the left end of the ON bit pattern is monitored, if there is a change in
the operation distance as with the straight ahead mode, some displacement may occur.
Gate output
The gate output is switched ON if even 1 of the 28 magnetic detection elements detects ON.
If the guide sensor comes away to the left or right from the guide tape, or if the sensor moves significantly away from
the correct operation distance and all the magnetic detection elements turn OFF, the gate sensor output turns OFF.
Also, since the gate output uses the same pattern analysis circuit as the deviation output, it cannot be used as an
operation error detection for the guide sensor.
10-95
Input and output circuit

Branching command input circuit SEL1 and SEL2
+ V (DC + 10.8 to + 30 V)
4.7 kΩ 10 kΩ
30 kΩ
Converter
SEL1
6 Black 10 kΩ
0V
SEL2 (Blue) input circuit is the same
Deviation output circuit
+ V (DC + 10.8 to + 30 V)
30 kΩ
100 kΩ
- 2 White
Deviation output
+
6 Black
0V
*Overcurrent protection element
(6.5 Ω max. @23 °C)
Gate output circuit
*Overcurrent protection
3 Green
element Gate output
(6.5 Ω max. @23 °C)
Vz = 33 V
6 Black
0V
2SC2882Y or
equivalent product
10-96
When installing the guide sensor, install the guide sensor in an position away from parts other than the magnetic
guide tape that generate a magnetic field (electric motors, electromagnetic brakes etc).
Furthermore, install the guide sensor on a non-magnetic attachment angle bracket.
However, if strong magnetic bodies such as iron must be present in the periphery of the guide sensor attachment
part, they may disturb the magnetic flux distribution from the magnetic tape, and adversely affect the accuracy of
detection. In such cases, provide a space of at least the dimensions shown in the table below.
Moreover, use non-magnetic screws for attaching the guide sensor.
Unit: mm [in]
10-97
Guide sensor external dimensions

Unit: mm [in]
6 pin waterproof 6 core cord
2-φ5 mounting holes
Detection
surface
10-98
Internal circuit
30 V max / 100 mA max
Power supply 1 Red
Load
Gate output 2 White
Deviation 3 Brown
DC + 10.8 to V + 30 V
SEL1 Input 4 Blue
SEL2 Input 5 Yellow
Power supply 6 Black
With contact point input possible
Cautionary points in handling

• Wire the input and output cord correctly. Incorrect wiring may destroy the guide sensor.
• Use a power supply voltage within the regulation voltage.
• Use a deviation output and gate output that are within the allowable capacity.
• Give consideration so that noise or excessive surge etc is not applied to the deviation output, gate output and
branching command input (SEL1 and 2).
• If the input cord is wired with the motive power and electric power cables there is a possibility of causing
malfunction, and in some cases this may cause unstable voltage in the deviation output also. Therefore, have
measures in place for the input cord on the input device side.
• Do not attach any source of magnetic field (motor etc) in the periphery of the guide sensor.
• Take care not to pull hard on the input and output cord, or to bend it back on itself, as there is a risk of breaking
a wire.
• This product is of waterproof construction IP67, however waterproof construction has not been used at the cord
terminals, therefore avoid use in which the device will be constantly immersed.
• Be wary of chemicals and solvents (thinners, acetone etc), and corrosive gas as there is a risk that these could
deform the case and the input cord.
10-99
Address sensor
GENERAL
The address sensor contains 3 pairs of highly sensitive magnetic sensors consisting of a N pole detecting element
and an S pole detecting element, and outputs a clock signal for a 6 bit data signal and read timing.
When a mark magnet approaches the center of the address sensor each detection element detects information.
When the detector elements A and C on both sides of the spot mark reader change to ON state, the clock signal is
outputted, and the read information of each detecting element is outputted according to the timing of this clock signal.
SYSTEM CONFIGURATION
Clock circuit section

Clock signal output
A. N pole signal output
A A. S pole signal output
B. N pole signal output
B B. S pole signal output
C. N pole signal output
C C. S pole signal output
Detecting Switch circuit Interface circuit section

elements
10-100
SPECIFICATIONS
Item SPECIFICATIONS
SMR-300H-I7C015P1
Power source voltage DC + 24 V ± 10% Ripple 1% or less
Operating temperature and humidity -10 to + 50 °C [14°F to 122°F] • 30 to 90% RH
range (No freezing or condensation)
Storage temperature and humidity -20 to +60 °C [-4°F to 140°F] • 30 to 90% RH
range (No freezing or condensation)
Protection structure IP67 (IEC standard)
Detected magnet SMG-300
Operating distance 20 mm to 40 mm [0.79 to 1.57 in] when using SMG-300
Displacement from track ± 10 mm or less [± 0.39 in]
N pole detection element 0.6 to 0.7 mT *1
A-C
Detection S pole detection element 0.6 to 0.7 mT *1
sensitivity N pole detection element 0.4 to 0.5 mT *1
B
S pole detection element 0.4 to 0.5 mT *1
Output type Transistor open collector output (normal open)
Output capacity Withstand voltage: DC + 30 V Max. Sink current: 50 mA max.
Output signal
Response time 1 ms or less
Output circuit Refer to output circuit diagram
SPECIFICATIONS φ7 twisted pair multi**** cable
Output cord Cord length 150 mm [5.91 in]
Connector type 10 pin waterproof connector: Tyco AMP Econoseal J series *2
Weight 355 g [0.783 lb]
Insulation resistance 100 MΩ Min. (across the case and 0V ****, at DC 500 V Megavolts)
*1: When approaching opposite polarity, mis-detection at approximately 4mT (40G).

