4CBT

4CBTK4 4CBTYK4 for Europe
4CBT2, 3 4CBTY2
4CBT2, 3
4CBTY2
4CBTK4
4CBTYK4
for Europe
Pub. No. CE662
PRINTED IN JAPAN Pub. No. CE662 Pub. No. CE662

FOREWORD
This Manual contains maintenance, specifications and repair procedures for the
chassis, body and material handling system of the TOYOTA ELECTRIC POWERED
TOWING TRACTOR 4CBT2, 3 • 4CBTY2 • 4CBTK4 • 4CBTYK4.
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
APPENDIX 10
0-1
GENERAL
Page Page
0
EXTERIOR VIEW OF HIGH PRESSURE HOSE 1
VEHICLE .............................. 0-2 FITTING TIGHTENING
TORQUE ............................ 0-16 2
VEHICLE MODELS................ 0-4
FRAME NUMBER .................. 0-4 RECOMMENDED LUBRICANT 3
QUANTITY AND TYPES .... 0-16
HOW TO USE THIS
LUBRICATION ..................... 0-17
4
MANUAL .............................. 0-5
EXPLANATION METHOD .......... 0-5 PERIODIC 5
MAINTENANCE ................. 0-18
TERMINOLOGY .......................... 0-6
PERIODIC REPLACEMENT
6
ABBREVIATIONS ....................... 0-6
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
WIRE ROPE SUSPENSION
SELLING POINT....................... 0-22 10
ANGLE LIST ........................... 0-10 MASTER CONTROL ................ 0-25
SAFE LOAD FOR
11
OPS........................................... 0-28
EACH WIRE ROPE
SUSPENSION ANGLE ........... 0-10 VEHICLE DIMENSIONS ........... 0-29 12
TOWING THE VEHICLE ........... 0-11 13
ELECTRICAL PARTS
INSPECTION........................... 0-12 14
BOLT & NUT TIGHTENING
TORQUES .......................... 0-13
15
BOLT STRENGTH CLASS 16
IDENTIFICATION METHOD AND
TIGHTENING TORQUE .......... 0-13 17
PRECOATED BOLTS ............... 0-15
18
0-2
EXTERIOR VIEW OF VEHICLE

4CBT2·3·4CBTK4
0-3
4CBTY2·4CBTYK4
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 4CBT2
2.0 tonnes
Standup 4CBTY2
Sit-down 3.0 tonnes 4CBT3 48 V
Sit-down 4CBTK4
4.0 tonnes
Standup 4CBTYK4
FRAME NUMBER
Vehicle model Punching format Punching position
Frame No.
4CBT2 4CBT2-10011
4CBTY2 4CBTY2-10011
4CBT3 4CBT2-10011
4CBTK4 4CBT2-10011
4CBTYK4 4CBTY2-10011
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→T=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.
4CBT2·3·4CBTK4
4CBTY2·4CBTYK4
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.
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
4CBT2·3·4CBTK4
II
III
4CBTY2·4CBTYK4
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
EXPLANATION
DEVELOPMENT OBJECTIVE
Toyota’s 2 t/3 t series of small battery-powered Towing Tractors have, in recent years, taken center stage in the
Japanese auto industry. Building on this success, and backed by increasing demand from overseas following the sale
of the CBT4,6 in 2003, the 2 t/3 t models have had their performance, specifications, and design overhauled in
preparation for a full-scale launch onto the world market. What is more, a new model, compact and yet capable of
towing 4 tonnes, has been developed for the series, strengthening the product lineup further still.
One of the biggest differences with the low-lift solid tires of competitor machines, and a key concept of these vehicles,
is their large-diameter pneumatic tires that provide riding comfort even when driving over the bumpiest of factory
floors.
We firmly believe that our new improved vehicles will be able to capitalize on the increased importance in the
automobile industry, both home and abroad, forecast for vehicles with towing capability to win a bigger and bigger
client base around the world.
SELLING POINT
1. Greater usability
(1) Compact body with a vehicle width of only 800 mm (31.5 in.).
(2) Rear section of the battery hood trimmed and a clearly visible drawbar.
(3) Maximum speed limit switch incorporating STD. Compliance with in-plant speed regulations.
• Operator’s seat equipped with switch for speed limit ON/OFF setting.
• 5 selectable speed limit levels: 6, 7, 8, 9, 10 km/h (3.7, 4.3, 5.0, 5.6, 6.2 mil/h).
• Speed limit selected using traveling controller DIP switch.
• Greater visibility + hand lever-operated rear drawbar (option) allows comfortable drawbar operation from
the operator's seat.
2. Superior operability
(1) AC drive giving smooth acceleration and deceleration.
Less judder when starting and decelerating for greater safety and stability when towing.
(2) Regenerative braking applied when the accelerator is released to allow deceleration with reduced brake
operation.
This reduced brake operation, that greater control over AC drive allows, means that the frequency with
which the operator has to apply the brake is lessened and with it the related operator fatigue.
(3) Small turning radius for high maneuverability in tight spaces.
3. Safety
(1) The Operator Presence Sensing (OPS) system is equipped as a standard feature to ensure superior safety
when operating the vehicle.
4CBT2·3·4CBTK4
The switch system fitted in the seat to detect the presence of the operator will automatically cut driving
power when the operator’s seat is vacated. The OPS system will activate when the seat switch remains
OFF for 2 consecutive seconds. If the seat switch is OFF and the direction lever is set to either forward or
reverse travel, an error indication will light up on the display to warn the operator that the OPS system is
active.
4CBTY2·4CBTYK4
The switch system fitted in the floor detects the presence of the operator and cuts driving power when the
operator leaves the vehicle. The OPS system reacts differently according to vehicle travel speed. At speeds
exceeding 1 km/h (0.62 mil/h), the system will be activated after the floor switch has been OFF for 2
seconds. At speeds of less than 1 km/h (0.62 mil/h), OPS becomes active immediately after the switch is
turned OFF.
0-23
4. Reduced maintenance costs

(1) Employing a driving AC motor.
The driving AC motor offers savings because there is no brush for the motor nor contactor for driving that
need to regularly checked and replaced.
(2) Battery used is same clad-type as forklift for longer life.
When recharging after 70% depletion, this battery has a 1200 recharge life-cycle.
The EB battery found in previous models, on the other hand, has a life-cycle of 650 at 70% depletion.
This means that the clad-type battery has an 85% longer life.
(3) The self-adjusting hydraulic brakes employed do not require link adjustment.
The footbrake on previous models used mechanical links and therefore needed adjustment for pedal height
which changed as a result of brake-pad wear. The hydraulic brake used in the new model automatically
adjusts shoe clearance reducing further still the need for frequent attention.
(4) In addition, the regenerative braking technology employed reduces the frequency with which the brake is
used in the first place. Less wear translates into longer periods of use between replacements.
(5) The battery and battery slide-out options for both standup type and sit-down type vehicles have been
standardized to greatly simplify the management of large factories that use both types.
5. Increasing operating time
(1) STD battery capacity of 48 V 129AH/5 Hr, a maximum battery capacity of 220AH, and regenerative braking
technology all help to increase the overall operating time of the vehicle.
6. Easy vehicle access and optimum driving position
(1) Getting in and out of the vehicle is effortless with the wide entry/exit opening and low floor height. The
design of the operator's seat has been designed to take into consideration the difference in physique
between Japanese and Western drivers. The new series reproduces the compact design of the incredibly
popular CBT4.
4CBT2·3·4CBTK4 4CBTY2·4CBTYK4
h
h
L
L
Height of hip point Entry/exit opening Floor height

