Ce676 4CBTR RM 1-4

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

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

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

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

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

0-9
HOISTING THE VEHICLE

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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


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

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

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

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

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

cylinder and looseness
wheel cylinder
0-20
Every Every Every


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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Size
Rear 4.00-8
SERVICE BRAKE Hydraulic

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Switch positions.
No. Line color

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

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

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

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

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

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

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

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

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

Fuse 175A
Red
Purple
Check line color and connection position

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Nut
FLOOR SWITCH ADJUSTMENT METHOD

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

not disappear
Normal operation is possible • Check for loose

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

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

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

Traveling disabled Yes
• Accelerator abnormality
Perform acceleration sensor check Abnormal

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

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

Replace controller Error indication
Disappears
Perform accelerator check Abnormal

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

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

Disappears

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

Disappears

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

Disappears

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

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

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

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

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

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

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

Error indication disappear See P3-12
Troubleshooting
Disappears

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

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

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

Disappears

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

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

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

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

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

3-18
Motor rpm sensor abnormality Display only Yes
Perform motor rpm sensor voltage check with the key switch
turned ON and the vehicle stopped
Within standard range
rpm sensor A CN101-14 to CN101-15 Replace controller
Standard range
1.2 V to 3.2 V
rpm sensor B CN101-29 to CN101-30
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
4CBT2R
4CBT3R
Free ventilation
ø202 × 277
4CBTK4R 48 2.3 Flange-type
[ø7.95 × 10.90]
Cage-type
4CBTY2R
4CBTYK4R
4-3
COMPONENTS
STD
Bolt, Washer
Bearing
Screw Plate
0
Bushing
Bracket
Collar
Stator
Bracket
1
Sensor Washer
Gear 2
Nut
Center cap
Bearing
3
4
5
Oil seal
Flange bolt Rotor

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

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

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

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

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

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

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

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

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

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

5-9
3. Remove the front axle hub.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

The vehicle should stop within 5 m [196.9 in.] when unloaded and driven at full speed (13 km/h
[8.07 mph]).
With a speed limiter;
Disable the speed limiter. The vehicle should stop within 5 m [196.9 in.] when unloaded and driven at full
speed (13 km/h [8.07 mph]).
If the vehicle does not stop within the standard value under the above conditions, repeat the bleeding
operation.

Ce676 4CBTR RM 1-4

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Ce676 4CBTR RM 1-4

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FOREWORD

EXTERIOR VIEW OF VEHICLE

Sit-down 3.0 tonnes 4CBT3R 48 V

HOW TO USE THIS MANUAL

2. How to read component figures

Abbreviation Meaning Abbreviation Meaning

ASSY Assembly SAE Society of Automotive Engineers (USA)

LH Left hand SST Special service tool

L/ Less STD Standard

OPT Option T= Tightening torque

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

PS Power steering U/S Undersize

RH Right hand W/ With

Wooden block point

Front section of frame Rear section of frame

HOISTING THE VEHICLE

Remove the toe board before hoisting the vehicle.

WIRE ROPE SUSPENSION ANGLE LIST

60° 1.16 time 0.58 time 60°

SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE

TOWING THE VEHICLE

GRADIENT AND TOW CAPACITY

Slope road (Slope start)

ELECTRICAL PARTS INSPECTION

(b) Digital circuit tester

BOLT & NUT TIGHTENING TORQUES

BOLT STRENGTH CLASS IDENTIFICATION METHOD AND

Type Shape and class Class

Hexagon head bolt

Bolt with three raised lines on head 7T

Bolt with four raised lines on head 8T

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

Identification by Part No.

Type Part No. Shape

Tightening Torque Table

Nominal diameter Pitch Standard tightening torque

6 1.0 5.4 55 48 in·lbf

6 1.0 6.5 65 56 in·lbf

6 1.0 7.8 80 69 in·lbf

HEXAGON FLANGE BOLT TIGHTENING TORQUE

Nominal diameter Pitch Standard tightening torque

7.5 (76.5) [5.5]

12.5 (128) [9.2]

115 (1173) [84.9]

180 (1837) [133]

280 (2857) [207]

HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE

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

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

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

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

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

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

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

RECOMMENDED LUBRICANT QUANTITY AND TYPES

Chassis parts Toyota genuine MP grease Appropriate amount

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

Item Every Every Every

Looseness in the connecting parts I ← ←

Commutator contamination, damage I ←

Electrolyte specific gravity M ← ←

Battery Terminal looseness I ← ←

Abnormality in the upper portion of the battery case I ← ←