*2: Connector specified by user.
Output circuit diagram
Clock, data output diagram
OUT
10-101
Output cord and connections

1. Output cord
Cord used: 10 core Multiple core cord
End processing: 10 pin waterproof connector (Tyco AMP)
2. Connector specification
Tyco AMP Econoseal J series
Housing : 174657-2
Double lock plate : 174658-7
Contactor : 173600-1
Rubber plug : 172746-1
Connector diagram Pin No. Input and output signal
1 DC + 24 V ± 10%
2 0V
3 Clock signal output
4 A • N pole signal output
5 A • S pole signal output
6 B • N pole signal output
7 B • S pole signal output
8 C • N pole signal output
9 C • S pole signal output
10 N.C.
3. Connection
The basic connection example for the spot mark reader is shown below.
DC + 30 V / 50 mA Max.
SMR-300H-I7C015P1
1
3
Load
4
Load
DC + 24 V
Main
circuit 0V
9
Load
Note:
When a relay or other inductance load is used, be sure to insert a diode to prevent reverse voltage and a
spike killer.
10-102
Attaching the spot mark reader

1. Environment for attaching the spot mark reader
When attaching the spot mark reader, attach it in a position away from objects that generate a magnetic field
(motors etc). Furthermore, when iron or other magnetic bodies are close to the spot mark reader, the magnetic
flux distribution is disturbed and the accuracy of the detectors is adversely affected. In such cases, provide a
space of the dimensions shown in the table below around the periphery of the spot mark reader.
The left and right mounting holes of the spot mark reader unit are to be attached to a smooth flat surface.
Furthermore, the angle mounting brackets used should be of non-magnetic material (brass, aluminum, SUS304
etc).
Peripheral space for the spot mark reader when the periphery includes magnetic bodies
d1 = 40 mm [1.57 in] or more, d2 = 20 mm [0.79 in] or more, d3 = 30 mm [1.18 in] or more
Mounting angle
bracket
Magnetic body Magnetic body
Non-magnetic
body
d3
d2
d1 d1 d1 d1
2. Allowable angle for mounting the spot mark reader

Attach the spot mark reader so as to fulfill the following conditions.
θ1 = with in ± 1°, θ2 = with in ± 1°
θ1
θ1
Detected magnet Detected magnet

θ2
10-103
Spot mark reader external dimensions

Unit: mm [in]
10 pin waterproof connector

10 core shielded cord φ7
Heat shrink tube
A B C
Detection Detection
position surface
Internal circuit
DC + 30 V / 50 mA Max.
Power supply 1
Load Load Load Load
Clock signal output 3

A • N pole signal output 4
DC + 24 V ± 10
A • S pole signal output 5
C • S pole signal output 9

Power supply 2
10-104

• When connecting a relay or other inductance load to the output, insert a diode to prevent reverse voltage and a
spike killer into the source.
• Wire the output cord correctly.Incorrect wiring may destroy the spot mark reader.
• Take care not to apply excessive tension to the output cord, or to bend it back on itself, as there is a risk of
breaking a wire.
• If the output cord is wired together with power or electrical cables it may cause malfunction. Wire it separately.
• Do not allow power lines carrying large current or magnetic field sources (motors etc) near to the periphery of
the spot marker reader.
• This product is of waterproof construction IP67, however waterproof construction has not been used at the cord
terminals, therefore avoid use in which the device will be constantly immersed.
• Be wary of chemicals and solvents (thinners, acetone etc), as there is a risk that these could deform the case
and the cord.
10-105
Setting addresses for stopping at multiple set points

GENERAL
Stop position addresses are comprised of N pole and S pole marker
magnets and can configure 12 different codes.
Marker magnets
The marker magnets may have 2 values (N pole and S pole) at both
ends, and 3 values (N pole, S pole and nothing) in the center.
In this way, 2 × 3 × 2 = total 12 codes are configured.
10-106
Auxiliary marker magnet

N pole auxiliary
The 3 values of the center part are obtained by N pole, S pole and
marker
nothing, however in the case of nothing, a magnetic field is
produced from the influence of the adjacent magnet and this may
cause malfunction.
Auxiliary marker magnets work to counteract the above magnetic
fields to prevent malfunction.
S pole auxiliary
marker
Address code number table

The marker magnets are in the order A, B, C when the direction
arrow is oriented to the left.
The address code numbers of the address magnet plates, and the
marker magnet combinations are as shown below.
Marker magnet arrangement

Address code No.
A B C
No. 1 N n N
No. 2 S – N
Reference No. 3 N N N
Type Polarity Color
symbol
No. 4 N S S
N N Yellow
Marker magnets
S S Green No. 5 S S S
Auxiliary marker n N Yellow No. 6 S S N

magnet s S Green No. 7 N – S
No. 8 S s S
No. 9 N N S
No. 10 S N S

10-107
Arrangement interval for address magnet plates
SMG-300 SMG-300
300 mm [11.8 in] or more
If address magnet plates are arranged closely together there is a risk that the spot mark reader might detect
alternating address magnet plates and malfunction. Separate the plates 300 mm [11.8 in] or more as shown in the
drawing.
Address magnet plate external drawing