H (mm) [in.] L (mm) [in.] h (mm) [in.]
4CBT2·3·4CBTK4 540 [21.26] 470 [18.50] 330 [13.00]
4CBTY2·4CBTYK4 — 470 [18.50] 200 [7.87]
• Tilt steering column (option) allows steering wheel position to be adjusted in both the fore and aft
directions.
• Driving position can be selected to best suit the height of the operator. (Optional high steering wheel
position for standup operation)
• Hip support for greater comfort on long rides.
0-24
7. Novel design
(1) The front protector and battery hood were molded to create a smoother, more contoured shape not seen
anywhere else in the market.
(2) By cutting away the back portion of the battery hood, visibility of the drawbar improved drastically and left
the vehicle with characteristic contours.
0-25
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.
0-26
3. Accelerator pedal
4CBT2·3·4CBTK4
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
ra
ngl
e
4CBTY2·4CBTYK4
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
0-27
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.
Axle bracket
Vehicle center
0-28
OPS
GENERAL
4CBT2·3·4CBTK4
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.
4CBTY2·4CBTYK4
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
4CBT2·3·4CBTK4
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.
4CBTY2·4CBTYK4
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.
0-29
VEHICLE DIMENSIONS
TOP/SIDE VIEW OF VEHICLE
4CBT2·3·4CBTK4
B2
B1
R
h1
h4
h3
h2
L4 L3 L5 L6
L2
L1
0-30
4CBTY2·4CBTYK4
B2
B1
R
h1
h1
h2
h3
L4 L3 L5 L6
h4
L2
L1
0-31
MAIN SPECIFICATIONS
Sit-down Type
Vehicle model
Item
4CBT2 4CBT3 4CBTK4
mm 1645 ← ←
L1 (w/ hitch)
in. 64.8 ← ←
Overall length
mm 1540 ← ←
L2 (w/o hitch)
in. 60.6 ← ←
mm 800 ← ←
B1 Overall width
in. 31.5 ← ←
mm 1255 ← ←
h1 Overall length
in. 49.4 ← ←
mm 1140 ← ←
L3 Wheelbase
in. 44.9 ← ←
mm 180 ← ←
L4 Front overhang
in. 7.1 ← ←
mm 215 ← ←
L5 Rear overhang (w/o hitch)
in. 8.5 ← ←
mm — — —
B2 Front wheel
in. — — —
Tread
Main dimensions
mm 670 ← ←
B3 Rear wheel
in. 26.4 ← ←
mm 105 ← ←
L6 Hitch length
in. 4.1 ← ←
mm 305 ← ←
h2 Hitch height
in. 12.0 ← ←
mm 330 ← ←
h3 Floor height
in. 13.0 ← ←
mm 80 ← ←
h4 Minimum ground clearance
in. 3.1 ← ←
kg 620 ← 730
(w/ battery)
lbs 1370 ← 1610
Vehicle weight
kg 360 ← ←
(w/o battery)
lbs 790 ← ←
kg 220 ← 270
Front wheel
lbs 490 ← 600
Axle weight (w/ battery)
kg 400 ← 460
Rear wheel
lbs 880 ← 1010
mm 1600 ← ←
R Minimum turning radius
in. 64.0 ← ←
0-32
Vehicle model
Item
4CBT2 4CBT3 4CBTK4
kg 2000 3000 4000
Rated tow capacity (60 mins. rating)
lbs 4400 6600 8800
N (kgf) 500 (50) 750 (75) 1000 (100)
Rated tractive force (60 mins. rating)
lbs 100 150 200
Performance
N (kgf) 2000 (200) 3000 (300) 4000 (400)

Maximum tractive force (3 mins. rating)
lbs 450 650 900
km/h 13.0 ← ←
No-load
MPH 8.1 ← ←
Traveling speed
km/h 9.0 ← 8.0
Loaded (*1)
MPH 5.6 ← 5.0
Climbing capacity (*2) % No-load 14 ← ←
No. of wheels Front/Rear 1/2 ← ←
Drive system
Front wheel Pneumatic 3.50-5-6PR

Tire size
Rear wheel Pneumatic 4.00-8-6PR
Foot brake Hydraulic
Parking brake Mechanical
Voltage V 48
Quantity AH/5HR 129 ← 220
Driving system
Rechargeable battery
kg 260 ← 370
Weight
lbs 570 ← 820
Output kW AC 2.3 ← ←
Drive motor
Control system Transistor inverter
*1: 2000 kg (4400 lbs) for 4CBT2, 3000 kg (6600 lbs) for 4CBT3, and 4000 kg (8800 lbs) for 4CBTK4
*2: 3 min. rating, theoretical value
0-33
Standup Type
Vehicle model
Item
4CBTY2 4CBTYK4
mm 1645 ←
L1 (w/ hitch)
in. 64.8 ←
Overall length
mm 1540 ←
L2 (w/o hitch)
in. 60.6 ←
mm 800 ←
B1 Overall width
in. 31.5 ←
mm 1240 ←
(w/o rear-view mirror)
in. 48.8 ←
h1 Overall length
mm 1450 ←
(w/ rear-view mirror)
in. 57.1 ←
mm 1140 ←
L3 Wheelbase
in. 44.9 ←
mm 180 ←
L4 Front overhang
in. 7.1 ←
mm 215 ←
L5 Rear overhang
in. 8.5 ←
mm — —
B2 Front wheel
Main dimensions
in. — —
Tread
mm 670 ←
B3 Rear wheel
in. 26.4 ←
mm 105 ←
L6 Hitch length
in. 4.1 ←
mm 305 ←
h2 Hitch height
in. 12.0 ←
mm 200 ←
h3 Floor height
in. 7.9 ←
mm 80 ←
h4 Minimum ground clearance
in. 3.1 ←
kg 620 730
(w/ battery)
lbs 1370 1610
Vehicle weight
kg 360 ←
(w/o battery)
lbs 790 ←
kg 220 270
Front wheel
lbs 490 600
Axle weight (w/ battery)
kg 400 460
Rear wheel
lbs 880 1010
kg 1600 ←
R Minimum turning radius
lbs 64.0 ←
0-34
Vehicle model
Item
4CBTY2 4CBTYK4
kg 2000 4000
Rated tow capacity (60 min. rating)
lbs 4400 8800
N (kgf) 500 (50) 1000 (100)
Rated tractive force (60 min. rating)
lbs 100 200
Performance
N (kgf) 2000 (200) 4000 (400)

Maximum tractive force (3 min. rating)
lbs 450 900
km/h 13.0 ←
No-load
MPH 8.1 ←
Traveling speed
km/h 9.0 8.0
Loaded (*1)
MPH 5.6 5.0
Climbing capacity (*2) % No-load 14 ←
No. of wheels Front/Rear 1/2 ←
Drive system
Front wheel Pneumatic 3.50-5-6PR ←

Tire size
Rear wheel Pneumatic 4.00-8-6PR ←
Foot brake Hydraulic
Parking brake Mechanical
Voltage V 48 ←
Quantity AH/5HR 129 220
Driving system
Rechargeable battery
kg 260 370
Weight
lbs 570 820
Output kW AC 2.3 ←
Drive motor
Control system Transistor inverter
*1: 2000 kg (4400 lbs) for 4CBTY2 and 4000 kg (8800 lbs) for 4CBTYK4
*2: 3 min. rating, theoretical value
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)
4CBT2·CBT3·4CBT 24 129
4CBTK4·4CBTYK4 ↑ 220
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.
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
4CBT2 4CBTK4
2 Model type 4CBT3
4CBTY2 4CBTYK4
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
1 Key switch All models 10* Model select switch 1 All models
2 Forward travel switch All models 11* Model select switch 2 All models
3 Reverse travel switch All models 12 Diagnosis display switch All models
4 Seat switch 4CBT2·3·4CBTK4 13 Error clearance switch All models
5 Floor switch 4CBTY2·4CBTYK4 14* Destination select switch 1 All models
6 Speed limit switch All models 15* Destination select switch 2 All models
7 Parking brake switch All models 16 Accelerator potentiometer switch 4CBTY2·4CBTYK4
8 Brake switch All models 17 Motor thermo-sensor All models
9 Accelerator switch 4CBTY2·3·4CBTK4 18 Motor rpm sensor All models
*: 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
4CBT2·3·4CBTK4
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
4CBTY2·4CBTYK4
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
4CBTY2·4CBTYK4
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.
4CBT2 • 3 • 4CBTK4
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.
4CBTY2 • 4CBTYK4
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
4CBT2 • 3 • 4CBTK4
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
4CBTY2 • 4CBTYK4
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
4CBT2 • 3 • 4CBTK4
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.
4CBTY2 • 4CBTYK4
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
4CBT2 • 3 • 4CBTK4
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
4CBTY2 • 4CBTYK4
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
4CBT2 • 3 • 4CBTK4
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.
4CBTY2 • 4CBTYK4
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
Outside standard range
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
4CBT2
4CBT3
Free ventilation
ø202 × 277
4CBTK4 48 2.3 Flange-type
[ø7.95 × 10.90]
Cage-type
4CBTY2
4CBTYK4
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 4CBT2, 3, 4CBTK4 4CBTY2, 4CBTYK4
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
4CBT2·3·4CBTK4
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
4CBTY2·4CBTYK4 (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
4CBT2·3·4CBTK4
Snap ring
Bearing
Wheel cap
Cotter pin
Bearing
Castle nut
Front axle shaft

Plate washer
Bearing
Front axle hub
Bearing
Dust seal
4CBTY2·4CBTYK4
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
4CBT2·3·4CBTK4
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)
4CBTY2·4CBTYK4
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 4CBT2·3 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 .......................... 6-18 9
DISASSEMBLY • INSPECTION • REASSEMBLY..... 6-18
10
11
12
13
14
15
16
17
18
6-2
GENERAL
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
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] 1.9 [0.5]

