FOREWORD

This Manual contains maintenance, specifications and repair procedures for

the chassis, body and material handling system of the TOYOTA ELECTRIC
POWERED TOWING TRACTOR CBT4,6 · CBTY4.

Please use these manuals for providing quick, correct servicing of the corr-
sponding towing tractor.

This manual deals with the above models as of September 2003. 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
ELECTRICAL SYSTEM TROUBLESHOOTING 3
MOTOR 4
DRIVE UNIT 5
FRONT AXLE 6
REAR AXLE 7
STEERING 8
BRAKE 9
BODY•FRAME 10
APPENDIX 11
 0-1

GENERAL

Page Page
PERIODIC MAINTENANCE ........0-18
0

VEHICLE EXTERIOR VIEW ...... 0-2 0

PERIODIC REPLACEMENT OF
Vehicle models ............................ 0-3
PARTS AND LUBRICANTS ....0-21
FRAME NUMBER ........................ 0-4
NEW MODEL FEATURES ..........0-22
HOW TO USE THIS MANUAL .. 0-5
DEVELOPMENT OBJECTIVES .....0-22
EXPLANATION METHOD ............. 0-5
SELLING POINTS ..........................0-22
TERMINOLOGY ............................. 0-6
OUTLINE OF MAJOR
ABBREVIATIONS .......................... 0-6 FUNCTIONS .................................0-23
OPERATING TIPS ........................ 0-7 PERFORMANCES ..........................0-25
GENERAL INSTRUCTIONS .......... 0-7 VEHICLE SPECIFICATIONS ..........0-26
JACK-UP POINT ........................... 0-8
HOISTING THE VEHICLE ............. 0-9
WIRE ROPE SUSPENSION
ANGLE LIST ............................... 0-10
SAFE LOAD FOR EACH WIRE
ROPE SUSPENSION ANGLE .... 0-10
MEMBER WEIGHTS ...................... 0-11
TOWING THE VEHICLE ................ 0-11
ELECTRICAL PARTS
INSPECTION ............................... 0-12
STANDARD BOLT & NUT
TIGHTENING TORQUES ......... 0-13
BOLT STRENGTH CLASS
IDENTIFICATION METHOD ........ 0-13
TIGHTENING TORQUE TABLE .... 0-14
PRECOATED BOLTS .................... 0-15
HIGH PRESSURE HOSE FITTING
TIGHTENING TORQUE ........... 0-15
RECOMMENDED LUBRICANT
QUANTITY AND TYPES .......... 0-16
LUBRICATION CHART .............. 0-17
 0-2

VEHICLE EXTERIOR VIEW

CBT4•6
0
 0-3

CBTY4
0

VEHICLE MODELS
Type Model Control method

CBT4 Transistor chopper

4.0 t
CBTY4 ↑

6.0 t CBT6 ↑
0-4

FRAME NUMBER
Vehicle model CBT4 CBTY4 CBT6

Punching format CBT4-10011 CBTY4-10011 CBT6-10011

CBT4•6

Left-hand frame side plate top

Punching position CBTY4

Left-hand front protector frame top

 0-5

HOW TO USE THIS MANUAL

EXPLANATION METHOD
1. Operating procedure
(1) Operating procedures are described using either pattern A or pattern B.
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. 0
Example of pattern B

DISASSEMBLY•INSPECTION•REASSEMBLY
Tightening torque unit T=N•m (kg•m) [ft•lbf]
Some step numbers may be omitted
in some illustrations.
When a part requiring tightening 4 1
torque instruction is not indicated in 2
the illustration, the part name is 3

described in the illustration frame.

7

5 6

T = 46.1 to 48.1
(470 to 490)
[34.0 to 35.5]

5
9 1

Disassembly Procedure
1 Remove the cover. [Point 1] Operation to be explained
2 Remove the bushing. [Point 2]
3 Remove the gear.

Point Operations

[Point 1] Explanantion of operation point with illustration

Disassembly:
Make match marks before removing the pump cover.