Unit: mm [in]
Laminated marker magnets
Base SPC
10-108

• If a strong magnetic body (iron plate, iron frame etc) is within a 300 mm [11.8 in] periphery of the address magnet
plate, the magnetic flux density distribution will be altered. Depending on the degree of change in the magnetic
flux density distribution, the stop mark reader SMR300 series may mis-read.
• Remove such magnetic bodies at least 300mm [11.8 in] from the magnetic tape also.
• Do not install the address magnet plate on top of an iron plate.The influence of the residual magnetic field may
cause mis-detection.The same applies when there is an iron frame underneath the installation surface.
• If a magnet (magnet with surface flux density of 100 mT or more, magnetic screw driver etc) is allowed close to
the address magnet plates, there is a risk that the magnetic flux density distribution could change.
• If iron particles, iron filings, or other magnetic bodies become attached to the surface of the address magnet
plates, they may influence the magnetic flux density distribution.Periodically remove and attached objects.
• A small degree of partial damage (scratching or denting) to the surface laminate film will not cause a problem.
However, if the laminate film is lost through continuous wear and moreover the dimensions of the magnet layer
are seen to change through wear, then the magnetic flux density distribution will be affected.
• When mechanically protecting the surface of the address magnet plate, select a non-magnetic material.
• The plates cannot be used in an environment where they will be exposed to machining oil, lubricating oil or
solvents (methanol, thinners etc). If any such substance should happen to come into contact with the plates,
remove it quickly.
10-109
Stop sensor
GENERAL
Unit: mm [in]
Detection
surface M12 x 1 Operation display lamp
10-110
SPECIFICATIONS
Item Standard
Power supply voltage DC + 12 to 24 V Ripple 1% or less
(Voltage variation range) DC + 10 to 30 V
Set detection sensitivity 0.8 mT ± 0.1 mT
Output type NPN open collector (normal open type)
Output capacity DC 30V 30 mA Max.
Response time 0.3 ms or less
Detected object Magnet (S pole)
Hysterisis 0.03 mT Max.
Circuit protection Reverse power supply connection, output surge
Display Lamp Red LED
-10 to + 50 °C [14 to 122 °F]
Operating temperature range
(But no freezing or condensation)
Operating humidity range 10 to 90% RH
Temperature influence 0.05 mT/10 °C or less
Insulation resistance DC 500 V 100 MΩ Min. (Energized section and external metal mounting)
Withstand voltage AC 1000 V 1 min (Energized section and external metal mounting)
Vibration Endurance: 10 to 55 Hz Double amplitude 1.5 mm 2 times each in X,Y and Z directions
Shock 50 G 3 times in X,Y and Z directions
Protection structure IP-65 or equivalent product
Nut tightening torque 0.78 N • m (8 kgf • cm) [0.58 ft • lbf]
Nut locking agent Recommended: ThreeBond 1401
5.1 flexible PVC/gray matt
Input and output cable
Conductor structure: 17/0.16 (0.3 mm2 [0.0005 in2] or equivalent product)
Brown: DC+
Input and output cable description Blue: 0 V
Black: Output
Connector specification
Sumitomo Wiring Systems 090 type waterproof 4P connector
Connector diagram Pin No. Input and output signal
1 DC + 24 V ± 10%
2 0V
3 Clock signal output
4 A • N pole signal output

10-111
Connection diagram
Brown
Load
Magnet detection Circuit
Black
DC power supply
Blue
10-112
Signal horn
GENERAL
WIRING DIAGRAM
10-113
Signal horn connection procedure
* Match the terminal symbols of the signal horn to the tag symbols on the harness side when assembling.
10-114
Removal Procedure
Signal horn 1. Remove the grommet from the cover.
Cover
Grommet
2. Remove the cover attachment bolts. (Two bolts)
Bolt
Bolt
3. Remove the signal horn W/bracket. (Four bolts)

Bracket Bolt
Signal
horn
Signal horn 4. Remove the harness from the signal horn following the
procedure below.
(1) Remove the plastic cover.
(2) Remove the harness.
Connector Plastic cover

10-115
5. Remove the signal horn from the bracket following the

procedure below.
Metal (1) Remove the metal mounting pieces.
pieces
(2) Remove the signal horn.
10-116
Switches and Lamps

Course detection
56550-40600-71
Pilot lamp (White) Harness
Emergency stop / bumper error / steering error
56590-02771-71
Red tape
Emergency stop Yellow tape
Bumper error
Blue tape Harness
Steering error
Pilot lamp (Red)
Emergency stop Bumper STEERING

L+ 3 31 32
L- 4 1 2
Terminal
arrangement
10-117
Ready switch
57440-40600-71
Illuminated switch (Green) Harness
Terminal arrangement
Reset switch
57420-40600-71
Harness
Non-illuminated switch (Yellow)
10-118
Address selection switch

57430-02771-71
Red tape
Panel upper stage
Blue tape
Panel lower stage

Illuminated switch (White)
SW1 SW2 Connected
(a) 3 4 LED PLC
(b) 1 11 LED 24 V
(c) 2 21 SW N1
(d) 5 6 SW PLC
LED Display Lamp

mm [in]
Yellow
Red
White
O (Yellow LED) R (Red LED)
Lights
(Rated voltage AC/DC 24 V) W (White LED) Y (Power supply)
Harness
10-119
Rear tower
GENERAL
Specification for inching operation and travel between 2 points operation
Antenna
Rear combination lamp
Receiver LED Display Lamp

Front cover
Under cover

10-120
Stop at multiple set points specification
Antenna
Rear combination lamp
Receiver
LED Display
Ready switch Lamp
Address selection switch Under cover
Ready switch
Ready switch

10-121
Terminal
Wiring color
number
21 R
R (Wound with black
22
tape)
13 O
14 Y
31 G-Y
O (Wound with black
32
tape)
X2 B
X1 GR
10-122
1. Park the vehicle on flat ground, and chock the wheels.
3. Open the battery hood
4. Temporarily suspend the rear tower.
Rear tower
5. Disconnect the wiring.
Rear tower
Wiring
6. Remove the 6 mounting bolts for the rear tower.

Rear tower mounting bolts
10-123
7. Hoist the rear tower.

Rear tower
8. Remove the rear tower bracket.

(Four bolts)
Rear tower bracket
9. Remove the under cover.
Under cover
10. Remove the address selection switch.