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
(204 to 306 kgf·cm) Shims
[15 to 22 ft·lbf]
O-ring
Breather
Drive shaft adjuster
Bearing
Bearing Rear cover
Drive shaft adjuster
T=20 to 30 N·m
O-ring (204 to 306 kgf·cm)
Lock plate Bearing [15 to 22 ft·lbf]
Drive shaft
T=78 to 88 N·m
Ring gear Differential case (795 to 897 kgf·cm)
[58 to 65 ft·lbf]
Bearing
Pinion thrust washer
Side gear
Pinion gear
Bearing
Bearing
Pinion shaft
Note: Counter gear
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. Place wooden blocks under the bottom of the rear axle
housing.
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 W/counter gear.
9. Remove the drive shaft adjuster. [Point 4]
10. Remove the drive shaft and ring gear. [Point 5]
11. Remove the drive pinion gear, drive pinion bearing retainer and joint. [Point 6]
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): 1.9l [0.5 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) Temporarily reassemble the differential ASSY and rear axle bracket (LH) to the rear axle case.
Note:
Do not apply thread tightener to the attaching bolts.
(2) 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.
(3) Reassemble the axle housing (RH) to the rear axle case, and temporarily tighten with bolts.
Note:
Do not apply thread tightener to the attaching bolts.
(4) Measure the gap A between the rear axle bracket (RH) and rear axle case.
(5) Insert a shim the size of gap A mm + 0.1 mm [A in. + 0.04 in.] and reassemble the rear axle brackets (LH
and RH) to the specified torque.
6-13
[Point 4]
Disassembly:
Use the SST to remove the drive shaft bearing retainer.
SST 09340-10330-71
SST
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]
6-14
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.
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.
6-15
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.)
(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 5]
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.
6-16
[Point 6]
Disassembly:
Make match marks before removing the adjusting nut.
Reassembly:
Match mark Align match marks when reassembling.
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
6-17
Disassembly:
Use the SST to remove the bearing outer race.
SST 09700-30200-71
SST
SST
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
6-18
DIFFERENTIAL CASE ASSY

T=N·m (kgf·cm) [ft·lbf]
T=78 to 88
(795 to 897)
[58 to 65]
1. Remove the counter gear. [Point 1]
2. Remove the side bearing. [Point 2]
3. Remove the pinion shaft, pinion gear, pinion thrust washer and side gear. [Point 3]
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 08833-76001-71 to the counter gear set bolt.
6-19
[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
4CBT2•3•4CBTK4
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
4CBT2•3•4CBTK4 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
4CBTY2•4CBTYK4
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
4CBT2•3•4CBTK4 4CBTY2•4CBTYK4
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
4CBT2•3•4CBTK4 4CBTY2•4CBTYK4
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
4CBT2•3•4CBTK4
*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
4CBTY2•4CBTYK4
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

4CBT2•3•4CBTK4
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
4CBTY2•4CBTYK4
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
4CBT2•3•4CBTK4
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
4CBT2 • 3 • 4CBTK4
0
1
2
3
4
5
6
Connect under toe board
Clamp under toe board

7
Clamp under battery
8
4CBTY2 • 4CBTYK4
9
10
11
12
13
14
15
16
17
18
8-4
MASTER CYLINDER
4CBT2 • 3 • 4CBTK4
4CBTY2 • 4CBTYK4
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
4CBT2 • 3 • 4CBTK4
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
4CBTY2 • 4CBTYK4
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

4CBT2 • 3 • 4CBTK4
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
4CBTY2 • 4CBTYK4
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
4CBT2 • 3 • 4CBTK4
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
4CBTY2 • 4CBTYK4
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
4CBT2 • 3 • 4CBTY4
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

4CBTY2 • 4CBTYK4
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

4CBT2 • 3 • 4CBTK4
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
4CBTY2 • 4CBTYK4
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

4CBT2 • 3 • 4CBTK4
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
4CBTY2 • 4CBTYK4
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
4CBT2 • 3 • 4CBTK4
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)
4CBTY2 • 4CBTYK4
• 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

4CBT2 • 3 • 4CBTK4
9-3
4CBTY2 • 4CBTYK4
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

4CBT2 • 3 • 4CBTK4
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
4CBTY2 • 4CBTYK4
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
4CBTY2 • 4CBTYK4
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 (4CBTY2 • 4CBTYK4)

Lever (4CBT2 • 3 • 4CBTK4)
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
4CBT2 • 3 • 4CBTK4 (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).
4CBTY2 • 4CBTYK4
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
4CBT2 • 3 • 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
4CBTY2 • 4CBTYK4
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
4CBT2 • 3 • 4CBTK4
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
4CBTY2 • 4CBTYK4
Floor switch
Roll-out
specification vehicle
Standard specification vehicle (Short connector)
Horn switch Accelerator
Indicator light switch
Flasher unit
9-18
10-1
APPENDIX
Page 0
SST LIST .......................................................... 10-2
1
SERVICE STANDARDS................................... 10-4
CONNECTOR DIAGRAM................................. 10-7
2
CONNECTION DIAGRAM.............................. 10-18 3
WIRING DIAGRAM ........................................ 10-20 4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
10-2
SST LIST
Section
Illust Part No. Part name
1 2 3 4 5 6 7 8 9
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
10-3
Section
Illust Part No. Part name
1 2 3 4 5 6 7 8 9
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
10-4
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 4CBT2 • 3 • 4CBTK4
Pedal operated ∞Ω
Continuity check of acceleration sensor Ω
Pedal not operated Continuity
ACCELERATOR
Item 4CBTY2 • K4
Limit switch continuity (tester range × 1k) Ω See P3-16 in this manual
FLOOR SWITCH
Item 4CBTY2 • K4
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]
10-5
FRONT AXLE
Item 4CBT2 • 3 • K4 4CBTY2 • 4CBTYK4
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 4CBT2 • 3 • 4CBTK4 4CBTY2 • 4CBTYK4

