Ce676 4CBTR RM 4-4

11-1
APPENDIX
Page 0
SST LIST .......................................................... 11-2
1
SERVICE STANDARDS................................... 11-4
CONNECTION DIAGRAM................................ 11-7
2
WIRING DIAGRAM .......................................... 11-9 3
CONNECTOR DIAGRAM............................... 11-13 4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
11-2
SST LIST
Section
Illust Part No. Part name
1 2 3 4 5 6 7 8 9 10
Lock nut remover

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

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

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

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

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

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

mm [in.]
N·m (kgf·cm) [ft·bt]

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

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

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

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

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

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

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

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

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

Clearance mm [in.]
Limit 0.6 [0.024]

Wheel cylinder set bolt Standard 4.22 to 6.18 (43 to 63) [3.1 to 4.6]
Brake pedal set bolt Standard 29.4 to 44.1 (300 to 450) [21.7 to 32.6]
Backing plate set nut Standard 88.26 to 117.68 (900 to 1200) [65.1 to 86.8]
11-7
CONNECTION DIAGRAM
4CBT2R • 3R • 4CBTK4R
Stop at Travel
multiple set between
Hazard light points two points
switch specification specification
Width sensor
Width sensor ready type (RH)
ready type (LH)
Battery slide out
Stop at multiple set points specification
Advance/reverse chime
Reverse buzzer ****

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

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

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

set points specification

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

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



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

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

Stop at multiple set

points specification

Battery roll out****
Hazard switch

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



Battery roll out****
OPT:Hazard switch

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

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

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

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

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

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

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

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

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

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

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

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

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

Travel between two points specification****

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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


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

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

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

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

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

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

Ce676 4CBTR RM 4-4

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Ce676 4CBTR RM 4-4

Uploaded by

Copyright:

Available Formats

11-1

Lock nut remover

09320-23000-71 Bearing remover {

Lock nut remover

09410-40150-71 Bearing replacer {

09420-40590-71 Pinion nut {

09430-40590-71 Bearing remover {

09561-40590-71 Shorting harness {

Brake hold down

Item All Models

Voltage upon end of discharge V 42.5

Insulation resistance MΩ 1 or more

Item All Models

F1 (fuse for drive circuit) A 175

F4 (fuse for lamp circuit) A 10

F5 (fuse for control circuit) A 10

Insulation resistance (at 500 VDC) MΩ 10 or more

Tightening torque N·m (kgf·cm) [ft·bt]

Item 4CBT2R • 3R • 4CBTK4R

Item 4CBTY2R • K4R

Item 4CBTY2R • K4R

Amount of protrusion of floor switch mm [in.] 25 [0.98]

Item All Models

Tightening torque N·m (kgf·cm) [ft·bt]

Item 4CBT2R • 3R • K4R 4CBTY2R • 4CBTYK4R

Minimum rotation radius mm [in.] 1600 [64.0] 0

Starting force of drive pinion

N·m (kgf·cm) [ft·bt]

0.49 to 0.99 (5.0 to 10.0) [0.4 to 0.7]

700 kPa (7.0 kgf/cm2)

Item 4CBT2R • 3R • 4CBTK4R 4CBTY2R • 4CBTYK4R

Steering wheel set nut Standard

Item 4CBT2R • 3R • 4CBTK4R 4CBTY2R • 4CBTYK4R

Standard 81.7 [3.217]

Standard 3.95 [0.156]

Standard 203.2 [8.00]

Pedal play mm [in.] 5 to 10 (0.2 to 0.39)

Pedal remaining depression margin mm [in.] — 10 (0.39)

Push rod play mm [in.] 1 to 2 (0.04 to 0.08)

Electromagnetic brake hub width accross flats mm [in.] Standard 27 [1.06]

Standard 9.0 [0.35]

Standard 0.3 [0.012]

Tightening torque N·m (kgf·cm) [ft·bt]

Battery slide out

Stop at multiple set points specification

Reverse buzzer ****

Battery slide out

Stop at multiple set points specification

Reverse buzzer ****

OPT: Speed reduction (for travel between two

OPT: Stop at multiple

OPT: Stop at multiple

OPT:Battery roll out****

OPT: Hazard switch

Remote inching Traveling between Stop at multiple set

OPT: Speed reduction (for travel between two

OPT: Stop at multiple

OPT: Stop at multiple

OPT:Battery roll out****

OPT: Hazard switch

Remote inching Traveling between Stop at multiple set

4CBTY2R • 4CBTKY4R (STD)

Stop at multiple set