(For stop at multiple set points specification)
Address Remove the front cover.
selection switch
(For inching operation and travel between 2 points
specification)
10-124
11. Remove the receiver.
Receiver
12. Remove the antenna.

Antenna
LED Display Lamp 13. Remove the LED display lamp.
14. Remove the emergency stop switch.
Emergency
stop switch
10-125
Procedure for setting receiver frequency and code

If a new supplementary receiver needs to be set to the frequency and code of a vehicle because the original receiver
failed or was lost, follow the procedure below.
Cautionary points when performing setting operation

Be sure to observe the following points to ensure safety when performing the setting.
DANGER:
When performing the setting operation, make sure that the vehicle power is switched OFF.
If the operation is performed with the vehicle power on, their is a risk that the vehicle might start moving due to
unintended transmission of electromagnetic wave.
Furthermore, operations should be performed with the battery removed from the transmitter, except for the
operation of checking after setting.
Prohibited:
Do not change any settings of the DipSW other than the frequency and code of the transmitter.
There is a risk that remote control travel will be disabled, or that unintended travel may occur.
Method for setting frequency and code

1. Transmitter
(1) Disconnect the battery plug of the vehicle whose frequency and code are to be set, and remove the key.
(2) Remove the battery from the transmitter, remove the 4 screws from the reverse side of the transmitter, and
remove the rear cover.
(3) Set the DipSW of the transmitter to the corresponding frequency and code, making reference to the
Frequency setting table, (Refer to 10-130) and the Code setting table, (Refer to 10-132) .
(4) Reattach the rear cover of the transmitter with the 4 screws, and re-insert the battery.
(5) In a safe place, turn the vehicle power ON. and operate the transmitter to check that the vehicle responds
correctly to commands.
(At this point initial supply of power may trigger memory processing, so that the vehicle may not move for
just the first operation).
(6) Write the set frequency and code on the nameplate in indelible marker pen so they cannot be erased, and
fix the nameplate to the rear cover of the transmitter.
2. Receiver
(1) Disconnect the battery plug of the vehicle whose frequency and code are to be set, and remove the key.
(2) Remove the 2 screws from the front side of the receiver and remove the front cover.
(3) Set the DipSW of the receiver to the corresponding frequency and code, making reference to the Frequency
setting table, (Refer to 10-130) and the Code setting table, (Refer to 10-132) .
(4) Reattach the front cover of the receiver with the 2 screws.
(5) In a safe place, turn the vehicle power ON and OFF once, then, turning the vehicle ON again, operate the
transmitter to check that the vehicle responds correctly to commands.
(Turning the vehicle power ON then OFF once is to allow the memory processing to be carried out on initial
supply of power).
(6) Write the set frequency and code on the nameplate in indelible marker pen so they cannot be erased, and
fix the nameplate to the front cover of the receiver.
10-126
Specification frequency table

No. IV V
STD/OPT (code) STD OPT (E55D)
58535-40600-71 58545-40600-71
Transmitter No.
58735-40600-71 58745-40600-71
Receiver No. 58635-40600-71 58645-40600-71
Wireless modem STD-302N-R-434 STD-302N-R-869
Frequency band 434 MHz band 869 MHz band
433.075 to 868.025 to
Frequency range
434.775 MHz 869.975 MHz
Number of channels 69 79
STEP 25 kHz 25 kHz
Number of codes 8,192 8,192
Number of combinations 565,248 647,168
Frequency DipSW 7Bit (Max.128)
Code DipSW 13Bit (Max.8,192)
10-127
Setting frequency and code

Frequency and code setting DipSW section
Inside the transmitter Inside the receiver
Harness
Base plate
Wireless 9V
module battery
DipSW Base plate
Antenna
Wireless
module
DipSW
DipSW details
ON position
OFF position
Frequency selection DipSW ID code selection DipSW

6Bit (7Bit) 14Bit (13Bit)
10-128
Transmitter - (Rear cover)
Nameplate
Write frequency
Write code No.

10-129
Receiver - (Front cover)
Nameplate
Write frequency
Write code No.

10-130
DipSW frequency setting table
IV
STD-302N-R 434 MHz frequency setting
(Transmitter: 58535-40600-71, 58735-40600-71) (Receiver: 58635-40600-71)
SW setting SW setting
Channel setting Frequency (MHz) Channel setting Frequency (MHz)
①②③④⑤⑥⑦ ①②③④⑤⑥⑦
0 433.075 35 433.950
1 433.100 36 433.975
2 433.125 37 434.000
3 433.150 38 434.025
4 433.175 39 434.050
5 433.200 40 434.075
6 433.225 41 434.100
7 433.250 42 434.125
8 433.275 43 434.150
9 433.300 44 434.175
10 433.325 45 434.200
11 433.350 46 434.225
12 433.375 47 434.250
13 433.400 48 434.275
14 433.425 49 434.300
15 433.450 50 434.325
16 433.475 51 434.350
17 433.500 52 434.375
18 433.525 53 434.400
19 433.550 54 434.425
20 433.575 55 434.450
21 433.600 56 434.475
22 433.625 57 434.500
23 433.650 58 434.525
24 433.675 59 434.550
25 433.700 60 434.575
26 433.725 61 434.600
27 433.750 62 434.625
28 433.775 63 434.650
29 433.800 64 434.675
30 433.825 65 434.700
31 433.850 66 434.725
32 433.875 67 434.750
33 433.900 68 434.775
34 433.925
: ON : OFF
10-131
V
STD-302N-R 869 MHz frequency setting
(Transmitter: 58535-40600-71, 58735-40600-71) (Receiver: 58635-40600-71)
SW setting SW setting
Channel setting Frequency (MHz) Channel setting Frequency (MHz)
①②③④⑤⑥⑦ ①②③④⑤⑥⑦
0 868.025 40 869.025
1 868.050 41 869.050
2 868.075 42 869.075
3 868.100 43 869.100
4 868.125 44 869.125
5 868.150 45 869.150
6 868.175 46 869.175
7 868.200 47 869.200
8 868.225 48 869.225
9 868.250 49 869.250
10 868.275 50 869.275
11 868.300 51 869.300
12 868.325 52 869.325
13 868.350 53 869.350
14 868.375 54 869.375
15 868.400 55 869.400
16 868.425 56 869.425
17 868.450 57 869.450
18 868.475 58 869.475
19 868.500 59 869.500
20 868.525 60 869.525
21 868.550 61 869.550
22 868.575 62 869.575
23 868.600 63 869.600
24 868.625 64 869.625
25 868.650 65 869.650
26 868.675 66 869.675
27 868.700 67 869.700
28 868.725 68 869.725
29 868.750 69 869.750
30 868.775 70 869.775
31 868.800 71 869.800
32 868.825 72 869.825
33 868.850 73 869.850
34 868.875 74 869.875
35 868.900 75 869.900
36 868.925 76 869.925
37 868.950 77 869.950
38 868.975 78 869.975