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
10-6
BRAKE
Item 4CBT2 • 3 • 4CBTK4 4CBTY2 • 4CBTYK4
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]
10-7
CONNECTOR DIAGRAM
4CBT2 • 3 • 4CBTK4
2 1 1 2
9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9
4 3 3 4
CN1 18 17 16 15 14 13 12 11 10 10 11 12 13 14 15 16 17 18
Display
TAB REC CN9
NO P C J NO P C J Direction switch
1 146 - DISP 1 146 L CN150-3 TAB REC
2 145 - DISP 2 145 L-W CN150-2 NO P C J NO P C J
3 17 - DISP 3 17 L-R CN150-4 1 1
4 18 - DISP 4 18 W-B CN150-1 2 43 - DS BU 2 103 LG CN120-1
3 43 - DS FO 3 120 P CN120-7
4 51 - DSF DSR 4 46 O CN123-10
5 45 - DSF 5 45 G CN123-11
1 1
6 46 - DSR 6 51 R-L J12
2 2 7 120 - DS FO 7 43 L J14
CN3 8 103 - DS BU 8 43 L J14
9 9
Horn switch 10 10
TAB REC 11 11
NO P C J NO P C J 12 12
1 48 P SWH 1 48 P CN120-8 13 13
2 41 Y SWH 2 41 Y J15 14 14
15 15
16 16
17 17
18 18
2 1 1 2
CN5
Stop light switch
TAB REC 2 1 1 2
NO P C J NO P C J 4 3 CN12 3 4
1 101 LS ST 1 101 R J17
2 111 LS ST 2 111 Y C120-5 Flasher relay
TAB REC
NO P C J NO P C J
1 N1 - FRY 1 N1 W J5
2 110 - FRY 2 110 GR CN120-2
3 3
2 1 1 2
CN6 4 41 - FRY 4 41 Y CN124-8
Brake switch
TAB REC
NO P C J NO P C J
1 51 LS B 1 51 R-L CN123-6 1 1
2 65 LS B 2 65 Y-G CN123-4 3 2 CN13 2 3
Hazard switch
TAB REC
6 5 4 3 2 1 1 2 3 4 5 6
NO P C J NO P C J
14 13 12 11 10 9 8 7 7 8 9 10 11 12 13 14 1 110 - SW HZ 1 110 GR CN151-3
CN8 2 108 - SW HZ 2 108 L CN150-11
3 109 - SW HZ 3 109 G-Y CN150-12
Turn and light switch
TAB REC
NO P C J NO P C J
1 1
2 2 2 1 1 2
3 3 CN14
4 4
5 5 Headlights
6 6 TAB REC
7 110 - SW F 7 NO P C J NO P C J
8 109 - SW F 8 115 P CN120-3 1 N1 - LH 1 N1 W J16
9 108 - SW F 9 116 LG CN120-4 2 102 - LH 2 102 R-G CN120-9
10 10 N1 W J16
11 N1 - SWH, SWT 11
12 116 - SW T 12 108 L CN120-11
13 115 - SW L 13 109 G-Y CN120-12
14 14 110 GR J18
2 1 1 2
CN15
Parking switch
TAB REC
NO P C J NO P C J
1 51 - LS PB 1 51 R-L J11
2 66 - LS PB 2 66 R CN123-5
10-8
3 2 1 1 2 3
2 1 1 2 6 5 4 4 5 6
CN16 CN33
Mode switch RR combination light LH
TAB REC TAB REC
NO P C J NO P C J NO P C J NO P C J
1 51 - SWM 1 51 R-L CN150-8 1 104 - RR COMBI LH, CN133-1 1 104 G-R CN46-4
2 68 - SWH 2 68 L CN150-9 2 2
3 111 - RR COMBI LH, CN133-3 3 111 Y CN120-5
4 4
5 109 - RR COMBI LH, CN133-5 5 109 G-Y CN120-12
6 N1 - RR COMBI LH, J30 6 N1 W J5
1 1
2 2
CN17
Chime 3 2 1 1 2 3
TAB REC
6 5 4 4 5 6
NO P C J NO P C J CN34
1 122 - CHIME 1 122 Y CN41-2
RR combination light RH
2 N1 - CHIME 2 N1 W J4
TAB REC
NO P C J NO P C J
1 104 - RR COMBI RH, J31 1 104 G-R J7
2 2
1 1
3 111 - RR COMBI RH, J32 3 111 Y J8
2 2
CN18 4 103 - RR COMBI RH, CN134-4 4 103 LG CN120-1
5 108 - RR COMBI RH, CN134-5 5 108 L CN120-11
Buzzer 6 N1 - RR COMBI RH, J30 6 N1 W J4
TAB REC
NO P C J NO P C J
1 103 - BZ 1 103 LG J9
2 N1 - BZ 2 N1 W J4
3 2 1
CN41 1 2 3
2 1 1 2 Diode
4 3 3 4 TAB REC
CN26 NO P C J NO P C J
1 131 - L 1 131 L F&R Chime
Accelerator sensor 2 122 - E 2 122 Y CN17-1
TAB REC 3 120 - B 3 120 P CN120-7
NO P C J NO P C J
1 51 SL CN26-1-1 1 51 L CN101-33
2 64 Y CN26-1-2 2 64 R CV101-17
3 52 R CN26-1-3 3 52 G CN101-34
1 1
4 54 GR CN26-1-4 4 54 W CN101-22
2 2
CN42
Seat switch
TAB REC
4 3 2 1 NO P C J NO P C J
1 2 3 4
CN28 1 67 L CN101-20 1 67 - LSD
2 69 G CN43-2 2 69 - LSD
TAB REC
NO P C J NO P C J
1 51 - A1N 1 51 SL CN26-1
2 64 - Din4 2 64 Y CN26-2
2 1 1 2
3 52 - Ain1 3 52 R CN26-3 CN43
4 54 - AIP5 4 54 GR CN26-4
Battery stopper switch
TAB REC
NO P C J NO P C J
1 51 - LS BA 1 51 R-L J1
2 1 1 2
2 69 - LS BA 2 69 G CN42-2
4 3 CN29 3 4
Key switch
TAB REC
NO P C J NO P C J 2 1 1 2
1 41 Y SWK 1 41 Y J15 4 3 CN45 3 4
2 2
3 3 Headlight relay
4 43 L SWK 4 43 L CN120-10 TAB REC
NO P C J NO P C J
1 101 - HRY 1 101 R J6
2 101 - HRY 2 101 R J6
3 115 - HRY 3 115 P CN120-3
4 102 - HRY 4 102 R-G CN120-9
10-9
2 1 1 2
2 1 1 2 4 3 CN74 3 4
4 3 CN46 3 4
Washer switch
Taillight relay TAB REC
TAB REC NO P C J NO P C J
NO P C J NO P C J 1 143 - WIPER 1 143 R-L CN151-2
1 101 - TRY 1 101 R CN124-7 2 144 - WIPER 2 144 R CN151-1
2 101 - TRY 2 101 R J6 3 148 - WIPER 3 148 P CN151-5
3 115 - TRY 3 116 LG CN120-1 4 149 - WIPER 4 149 G-Y CN151-6
4 104 - TRY 4 104 G-R CN33-1
10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10
22 21 20 19 18 17 16 15 14 13 12 11 11 12 13 14 15 16 17 18 19 20 21 22
1 1 34 33 32 31 30 29 28 27 26 25 24 23 23 24 25 26 27 28 29 30 31 32 33 34
2 2
CN50
CN101
Strobo lamp
TAB REC Controller
NO P C J NO P C J
TAB REC
NO P C J NO P C J
1 43 L LR 1 43 L J3
1 43 - DSR 1 43 L CN131-1
2 N1 W LR 2 N1 W J4
2 2
3 3
4 2 - EX02N 4 2 R CN136-1
5 1 - EX02P 5 1 V CN136-1-1
6 17 - BDI 6 17 L-R CN123-2
2 1 1 2
CN52 7
8
43
P1
-
-
KEY
VB
7
8
43
P1
L
B
CN120-10
J2
Thermo-sensor 9 4 - RCH+ 9 4 L CN137-1
TAB REC 10 3 - RCH- 10 3 Y CN137-2
NO P C J NO P C J 11 146 - RXDN 11 146 L CN123-1
1 87 - STMD 1 87 W-G CN101-32 12 12
2 78 - STMD 2 78 P CN101-21 13 - - SHLD1 13 - B Shielded line 1
14 80 - CNTIA 14 80 R CN53-1
15 79 - PS14VI 15 79 W CN53-2
16 51 - 0V 16 51 R-L CN123-6
17 64 - Din4 17 64 R CN26-2
18 65 - Din3 18 65 Y-G CN123-4
2 1 1 2
CN53 19
20
66
67
-
-
Din2
Din1
19
20
66
67
R
L
CN123-5
CN42-1
Traveling speed sensor A 21 78 - A4N 21 78 P CN52-2
TAB REC 22 54 - A1PS 22 54 W CN26-4
NO P C J NO P C J 23 145 - TXDN 23 145 L-W CN123-8
1 80 - SSD1 1 80 R CN101-14 24 18 - DSPN 24 18 W-B CN123-7
2 79 - SSD1 2 79 W CN101-15 25 25
26 - - P14V2COM 26 - B Shielded line 2
27 27
28 28
29 76 - CNTIB 29 76 L CN54-1
30 75 - PS14V 30 75 G CN54-2
2 1 1 2
CN54 31 31
32 87 - Ain4 32 87 W-G CN52-2
Traveling speed sensor B 33 51 - A1N 33 51 L CN26-1
TAB REC 34 52 - Ain1 34 52 G CN26-3
NO P C J NO P C J
1 76 - SSD2 1 76 L CN101-29
2 75 - SSD2 2 75 G CN101-30
4 3 2 1 1 2 3 4
8 7 6 5 5 6 7 8
CN70
Wiper and washer relay
TAB REC
NO P C J NO P C J
1 143 R-L CN124-3 1 143 - WIPER & WASHER
2 144 R CN124-2 2 144 - WIPER & WASHER
3 43 L J3 3 43 - WIPER & WASHER
4 P1 B J10 4 P1 - WIPER & WASHER
5 148 P CN124-1 5 148 - WIPER & WASHER
6 149 G-Y CN124-8 6 149 - WIPER & WASHER
7 N1 W J5 7 N1 - WIPER & WASHER
8 P1 B J10 8 P1 - WIPER & WASHER
10-10
8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 4 3 2 1 1 2 3 4
17 16 15 14 13 12 11 10 9 9 10 11 12 13 14 15 16 17 8 7 6 5 5 6 7 8
26 25 24 23 22 21 20 19 18 18 19 20 21 22 23 24 25 26
CN124
CN102 TAB REC
NO P C J NO P C J
Controller 1 148 P CN70-5 1 148 P CN151-5
TAB REC 2 144 R CN70-2 2 144 R CN151-1
NO P C J NO P C J 3 143 R-L CN70-1 3 143 R-L CN151-2
1 1 4 N1 W N1 4 N1 W J16
2 2 5 41 Y CN12-4 5 41 Y CN152-4
3 3 6 6
4 4 7 101 R CN46-1 7 101 R CN152-3
5 5 8 149 G-Y CN70-6 8 149 G-Y CN151-6
6 6
7 60 - EXOTN 7 60 R CN131-3
8 8 2 1
9 9
1 2
4 3
10 10 3 4
11 51 - Din07 11 51 R-L CN141-2 CN131
12 51 - Din06 12 51 R-L CN140-2
13 68 - Din05 13 68 L CN123-12 Elecromagnetic brake
14 14 TAB REC
15 15 NO P C J NO P C J
16 51 - Ain2 16 51 R-L J2 1 43 W CN131-2 1 43 L CN101-1
17 17 2 43 W CN131-1 2 43 L J3
18 51 - OV 18 51 R-L CN123-3 3 60 R CN231-1 3 60 R CN102-7
19 45 - Din10 19 45 G CN123-11 4 P1 B CN231-2 4 P1 B J10
20 46 - Din9 20 46 O CN123-10
21 21
22 22
23 23
24 24 1 1
25 25 CN136
26 26
Contactor panel No. 1
TAB REC
4 3 2 1 1 2 3 4 NO P C J NO P C J
8 7 6 5 5 6 7 8 1 2 - MC 1 2 R CN101-4
12 11 10 9 9 10 11 12
CN120
TAB REC 1 1
NO P C J NO P C J CN136-1
1 103 LG CN34-4 1 103 LG CN9-2
2 110 GR CN12-2 2 110 GR CN151-3 Contactor panel No. 3
3 115 P CN45-3 3 115 P CN8-8 TAB REC
4 116 LG CN46-3 4 116 LG CN8-9 NO P C J NO P C J
5 11 Y CN33-3 5 11 Y CN5-2 1 1 - MC 1 1 V CN101-5
6 P1 B P1 6 P1 B CN152-2
7 120 P CN41-3 7 120 P CN9-3
8 48 P HORN 8 48 P CN3-1
9 102 R-G CN45-4 9 102 R-G CN14-2
10 43 L CN101-7 10 43 L CN29-4 2 1 1 2
11 108 L CN34-5 11 108 L CN8-12 CN137
12 109 G-Y CN33-5 12 109 G-Y CN8-13
TAB REC
NO P C J NO P C J
6 5 4 3 2 1 1 2 3 4 5 6 1 4 - R 1 4 L CN101-9
12 11 10 9 8 7 7 8 9 10 11 12 2 3 - R 2 3 Y CN101-10
CN123
TAB REC 1
NO P C J NO P C J
2
1 146 L CN101-11 1 146 L CN150-3 CN140
2 17 L-R CN101-6 2 17 L-R CN150-4
3 51 R-L CN102-18 3 51 R-L CN150-8 Error clear
4 65 Y-G CN101-18 4 65 Y-G CN6-2
REC
5 66 R CN101-19 5 66 R CN15-2 NO P C J
6 51 R-L CN101-16 6 51 R-L CN6-1 1 51 R-L J2
7 18 W-B CN101-24 7 18 W-B CN150-1 2 51 R-L CN102-12
8 145 L-W CN101-23 8 145 L-W CN150-2
9 9
10 46 O CN102-20 10 46 O CN9-4
11 45 G CN102-19 11 45 G CN9-5 1
12 68 L CN102-13 12 68 L CN150-9 2
CN141
Diagnosis
REC
NO P C J
1 51 R-L J2
2 51 R-L CN102-11
10-11
3 2 1 1 2 3
2 1 1 2
6 5 4
CN133 4 5 6 CN231
RR combination light LH
TAB REC TAB REC
1 104 - RR COMBI LH 1 104 G-R CN33-1 1 60 - SOLB 1 60 R CN131-3
2 2 2 P1 - SOLB 2 P1 B CN131-4
3 111 - RR COMBI LH 3 111 Y CN33-3
4 4
5 109 - RR COMBI LH 5 109 G-Y CN33-5
6 N1 - RR COMBI LH 6 N1 W J30
3 2 1 1 2 3
6 5 4 4 5 6
CN134
TAB REC
NO P C J NO P C J
1 104 - RR COMBI RH 1 104 G-R J31
2 2
3 111 - RR COMBI RH 3 111 Y J32
4 103 - RR COMBI RH 4 103 LG CN34-4
5 108 - RR COMBI RH 5 108 L CN34-5
6 N1 - RR COMBI RH 6 N1 W J30
4 3 2 1 1 2 3 4
8 7 6 5 5 6 7 8
12 11 10 9 9 10 11 12
CN150
TAB REC
NO P C J NO P C J
1 18 W-B CN1-4 1 18 W-B CN123-7
2 145 L-W CN1-2 2 145 L-W CN123-8
3 146 L CN1-1 3 146 L CN123-1
4 17 L-R CN1-3 4 17 L-R CN123-2
5 41 Y HM 5 41 Y J15
6 N1 W HM 6 N1 W J16
7 49 O HM 7 49 O HM-ST
8 51 R-L CN16-1 8 51 R-L CN123-3
9 68 L CN16-2 9 68 L CN123-12
10 10
11 108 L CN13-2 11 108 L J20
12 109 G-Y CN13-3 12 109 G-Y J19
3 2 1 1 2 3
6 5 4 CN151 4 5 6
TAB REC
NO P C J NO P C J
1 144 R CN74-2 1 144 R CN124-2
2 143 R-L CN74-1 2 143 R-L CN124-3
3 110 GR CN13-1 3 110 GR CN120-2
4 4
5 148 P CN74-3 5 148 P CN124-1
6 149 G-Y CN74-4 6 149 G-Y CN124-8
2 1 1 2
4 3 CN152 3 4
Fuse
TAB REC
NO P C J NO P C J
1 P1 B J13 1 P1 - F4
2 P1 B CN120-6 2 P1 - F5
3 101 R CN124-7 3 101 - F4
4 41 Y CN124-5 4 41 - F5
10-12
JOINT
CN43-1 CN34-3 CN29-1 CN3-2 CN33-1 CN133-1
J1 J8 CN152-4 J15 J31
CN101-16 CN123-6 CN33-3 CN120-5 CN124-5 CN150-5 CN34-1 CN134-1
(51,R-L) (111,Y) (41,Y) (104,GR)
CN102-16
CN102-18 CN140-1 CHIME CN18-1 CN8-11 FR F/L LH CN34-3 CN33-3
J2 J9 CN150-6 J16 CN14-1 J32
CN123-3 CN141-1 CN34-4 CN120-1 CN124-4 FR F/L RH CN134-3 CN133-3
(51,R-L) (103,LG) (N1,W) (111,Y)
CN50-1 CN131-2 CN101-8 CN5-1 CN231-2
CN70-4
J3 CN120-6 J10 CN70-8 J17 J33