10-132
39 869.000
: ON : OFF Not available
DipSW code setting table

SW setting
Code Remarks
①②③④⑤⑥⑦⑧⑨⑩⑪⑫⑬⑭
00000
00001
00002
00003
00004
00005
00006
00007
00008
00009
00010
08191 Export (Max. 8,192 types)****
: ON : OFF
11-1
APPENDIX
Page 0
SST LIST .......................................................... 11-2
1
SERVICE STANDARDS................................... 11-4
CONNECTION DIAGRAM................................ 11-7
2
WIRING DIAGRAM .......................................... 11-9 3
CONNECTOR DIAGRAM............................... 11-13 4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
11-2
SST LIST
Section
Illust Part No. Part name
1 2 3 4 5 6 7 8 9 10
Lock nut remover

09310-10330-71 {
and replacer
09320-23000-71 Bearing remover {
Lock nut remover

09340-10330-71 {
and replacer
09410-40150-71 Bearing replacer {
09420-40590-71 Pinion nut {
09430-40590-71 Bearing remover {
09561-40590-71 Shorting harness {
Brake hold down

09510-31960-71 spring remover {
and replacer
11-3
Section
Illust Part No. Part name
1 2 3 4 5 6 7 8 9 10
09700-30200-71
Spring pin tool
remover
{ 0
1
09717-76001-71
(09717-20010)
Brake shoe
return spring {
2
remover
3
09718-76001-71
Brake shoe
return spring {
4
(09718-20010)
remover
5
09950-76013-71
6
Puller B set { { {
(09950-40010)
7
09950-76018-71
8
Replacer A set { { {
9
(09950-60010)
10
09950-76020-71
Handle set { { {
(09950-70010)
11
12
25009-13200-71 Battery hanger {
13
14
15
16
17
18
11-4
SERVICE STANDARDS
BATTERY
Item All Models
Specific gravity upon complete recharging (reference) (at 20°C [68°F]) 1.280
Specific gravity upon end of discharge (reference) (at 20°C [68°F]) 1.150
Voltage upon end of discharge V 42.5
Insulation resistance MΩ 1 or more
CONTROLLER
Item All Models
Traveling controller
F1 (fuse for drive circuit) A 175
F4 (fuse for lamp circuit) A 10
F5 (fuse for control circuit) A 10
Insulation resistance (at 500 VDC) MΩ 10 or more
Tightening torque N·m (kgf·cm) [ft·bt]

Cable terminal Standard 7.8 to 11.8 (80 to 120) [5.79 to 8.69]
ACCELERATOR PEDAL
Item 4CBT2R • 3R • 4CBTK4R
Pedal operated ∞Ω
Continuity check of acceleration sensor Ω
Pedal not operated Continuity
ACCELERATOR
Item 4CBTY2R • K4R
Limit switch continuity (tester range × 1k) Ω See P3-16 in this manual
FLOOR SWITCH
Item 4CBTY2R • K4R
Amount of protrusion of floor switch mm [in.] 25 [0.98]
DRIVE MOTOR
Item All Models

Drive motor set bolt Standard 68.6 to 88.2 (700 to 900) [50.6 to 65.1]
11-5
FRONT AXLE
Item 4CBT2R • 3R • K4R 4CBTY2R • 4CBTYK4R
Front axle hub starting force (at hub bolt) N (kgf) Standard 14.7 to 34.3 (1.5 to 3.5)
Minimum rotation radius mm [in.] 1600 [64.0] 0

Castle nut Standard 29.4 to 49 (300 to 500) [21.7 to 36.2] 1
DRIVE UNIT AND REAR AXLE 2
Ring gear starting force
Item
N·m (kgf·cm) [ft·bt] Standard
All Models
0.49 to 0.99 (5.0 to 10.0) [0.4 to 0.7]
3
Backlash between drive pinion and ring gear
Starting force of drive pinion

mm [in.]
N·m (kgf·cm) [ft·bt]

Standard
Standard
0.10 to 0.15 [0.004 to 0.006]
0.49 to 0.99 (5.0 to 10.0) [0.4 to 0.7]

4
Tightening torque N·m (kgf·cm) [ft·bt] 5
Rear axle set bolt Standard 68.6 to 88.2 (700 to 899) [51 to 65]
Front cover and rear cover set bolt Standard 20 to 30 (204 to 306) [14.8 to 22.1] 6
WHEELS 7
Item
Pneumatic
Tire size
3.50-5-6PR
Tire pressure
700 kPa (7.0 kgf/cm2)

8
Front
Non-puncture 3.50-5 —
9
Pneumatic 4.00-8-6PR 700 kPa (7.0 kgf/cm2)
Rear
Non-puncture 4.00-8 — 10
Front wheel hub nut Standard 34.0 to 68.6 (350 to 700) [25 to 51] 11
Rear wheel hub nut Standard 88.2 to 156.8 (900 to 1600) [65.1 to 115.7]
12
STEERING
Item 4CBT2R • 3R • 4CBTK4R 4CBTY2R • 4CBTYK4R

13
Steering gear ratio 1:4 —
14
Steering wheel set nut Standard

25 to 45 (255 to 460)
[18.4 to 33.2]
— 15
Tilt lock lever set bolt Standard
10 to 14 (102 to 142)
[7.4 to 10.3]
— 16
Universal joint set bolt Standard
5 to 7 (50 to 70)
[3.6 to 5.0]
10 to 15 (102 to 153)
[7.2 to 10.8] 17
18
11-6
BRAKE
Item 4CBT2R • 3R • 4CBTK4R 4CBTY2R • 4CBTYK4R
Service brake
Standard 20 [0.79]
Shoe hold down spring mm [in.]
Limit 18 [0.71]
Standard 30 [1.18]
Actuator spring mm [in.]
Limit 27 [1.06]
Standard 81.7 [3.217]

Shoe return spring mm [in.]
Limit A gap is present between the coils
Standard 20 [0.79]
Strut to shoe spring mm [in.]
Limit 18 [0.71]
Standard 60 [2.36]
Adjuster spring mm [in.]
Limit A gap is present between the coils
Standard 3.95 [0.156]

Brake lining thickness mm [in.]
Limit 1.0 [0.04]
Clearance between wheel cylinder and piston mm [in.] Standard 0.18 [0.007]
Standard 203.2 [8.00]

Brake drum inside diameter mm [in.]
Limit 205.0 [8.07]
Parking brake
Number of notches in parking brake lever operation 3 to 5
Brake pedal
128 to 133 162 to 167
Clearance between toe board and pedal (with a pad) mm [in.]
(5.03 to 5.24) (6.38 to 6.57)
Pedal play mm [in.] 5 to 10 (0.2 to 0.39)
Pedal remaining depression margin mm [in.] — 10 (0.39)
Push rod play mm [in.] 1 to 2 (0.04 to 0.08)
Electromagnetic brake hub width accross flats mm [in.] Standard 27 [1.06]
Standard 9.0 [0.35]

Inner disc thickness mm [in.]
Limit 7.8 [0.31]
Standard 0.3 [0.012]

Clearance mm [in.]
Limit 0.6 [0.024]

Wheel cylinder set bolt Standard 4.22 to 6.18 (43 to 63) [3.1 to 4.6]
Brake pedal set bolt Standard 29.4 to 44.1 (300 to 450) [21.7 to 32.6]
Backing plate set nut Standard 88.26 to 117.68 (900 to 1200) [65.1 to 86.8]
11-7
CONNECTION DIAGRAM
Stop at Travel
multiple set between
Hazard light points two points
switch specification specification
Width sensor
Width sensor ready type (RH)
ready type (LH)
Battery slide out
Advance/reverse chime
Reverse buzzer ****

Remote inching Traveling between Stop at multiple set
function two points function points function
Remote unmanned start
device not specified
Remote unmanned
start device
* When the specification with remote unmanned start device is selected, the start SW for travel
between two points function and stop at multiple set points function is fitted to the remote
controller.
denotes OPT features
11-8
4CBTY2R • 4CBTKY4R
Stop at Travel
multiple set between
Hazard light points two points
switch specification specification
Width sensor
Width sensor ready type (RH)
ready type (LH)
Battery slide out
Advance/reverse chime
Reverse buzzer ****

Remote unmanned
start device
controller.
11-9
WIRING DIAGRAM
4CBT2R • 3R • 4CBTK4R (STD)
Travel between two points specification Width sensor ready type
OPT: Speed reduction (for travel between two

points, stop at multiple set points)
When start switch is present, (E03D) is not fitted
OPT: Stop at multiple

set points specification

OPT:Battery roll out****
OPT: Hazard switch

Remote unmanned
start device
controller.
OPT:Reverse buzzer **** OPT:Forward and reverse chime
11-10
4CBT2R • 3R • 4CBTK4R (Travel between two points, stop at multiple set points specification)
OPT: Speed reduction (for travel between two



OPT:Battery roll out****
OPT: Hazard switch

Remote unmanned
start device
controller.
OPT:Reverse buzzer **** OPT:Forward and reverse chime
11-11
4CBTY2R • 4CBTKY4R (STD)

Stop at multiple set

points specification

Battery roll out****
Hazard switch

Remote unmanned
start device
controller.
Reverse buzzer **** Forward and reverse chime
11-12
4CBTY2R • 4CBTKY4R (Travel between two points, stop at multiple set points specification)
OPT:Speed reduction (for travel between two



Battery roll out****
OPT:Hazard switch

Remote unmanned
start device
controller.
Reverse buzzer **** Forward and reverse chime denotes OPT features
11-13
CONNECTOR DIAGRAM
4CBT2R • 3R • 4CBTK4R (Inching operation specification)
CN1:Display CN8:Turn & light SW
CN3:Horn SW
CN5:Stop lamp SW
CN9:Direction SW.
CN6:Brake SW
11-14
CN12:Flasher relay CN18:Reverse buzzer ****
CN13:Hazard SW CN26:Acceleration sensor
CN14:Head lights
CN28:Acceleration sensor
CN15:Parking SW
CN29:Key SW
CN16:Mode SW
CN34:RR combination lamp****
CN17:Forward and reverse chime