CN70-3 P1 CN131-4
CN120-10 CN101-7 CN124-7 CN152-3 RBR CN131-4
(43,L) (P1,B) (101,R) (P1,B)
CN17-2 CN18-2 CN15-1 CN8-14 CN231-1
N1
J4 HORN J11 J18 J34

CN50-2
CN34-6 CN33-6 CN123-6 CN6-1 CN120-2 CN151-3 DBR CN131-3
(N1,W) (51,R-L) (110,GR) (60,R)
N1 CN12-1 CN9-6 CN8-8
J5 J12 J19
CN70-7 CN124-4 CN150-8 CN123-3 CN120-12 FR F/L LH
(N1,W) (51,R-L) (109,G-Y)
CN46-2 CN45-2 CN152-2 CN8-9
CN124-7 J6 J13 J20
CN46-1 CN45-1 CN120-6 CN152-1 CN120-11 FR F/L RH
(101,R) (P1,B) (108,L)
CN34-1 CN9-8 CN29-4 CN33-6 CN134-6
J7 CN9-7 J14 CN34-6 J30 CN133-6
CN33-1 CN46-4 HM-ST CN120-10 LR CN50-2
(104,G-R) (43,L) (N1,W)

10-13
4CBTY2 • 4CBTYK4
2 1 1 2 1 1
4 3 CN1 3 4 3 2 CN10 2 3
Display Lighting switch
TAB REC TAB REC
1 146 - DISP 1 146 L CN150-3 1 102 - SW HZ 1 102 R-G CN151-1
2 145 - DISP 2 145 L-W CN150-2 2 104 - SW HZ 2 104 G-R CN151-2
3 17 - DISP 3 17 L-R CN150-4 3 101 - SW HZ 3 101 R CN151-6
4 18 - DISP 4 18 W-B CN150-1
2 1 1 2
1 1
2 2
4 3 CN12 3 4
CN3
Flasher relay
Horn switch TAB REC
NO P C J NO P C J 1 N1 - FRY 1 N1 W J6
1 41 Y SWH 1 41 Y CN154-1 2 110 - FRY 2 110 GR CN120-2
2 48 P SWH 2 48 P CN154-2 3 3
4 41 - FRY 4 41 Y CN124-5
2 1 1 2
CN5 1 1
Stop light switch