11-15
CN41:Diode CN52:Thermo-sensor
CN42:Seat SW harness CN53:Vehicle speed sensor No.1
CN54:Vehicle speed sensor No.2

CN43:Battery stopper SW
CN45:Head light relay
CN46:Tail light relay
CN50:Storobo lamp
11-16
CN101:Travel controller No.1 CN102:Travel controller No.2
CN120:FR harness connection No.1

11-17
CN123:FR harness connection No.2 CN134:RR combination RH
CN137:Contactor panel No.2
CN140:Error clear
CN141:Diag. ****
CN131:Electromagnetic brake harness
CN133:RR combination LH
11-18
CN150:RH Instrument panel harness No.1 CN211:Bumper SW RH
CN216:Stop sensor
CN151:RH Instrument panel harness No.2
CN217:Address sensor
CN152:Fuse
CN218:Guide sensor
CN210:Bumper SW LH
11-19
CN220:Horn signal CN249:Obstacle sensor
CN221:Width sensor, LH
CN250:LH Instrument panel No.1
CN222:Width sensor, RH
CN226:Retractable SW
CN251:Reset SW
CN228:FR axle harness No.2
CN252:Ready SW
CN231:Electromagnetic brake
11-20
CN253:Course detection lamp CN259:LH Instrument panel No.2
CN254:Warning lamp
CN260:FR axle harness
CN256:Emergency stop SW RH
CN257:Emergency stop SW LH
CN258:Steering motor
11-21
CN261:Bumper harness CN274:Receiver
CN275:Emergency stop SW LH, RR
CN262:FR harness connection
CN276:Emergency stop SW RH, RR
CN272:Travel between two points SW RH
CN273:LED display lamp

11-22
CN277:LH, RH pillar connection CN313:Remote system controller (traveling) No.2
CN314:Remote system controller (signal horn) No.2

CN279:Travel between two points SW LH
CN311:Remote system controller (traveling) No.3
CN321:Remote system controller (steering motor)

11-23
CN322:Remote system controller (sensor) No.1 CN324:Remote system controller (sensor) No.3
CN331:Remote system controller (receiver)
CN323:Remote system controller (sensor) No.2

11-24
CN352:Ready SW
CN377:Emergency stop relay

11-25
4CBT2R • 3R • 4CBTK4R (Travel between two points, stop at multiple set points specification)
CN1:Display CN8:Turn & light SW
CN3:Horn SW
CN5:Stop lamp SW
CN9:Direction SW.
CN6:Brake SW
11-26
CN12:Flasher relay CN18:Reverse buzzer ****
CN13:Hazard SW CN26:Acceleration sensor
CN14:Head lights
CN28:Acceleration sensor
CN15:Parking SW
CN29:Key SW
CN16:Mode SW
CN34:RR combination lamp****

11-27
CN41:Diode CN52:Thermo-sensor
CN42:Seat switch harness CN53:Vehicle speed sensor No.1

CN45:Head light relay
CN46:Tail light relay
CN50:Storobo lamp
11-28
CN101:Travel controller No.1 CN102:Travel controller No.2

11-29
CN123:FR harness connection No.2 CN134:RR combination RH
CN140:Error clear
CN141:Diag. ****
11-30
CN150:RH Instrument panel harness No.1 CN211:Bumper SW RH
CN216:Stop sensor
CN152:Fuse
CN218:Guide sensor
CN210:Bumper SW LH
11-31
CN220:Horn signal
CN249:Obstacle sensor
CN251:Reset SW

11-32
CN252:Ready SW CN257:Emergency stop SW LH
CN253:Course detection lamp
CN258:Steering motor****
CN254:Warning lamp
11-33
CN260:FR axle harness CN261:Bumper harness

Travel between two points specification****

11-34
CN274:Receiver CN277:LH, RH pillar connection
CN281:Stop at multiple set points ST SW No.1

11-35
CN282:Stop at multiple set points ST SW No.2 CN311:Remote system controller (traveling) No.3
CN292:Stop at multiple set points reset switch

11-36
CN321:Remote system controller (steering motor) CN324:Remote system controller (sensor) No.3
CN331:Remote system controller

11-37
CN342:Remote system controller CN377:Emergency stop relay

(multiple set points) No.1
CN343:Remote system controller

(multiple set points) No.2
CN352:Ready SW
11-38
4CBTY2R • 4CBTKY4R (Inching operation specification)

CN1:Display CN9:Accelerator
CN3:Horn SW
CN10:Light SW
CN5:Stop lamp SW
CN12:Flasher relay
CN6:Brake SW
CN13:Hazard SW
CN8:Flasher SW
CN14:Head lights
11-39
CN15:Parking SW CN34:RR combination lamp****
CN16:Mode SW
CN41:Diode
CN42:Floor SW
CN18:Reverse buzzer ****
CN29:Key SW
CN50:Storobo lamp
CN52:Thermo-sensor
11-40
CN53:Vehicle speed sensor No.1 CN101:Travel controller No.1

11-41
CN102:Travel controller No.2 CN123:FR harness connection No.2
11-42
CN134:RR combination RH CN150:RH Instrument panel harness No.1

CN140:Error clear
CN141:Diag. ****
CN152:Fuse
11-43
CN153:Control box harness No.1 CN218:Guide sensor
CN220:Horn signal
CN154:Control box harness No.2
CN210:Bumper SW LH
CN211:Bumper SW RH CN226:Retractable SW
11-44
CN228:FR axle harness No.2 CN252:Ready SW
CN253:Course detection lamp
CN249:Obstacle sensor
CN254:Warning lamp
CN251:Reset SW
11-45
CN257:Emergency stop SW LH CN260:FR axle harness
CN258:Steering motor
CN261:Bumper harness
11-46
CN262:FR harness connection CN275:Emergency stop SW LH, RR
CN272:Travel between two points SW RH CN276:Emergency stop SW RH, RR
CN277:LH, RH pillar connection
CN274:Receiver