3 2 CN13 2 3
TAB REC Hazard switch

NO P C J NO P C J TAB REC
1 101 LS ST 1 101 R CN124-7 NO P C J NO P C J
2 111 LS ST 2 111 Y CN33-3 1 110 - SW HZ 1 110 GR CN151-3
2 108 - SW HZ 2 108 L CN150-10
3 109 - SW HZ 3 109 G-Y CN150-9
2 1 1 2
CN6
2 1 1 2
Brake switch CN14
TAB REC
NO P C J NO P C J Headlights
1 51 LS B 1 51 R-L J1 TAB REC
2 65 LS B 2 65 Y-G CN101-18
NO P C J NO P C J
1 N1 - LH 1 N1 W J14
2 102 - LH 2 102 R-G CN151-1
3 2 2 3
CN8
Flasher switch 2 1 1 2
TAB REC
CN15
NO P C J NO P C J Parking switch
1 110 - SWF 1 110 GR CN154-4 TAB REC
2 108 - SWF 2 108 L CN154-6
NO P C J NO P C J
3 109 - SWF 3 109 G-Y CN154-5
1 51 - LS PB 1 51 R-L CN123-6
2 66 - LS PB 2 66 R CN123-5
5 4 3 2 1 1 2 3 4 5
10 9 8 7 6 6 7 8 9 10
CN9 2 1 1 2
Accelerator CN16
TAB REC Mode switch
NO P C J NO P C J TAB REC
1 51 - DS F,DS R 1 51 R-L CN153-1
NO P C J NO P C J
2 45 - DS F 2 45 G CN153-2
1 51 - SW-M 1 51 R-L CN150-5
3 3
2 68 - SW-M 2 68 L CN150-12
4 46 - DS R 4 46 O CN153-4
5 43 - DSFO,DSBU 5 43 L CN153-5
6 103 - DSBU 6 103 Y CN153-7
7 120 - DSFO 7 120 P CN153-6
8 52 - VRAD 8 52 Y CN153-8 1 1
2 2
9
10
51
54
-
-
VRAD+
VRAD-
9
10
51
54
V
Y
CN153-9
CN153-10
CN17
Chime
TAB REC
NO P C J NO P C J
1 122 - CHIME 1 122 Y CN41-2
2 N1 - CHIME 2 N1 W J5
10-14
1 1
2 2
CN18 2 1 1 2
CN43
Buzzer
TAB REC Battery stopper switch
TAB REC
NO P C J NO P C J
NO P C J NO P C J
1 103 - BZ 1 103 LG J9
1 51 R-L LS BA 1 51 R-L J1
2 N1 - BZ 2 N1 W J5
2 69 G LS BA 2 69 G CN42-1
2 1 1 2 1 1
4 3 CN29 3 4 2
CN50 2
Key switch Strobo lamp

TAB REC TAB REC
NO P C J NO P C J
NO P C J NO P C J
1 41 - SW K 1 41 Y J19
1 43 - LR 1 43 L J4
2 2
2 N1 - LR 2 N1 W J5
3 3
4 43 - SW K 4 43 L J20
2 1 1 2
3 2 1 1 2 3 CN52
6 5 4 4 5 6
CN33 Thermo-sensor
TAB REC
RR combination light LH NO P C J NO P C J
TAB REC
1 87 - STMD 1 87 W-G CN101-32
NO P C J NO P C J
2 78 - STMD 2 78 P CN101-21
1 104 - RR COMBI LH, CN133-1 1 104 G-R CN124-6
2 2
3 111 - RR COMBI LH, CN133-3 3 111 Y CN5-2
4 4
5 109 - RR COMBI LH, CN133-5 5 109 G-Y CN120-12
6 N1 - RR COMBI LH, J31 6 N1 W J5 2 1 1 2
CN53
Traveling speed sensor A
TAB REC
3 2 1 1 2 3 NO P C J NO P C J
6 5 4 4 5 6 1 80 R SSD1 1 80 R CN101-14
CN34 2 79 W SSD1 2 79 W CN101-15
TAB REC
NO P C J NO P C J
1 104 - RR COMBI RH, J31 1 104 G-R J7
2 2 2 1 1 2
3 111 - RR COMBI RH, J32 3 111 Y J8 CN54
4 103 - RR COMBI RH, CN134-4 4 103 LG CN120-1
5 108 - RR COMBI RH, CN134-5 5 108 L CN120-11
Traveling speed sensor B
TAB REC
6 N1 - RR COMBI RH, J30 6 N1 W J5
NO P C J NO P C J
1 76 L SSD2 1 76 L CN101-29
2 75 G SSD2 2 75 G CN101-30
3 2 1 1 2 3
CN41
Diode
TAB REC
NO P C J NO P C J
1 131 - L 1 131 L F&R Chime
2 122 - E 2 122 Y CN17-1
3 120 - B 3 120 P CN120-7
2 1 1 2
CN42
Floor switch
TAB REC
NO P C J NO P C J
1 69 - LS D 1 69 G CN43-2
2 67 - LS D 2 67 L CN101-20
10-15
10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 4 3 2 1 1 2 3 4
22 21 20 19 18 17 16 15 14 13 12 11 11 12 13 14 15 16 17 18 19 20 21 22 8 7 6 5 5 6 7 8
34 33 32 31 30 29 28 27 26 25 24 23 23 24 25 26 27 28 29 30 31 32 33 34 12 11 10 9 9 10 11 12
CN120
CN101
Controller TAB REC
NO P C J NO P C J 1 103 LG CN34-4 1 103 LG CN153-7
1 43 - DSR 1 43 L CN131-1 2 110 GR CN12-2 2 110 GR CN151-3
2 43 - DSF 2 43 L J4 3 3
3 3 4 4
4 2 - EX02N 4 2 R CN136-1 5 5
5 1 - EX02P 5 1 V CN136-1-1 6 P1 B P1 6 P1 B CN152-2
6 17 - BDI 6 17 L-R CN123-2 7 120 P CN41-3 7 120 P CN153-6
7 43 - KEY 7 43 L CN120-10 8 48 P HORN 8 48 P CN154-2
8 P1 - VB 8 P1 B J3 9 9
9 4 - RCH+ 9 4 L CN137-1 10 43 L CN101-7 10 43 L CN153-5
10 3 - RCH- 10 3 Y CN137-2 11 108 L CN34-5 11 108 L CN154-6
11 146 - RXDN 11 146 L CN123-1 12 109 G-Y CN33-5 12 109 G-Y CN154-5
12 12
13 - - SHLD1 13 - B SHLD1
14 80 - CNTIA 14 80 R CN53-1
15 79 - PD14VI 15 79 W CN53-2 6 5 4 3 2 1 1 2 3 4 5 6
16 51 - 0V 16 51 R-L CN123-6
12 11 10 9 8 7 7 8 9 10 11 12
17
18 65 - Din3
17
18 65 Y-G CN6-2
CN123
19 66 - Din2 19 66 R CN123-5
20 67 - Din1 20 67 L CN42-2 TAB REC
21 78 - A4N 21 78 P CN52-2 NO P C J NO P C J
22 54 - A1PS 22 54 W CN124-1 1 146 L CN101-11 1 146 L CN150-3
23 145 - TXDN 23 145 L-W CN123-8 2 17 L-R CN101-6 2 17 L-R CN150-4
24 18 - DSPN 24 18 W-B CN123-7 3 51 R-L CN102-18 3 51 R-L CN150-5
25 25 4 4
26 26 5 66 R CN101-19 5 66 R CN15-2
27 27 6 51 R-L CN101-16 6 51 R-L CN15-1
28 28 7 18 W-B CN101-24 7 18 W-B CN150-1
29 76 - P14V2COM 29 76 L CN54-1 8 145 L-W CN101-23 8 145 L-W CN150-2
30 75 - PS14V 30 75 G CN54-2 9 9
31 31 10 46 O CN102-19 10 46 O CN153-4
32 87 - Ain4 32 87 W-G CN52-1 11 45 G CN102-20 11 45 G CN153-2
33 51 - A1N 33 51 L CN124-3 12 68 L CN102-13 12 68 L CN150-12
34 52 - Ain1 34 52 G CN124-2
4 3 2 1 1 2 3 4
8 7 6 5 5 6 7 8
8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8
CN124
17 16 15 14 13 12 11 10 9 9 10 11 12 13 14 15 16 17 JOINT
26 25 24 23 22 21 20 19 18 18 19 20 21 22 23 24 25 26 TAB REC
NO P C J NO P C J
CN102 1
2
54
52
W
G
CN101-22
CN101-34
1
2
54
52
Y
LG
CN153-10
CN153-8
Controller 3 51 L CN101-33 3 51 V CN153-9
TAB REC 4 N1 W N1 4 N1 W FR F/L LH
NO P C J NO P C J 5 41 Y CN12-4 5 41 Y CN152-4
1 1 6 104 G-R CN33-1 6 104 G-R CN151-2
2 2 7 101 R CN5-1 7 101 R CN152-3
3 3 8 8
4 4
5 5
6 6
2 1
1 2
7 60 - EXOTN 7 60 R CN131-3 4 3
8 8 3 4
9 9 CN131
10 10
11 51 - Din7 11 51 R-L CN141-2 Elecromagnetic brake
12 51 - Din6 12 51 R-L CN140-2 TAB REC
13 68 - Din5 13 68 L CN123-12 NO P C J NO P C J
14 14 1 43 W CN131-2 1 43 L CN101-1
15 15 2 43 W CN131-1 2 43 L J4
16 51 - Ain2 16 51 R-L J2 3 60 P CN231-1 3 60 R CN102-7
17 17 4 P1 B CN231-2 4 P1 B J3
18 51 - OV 18 51 R-L CN123-3
19 46 - Din10 19 46 O CN123-10
20 45 - Din9 20 45 G CN123-11
21 21
22 22
23 23
24 24
25 25
26 26
10-16
3 2 1 1 2 3
6 5 4 4 5 6
CN133
RR combination light LH
TAB REC
NO P C J NO P C J
1 104 - RR COMBI LH 1 104 G-R CN33-1
2 2
3 111 - RR COMBI LH 3 111 Y CN33-3
4 4
5 109 - RR COMBI LH 5 109 G-Y CN33-5
6 N1 - RR COMBI LH 6 N1 W J30
3 2 1 1 2 3
6 5 4 4 5 6
CN134
TAB REC
NO P C J NO P C J
1 104 - RR COMBI RH 1 104 G-R J31
2 2
3 111 - RR COMBI RH 3 111 Y J32
4 103 - RR COMBI RH 4 103 LG CN34-1
5 108 - RR COMBI RH 5 108 L CN34-5
6 N1 - RR COMBI RH 6 N1 W J30
1 1
CN136
TAB REC
NO P C J NO P C J
1 2 MC 1 2 R CN101-4
1 1
CN136-1
TAB REC
NO P C J NO P C J
1 1 MC 1 1 V CN101-5
2 1 1 2
CN137
TAB REC
NO P C J NO P C J
1 4 R 1 4 L CN101-9
2 3 R 2 3 Y CN101-10
1
2
CN140
Error clear
REC
NO P C J
1 51 R-L J2
2 51 R-L CN102-12
10-17
JOINT
CN6-1 CN43-1 CN5-2 CN151-6 CN33-1 CN133-1
J1 J8 J15 J31
(51,R-L) (111,Y) (101,R) (104,GR)
CN102-16
CN140-1 CHIME CN18-1 CN154-4 CN34-3 CN33-3
J2 J9 J16 J32
(51,R-L) (103,LG) (110,GR) (111,Y)
P1 CN131-4 CN153-1 CN154-5 CN231-2
J3 J10 J17 J33
CN120-6 CN101-8 CN123-3 CN150-5 CN120-12 FR F/L LH RBR CN131-2
(P1,B) (51,R-L) (109,G-Y) (P1,B)
CN50-1 CN131-2 CN152-2 CN154-6 CN231-1
J4 J11 J18 J34