11-47
CN311:Remote system controller (traveling) No.3 CN321:Remote system controller (steering motor)

11-48
CN323:Remote system controller (sensor) No.2 CN331:Remote system controller (receiver)
CN352:Ready SW

11-49
4CBTY2R • 4CBTKY4R (Travel between two points or stop at multiple set points specification)
CN1:Display CN9:Accelerator
CN3:Horn SW
CN10:Light SW
CN5:Stop lamp SW
CN12:Flasher relay
CN6:Brake SW
CN8:Flasher SW CN13:Hazard SW
CN14:Head lights
11-50
CN15:Parking SW CN34:RR combination lamp****
CN16:Mode SW
CN41:Diode
CN42:Floor SW
CN18:Reverse buzzer ****
CN29:Key SW CN50:Storobo lamp
CN52:Thermo-sensor
11-51
CN53:Vehicle speed sensor No.1 CN101:Travel controller No.1

11-52
CN102:Travel controller No.2 CN123:FR harness connection No.2
11-53
CN134:RR combination RH CN150:RH Instrument panel harness No.1

CN140:Error clear
CN141:Diag. ****
CN152:Fuse
11-54
CN153:Control box harness No.1 CN216:Stop sensor
CN154:Control box harness No.2
CN218:Guide sensor
CN210:Bumper switch LH
CN211:Bumper switch RH
CN220:Horn signal
11-55
CN221:Width sensor, LH CN249:Obstacle sensor

CN251:Reset SW
CN252:Ready SW
11-56
CN253:Course detection lamp CN259:LH Instrument panel No.2
CN254:Warning lamp
CN257:Emergency stop SW LH
CN258:Steering motor****
11-57
CN260:FR axle harness CN261:Bumper harness


11-58
CN274:Receiver CN277:LH, RH pillar connection

11-59
CN282:Stop at multiple set points ST SW No.2 CN311:Remote system controller (traveling) No.3
CN292:Stop at multiple set points reset switch

11-60
CN321:Remote system controller (steering motor) CN323:Remote system controller (sensor) No.2
CN331:Remote system controller (receiver)

11-61
CN341:Remote system controller (sensor) No.4 CN352:Ready SW
CN342:Remote system controller (multiple set points) No.1
CN343:Remote system controller (multiple set points) No.2

11-62
Published by
1st Printing: Mar. 2006

2nd Printing: June 2008
Pub. No. CE676
Printed in Japan

4CBT2R, 3R 4CBTK4R, 4cbtyk4r Ce676 PDF

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FOREWORD

EXTERIOR VIEW OF VEHICLE

Sit-down 3.0 tonnes 4CBT3R 48 V

HOW TO USE THIS MANUAL

2. How to read component figures

Abbreviation Meaning Abbreviation Meaning

ASSY Assembly SAE Society of Automotive Engineers (USA)

LH Left hand SST Special service tool

L/ Less STD Standard

OPT Option T= Tightening torque

O/S Oversize {{T Number of teeth ({{T)

PS Power steering U/S Undersize

RH Right hand W/ With

Wooden block point

Front section of frame Rear section of frame

HOISTING THE VEHICLE

Remove the toe board before hoisting the vehicle.

WIRE ROPE SUSPENSION ANGLE LIST

60° 1.16 time 0.58 time 60°

SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE

TOWING THE VEHICLE

GRADIENT AND TOW CAPACITY

Slope road (Slope start)

ELECTRICAL PARTS INSPECTION

(b) Digital circuit tester

BOLT & NUT TIGHTENING TORQUES

BOLT STRENGTH CLASS IDENTIFICATION METHOD AND

Type Shape and class Class

Hexagon head bolt

Bolt with three raised lines on head 7T

Bolt with four raised lines on head 8T

2 mm groove(s) on one/both edge(s) 6T

Identification by Part No.

Type Part No. Shape

Tightening Torque Table

Nominal diameter Pitch Standard tightening torque

6 1.0 5.4 55 48 in·lbf

6 1.0 6.5 65 56 in·lbf

6 1.0 7.8 80 69 in·lbf

HEXAGON FLANGE BOLT TIGHTENING TORQUE

Nominal diameter Pitch Standard tightening torque

7.5 (76.5) [5.5]

12.5 (128) [9.2]

115 (1173) [84.9]

180 (1837) [133]

280 (2857) [207]

HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE

Standard tightening torque N·m (kgf·cm) [ft·lbf]

7/16-20 UNF 25 (50) [18.1] 24 to 26 (240 to 270) [17.4 to 19.5] 6 (0.24)

9/16-18 UNF 49 (500) [36.2] 47 to 52 (480 to 530) [34.7 to 38.3] 9 (0.35)

3/4-16 UNF 59 (600) [43.4] 56 to 62 (570 to 630) [41.2 to 45.6] 12 (0.47)

PF1/4 25 (250) [18.1] 24 to 26 (240 to 270) [17.4 to 19.5] 6 (0.24)

PF3/8 49 (500) [36.2] 47 to 52 (480 to 530) [34.7 to 38.3] 9 (0.35)

PF1/2 59 (600) [43.4] 56 to 62 (570 to 630) [41.2 to 45.6] 12 (0.47)

RECOMMENDED LUBRICANT QUANTITY AND TYPES

Chassis parts Toyota genuine MP grease Appropriate amount

{: Inspection & addition I. Inspection every 8 hours (daily)

Item Every Every Every

Looseness in the connecting parts I ← ←