CN101-7
CN120-10 CN101-2 CN120-6 CN152-1 CN120-11 FR F/L RH DBR CN131-1
(43,L) (P1,B) (108,L) (60,R)
CN17-2 CN18-2 CN120-10 CN154-1
N1
J5 HORN J12 J19

CN50-2
CN34-6 CN33-6 HM-ST CN153-5 CN29-1 CN3-1
(N1,W) (43,L) (41,Y)
N1 CN12-1 CN154-1 CN153-5
J6 J13 J20
CN124-4 CN124-5 CN152-4 CN29-4 CN9-5
(N1,W) (41,Y) (43,L)
CN34-1 FR F/L LH CN33-6 CN134-6
J7 J14 CN34-6 J30 CN133-6
CN124-6 CN33-1 CN124-4 FR F/L RH LR CN50-2
(104,G-R) (N1,W) (N1,W)

4CBT2 • 3 • K4
L FL LS PB SW M SWHZ
HM L FR
DISP
NC
NO
SW
COM
COMBI TAB
REC
TAB
TAB
REC
REC
TAB CN1 CN13

(41,Y)
(49,O)
(N1,W)
CN9 REC CN3 CN16

TAB
TAB CN8 TAB
CN15 REC
REC REC
CONNECTION DIAGRAM
(N1,W)
(109,G-Y)
(108,L)
(N1,W)
LS ST L SB
CN150 CN151
F4 F5 TAB TAB
CN14
REC REC
NC
NC
NO
NO
COM
COM
CN29
TAB
REC
L H
(101,R)
TAB
SW K
(111,SL)
(65,BR)
(51,R)
REC
TAB CN152 TAB TAB

REC CN5 CN6
REC REC
ACCEL
+
TAB
BATT REC CN123
CN28
-
TAB TAB TAB TAB
REC CN26 CN124 REC REC REC
CN120
CN136-1
HRY TR Y FR Y
P1
TAB
REC
CN137 TAB TAB TAB

CONTACTOR
REC REC REC LS BA
TAB
PANEL
REC
TAB CN45 CN46 CN12
REC
NC
NO
P3
COM
CN136
(65,BR)
(51,R)
CN41 TAB
CHMS
CHMS
REC CN43
TAB
REC
TAB TAB
REC REC
CN101 CN102 HORN
P1 U
DRIVE CONTROL
V
(48,P)
UNIT ACMD
(N1,W)
SOL B
N1 CN17
W CN53 CN54 CN52
U V W TAB TAB TAB TAB
REC REC REC REC CHIM
TAB
REC
CN231
TAB
REC
BZ
TAB
REC
CN33 CN131
RR COMBI CN18 RR COMBI
TAB
TAB
REC
REC
LH RH
REC REC
TAB CN34
CN42 REC CN140 CN141 CN50 TAB
REC
LS D OPT:ROTARY LAMP
CN133 CN134
RR COMBI RR COMBI
TAB
TAB
REC
REC
LH RH
(43,W)
LR
(N1,B)
10-18
4CBTY2 • K4
L FL LS PB SW MODE SWL SWHZ

HM L FR
DISP
NC
NO
COM
TAB
SW H REC
ACCEL
(41,Y)
(49,O)
(N1,W)
SW F
CN1 CN16 CN10 CN13
TAB TAB TAB TAB
REC
CN15 TAB REC REC REC
(N1,W)
(109,O)
REC
(108,L)
(N1,W)
CN3
CN9 TAB
REC
CN8
TAB
REC
CN14 CN29
CN150 CN151
F4 F5 TAB TAB
TAB
REC
LH REC REC
TAB
SW K
REC
TAB CN152 CN153 CN154

TAB TAB
REC
REC REC
LS D LS ST LS B
NC
NC
NC
NO
NO
NO
COM
COM
COM
(101,R)
(111,SL)
(65,BR)
(51,R)
CN123
TAB TAB TAB
CN42 REC
CN5 REC
CN6 REC
TAB TAB TAB
CN124 REC REC REC CN120
+
BATT
-
FR Y LS BA
CN136-1
NC
NO
TAB
COM
P1 REC
TAB
REC
CN137 CN12
CONTACTOR
TAB
(65,BR)
(51,R)
PANEL
REC
TAB
REC
P3
CN41 TAB
CHMS
CHMS
REC CN43
TAB
REC
CN136
TAB TAB
REC REC HORN
CN101 CN102 U
P1
V ACMD
(N1,W)
DRIVE CONTROL SOL B

UNIT
W CN53 CN54 CN52 CN17
N1
TAB TAB TAB TAB
REC REC REC REC CHIM
TAB
REC
U V W
CN231
TAB
REC
BZ
TAB
REC
CN131
CN33
TAB
TAB
REC
REC
LH RH
CN34
REC REC
CN140 CN141 CN50 TAB
REC
ERROR CLEAR DIAG
OPT:ROTARY LAMP
CN133
TAB
TAB
REC
LH REC RH
(43,W)
LR
(N1,B)
10-19
10-20
WIRING DIAGRAM
4CBT2 • 3 • K4
MC
F1 175A
P2
LS BA
SW K
F5 10A ACCEL
(P1,B) (41,Y) (43,L)
VRAD
(69,G)
OPT:SUNSHADE
F4 10A LS D LS PB LS B SW M DS F DS R
(101,R)
F6 F7 LS ST
FR Y
TR Y HR Y
(140,R-B) (145,R-B)
(116,LG) (115,P)
(51,L)
(67,L)
(68,L)
(66,R)
(45,G)
(46,O)
(64,R)
(52,G)
(54,W)
(51,R-L)
(51,R-L)
R YWP
(65,Y-G)
SW L
(110,GR)
SW L
0V
0V
VB
A1N
KEY
DSF
DSF
Ain1
Din4
Din1
Din2
Din3
Din5
Din6
Din7
Din8
DSR
DSR
AIP5
DS BU DS FO
(111,Y)
T HS
(141,B-R) (146,V)
SW F SW HZ
(102,R-G)
(104,G-R) (17,L-R)
BATT
R WP1 R WA1 EX04
(146,L)
L T-L LH L ST-L RXDN
(145,L-W)
(120,P)
(103,LG)
CU TXON
(142,R-W) (147,R-W) (18,W-B)
(108,L)
DSPN
(109,G-Y)
R WP2
R WA2 L T-R L ST-R
(131,L)
CHMCR
LED DISP
(148,P)
EX01N
EX02P
EX02N
RCHN
RCHP
Ain4
A4N
PS14VI
CINA
PS14V2
CNT1B
(143,R-L)
SW H
P9
P8
P7
(W)
(V)
(U)
(4,L)
(122,Y)
(1,V)
(3,Y)
(2,R)
(76,L)
(78,P)
(80,R)
(75,G)
(79,W)
(60,R)
LR
(87,W-G)
L F-L L F-R
LBU-R
SA SOL B
HM-ST
MC
CHI
(144,R)
M WP
(149,G-Y)
(49,O)
BZ L F-LR L F-RR SSD2 AM D STMD
(48,P)
M M WA H HM
SSD1
(N1,W)
(N1,W)
BATT BATTERY SA SURGE ABSOBER L H LAMP, HEAD

L T-L LAMP, TAIL LH
F1 FUSE, DRIVE L T-R LAMP, TAIL RH
F4 FUSE, LAMP DS F DIRECTION SWITCH, FORWARD L ST-L LAMP, STOP LH
F5 FUSE, CONTROL CIRCUIT DS R DIRECTION SWITCH, REVERSE L ST-R LAMP, STOP RH
DS FO DIRECTION SWITCH, FORWARD OPTIONAL L BU-R LAMP, BACK-UP RH
LED DISP LED DISPLAY DS BU DIRECTION SWITCH, BACK-UP L F-L LAMP, FLASHER LH
L F-R LAMP, FLASHER RH
AM D MOTOR, DRIVE LS B LIMIT SWITCH, BRAKE L F-LR LAMP, FLASHER LH (REAR)
LS ST LIMIT SWITCH, STOP LAMP L F-RR LAMP, FLASHER RH (REAR)
VRAD VARI-OHM, ACCEL, DRIVE LS PB LIMIT SWITCH, PARKING BRAKE L R LAMP, ROTALY
LS BA LIMIT SWITCH, BATTERY STOPPER
CU CONTROL UNIT LS D LIMIT SWITCH, DEADMAN FR Y RELAY, FLASHER
SW HZ SWITCH, HAZARD TR Y RELAY, TAIL LAMP

SSD1 SENSOR, SPEED, DRIVE 1 SW M SWITCH, MODE HR Y RELAY, HEAD LAMP
SSD2 SENSOR, SPEED, DRIVE 2 SW L SWITCH, LIGHT
SW H SWITCH, HORN CHI CHIME
STMD SENSOR, TEMPRETURE, DRIVE SW K SWITCH, KEY CHMCR CHIME CONNECTOR, REVERSE
SW F SWITCH, FLASHER HM-ST HOUR METER START CONNECTOR
MC CONTACTOR, CONTROL SOL B SOLENOID, BRAKE HM METER, HORN
B Z BUZZER H HORN
10-21
4CBTY2 • K4
MC
F1 175A
P2
LS BA
SW K
F5 10A ACCEL
(P1,B) (41,Y) (43,L)
VRAD
(69,G)
F4 10A LS D LS PB LS B SW M DS F DS R
(101,R)
LS ST
FR Y
SW L
(51,L)
(67,L)
(68,L)
(66,R)
(45,G)
(46,O)
(52,G)
(54,W)
(51,R-L)
(51,R-L)
(65,Y-G)
(110,GR)
0V
0V
VB
A1N
KEY
DSF
DSF
Ain1
Din4
Din1
Din2
Din3
Din5
Din6
Din7
Din8
DSR
DSR
AIP5
DS BU DS FO
(111,Y)
SW F SW HZ
(17,L-R)
(102,R-G)
(104,G-R)
EX04
(146,L)
L T-L LH L ST-L RXDN
(145,L-W)
(120,P)
(103,LG)
CU TXON
(18,W-B)
(108,L)
DSPN
(109,G-Y)
BATT L T-R L ST-R
(131,L)
CHMCR
LED DISP
EX01N
EX02P
EX02N
RCHN
RCHP
Ain4
A4N
PS14VI
CINA
PS14V2
CNT1B
SW H
P9
P8
P7
(W)
(V)
(U)
(4,L)
(122,Y)
(1,V)
(3,Y)
(2,R)
(76,L)
(78,P)
(80,R)
(75,G)
(79,W)
(60,R)
LR
(87,W-G)
L F-L L F-R
LBU-R
SA SOL B
HM-ST
MC
CHI
(49,O)
BZ L F-LR L F-RR SSD2 AM D STMD
(48,P)
H HM
SSD1
(N1,W)
(N1,W)
BATT BATTERY SA SURGE ABSOBER L H LAMP, HEAD

L T-L LAMP, TAIL LH
F1 FUSE, DRIVE L T-R LAMP, TAIL RH
F4 FUSE, LAMP DS F DIRECTION SWITCH, FORWARD L ST-L LAMP, STOP LH
F5 FUSE, CONTROL CIRCUIT DS R DIRECTION SWITCH, REVERSE L ST-R LAMP, STOP RH
DS FO DIRECTION SWITCH, FORWARD OPTIONAL L BU-R LAMP, BACK-UP RH
LED DISP LED DISPLAY DS BU DIRECTION SWITCH, BACK-UP L F-L LAMP, FLASHER LH
L F-R LAMP, FLASHER RH
AM D MOTOR, DRIVE LS B LIMIT SWITCH, BRAKE L F-LR LAMP, FLASHER LH (REAR)
LS ST LIMIT SWITCH, STOP LAMP L F-RR LAMP, FLASHER RH (REAR)
VRAD VARI-OHM, ACCEL, DRIVE LS PB LIMIT SWITCH, PARKING BRAKE L R LAMP, ROTALY
LS BA LIMIT SWITCH, BATTERY STOPPER
CU CONTROL UNIT LS D LIMIT SWITCH, DEADMAN FR Y RELAY, FLASHER
SSD1 SENSOR, SPEED, DRIVE 1 SW M SWITCH, MODE CHI CHIME

SSD2 SENSOR, SPEED, DRIVE 2 SW L SWITCH, LIGHT B Z BUZZER
SW H SWITCH, HORN SOL B SOLENOID, BRAKE
STMD SENSOR, TEMPRETURE, DRIVE SW K SWITCH, KEY H HORN
SW F SWITCH, FLASHER HM METER, HOUR
MC CONTACTOR, CONTROL SW HZ SWITCH, HAZARD CHHCR CHIME CONNECTOR, REVERSE
HM-ST HOUR METER START CONNECTOR
Published by
1st Printing: Mar. 2006
Pub. No. CE662
Printed in Japan
C
4CBTK4 4CBTYK4 for Europe
4CBT2, 3 4CBTY2
4CBT2, 3
4CBTY2
4CBTK4
4CBTYK4
for Europe
Pub. No. CE662
PRINTED IN JAPAN Pub. No. CE662 Pub. No. CE662

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4CBTK4 4CBTYK4 for Europe

Pub. No. CE662

PRINTED IN JAPAN Pub. No. CE662 Pub. No. CE662

EXTERIOR VIEW OF VEHICLE

Sit-down 3.0 tonnes 4CBT3 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

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 ← ←

Commutator contamination, damage I ←