[Point 2]
Inspection:
Measure the bushing inside diameter.
Inspection:Limit 19.12 mm (0.7528 in)
0-6

2. How to read component figures

(Example)
(1) The component figures use the illustration in the parts
catalog for the vehicle model. Please refer to the 3201
catalog to check the part name.
Parts catalog
3. Matters omitted from this manual
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
Society of Automotive Engineers
ASSY Assembly SAE
(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

JACK-UP POINT
Always observe the following instructions when jacking up the vehicle:
• Park 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.
CBT4•6

Jack-up points

Wooden block or stand

setting points

CBTY4

Jack-up points

Wooden block or stand

setting points
 0-9

HOISTING THE VEHICLE

When hoisting the vehicle, always observe the specified hoist attachment section and method. Never hoist
by any other attachment section as it is very dangerous.
CBT4•6

CBTY4
0-10

WIRE ROPE SUSPENSION ANGLE LIST

Suspension Suspension Suspension Suspension
Tension Compression Tension Compression
angle method angle method

1.00 1.41
0° 0 time 90° 1.00 time 90°

1tf
time time

tf
41
1.
2t 2t

30°
1.04 2.00

tf
30° 0.27 time 120° 1.73 time
1 .0 4
time time 120°

f
2t
2t 2t

60°
1.16
60° 0.58 time
time
6tf
1.1

2t

SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE

Unit: N (tf) [lbf]
Single-rope
Rope Cutting suspension Two-rope suspension Four-rope 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

MEMBER WEIGHTS
unit: kg (lbs)
Member Vehicle model Weight
Battery ASSY See page 1-2
CBT4•CBTY4 Approx. 27 (60)
Drive motor ASSY
CBT6 Approx. 45 (99)
CBT4•CBTY4 Approx. 96 (112)
Rear axle and drive unit ASSY W/drive motor
CBT6 Approx. 117 (258)
Front axle ASSY (W/LH and RH front wheels) All models Approx. 15 (33)
Battery hood CBTY4 Approx. 90 (200)
CBT4 980 (2160)
Vehicle weight CBTY4 975 (2150)
CBT6 1055 (2325)

TOWING THE VEHICLE

Note the cautions below when towing the vehicle.

1. There are two towing methods:

(1) Lift the front wheels (Fig. 1)
(2) Not lift the front wheels (Fig. 2)
Steering operation is necessary.

2. The traveling speed when towing must not exceed the

maximum traveling speed of the vehicle.
Fig.1

3. Before starting towing, always set the key switch to OFF

and the direction switch to the neutral position.
CBTY4:EEC

1. Disconnect the parking brake cable. (See PARKING

BRAKE in Section 9 for the disconnection procedures.)

2. There are two towing methods:

(1) Lift the front wheels (Fig. 1)
(2) Not lift the front wheels (Fig. 2)
Steering operation is necessary.
Fig.2
3. The traveling speed when towing must not exceed the
maximum traveling speed of the vehicle.

4. Before starting towing, always set the key switch to OFF

and the direction switch to the neutral position.
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
* 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.
1) Analog circuit tester

Example of measurement result

Tester range: kΩ range
Analog type
Continuity
Forward
11 kΩ
No continuity
Reverse
∞

2) Digital circuit tester

Example of measurement result

Forward Reverse
Tester range: 2 MΩ range
Digital type
No continuity
Forward
1
Continuity
Reverse
2 MΩ
 0-13

STANDARD BOLT & NUT TIGHTENING TORQUES

Tightening torques for standard bolts and nuts are not indicated throughout the manual.
Use the charts and table below to judge the standard tightening torque.
1. Find the class of the bolt strength in the table below and then find the bolt tightening torque in the
tightening torque table.
2. The nut tightening torque can be judged from its corresponding bolt type.

BOLT STRENGTH CLASS IDENTIFICATION METHOD

Identification by bolt shape Identification by part No.

Shape and class Class Hexagon head bolt

Hexagon 4 = 4T
head bolt Bolt with raised or 5 = 5T Part No.
etched numeral on 6 = 6T
91611-40625
Hexagon head 7 = 7T
Length (mm)
bolt 8 = 8T
Nominal diameter (mm)
Class
No mark 4T
(standard)

Hexagon
No mark 4T
flange bolt
Nominal diameter

Hexagon Bolt with two

head bolt raised lines on 5T Length
(standard) head
Bolt with two
Hexagon
raised lines on 6T
flange bolt
head
Hexagon Bolt with three
head bolt raised lines on 7T
Stud bolt
(standard) head
Hexagon Bolt with four Part No.
head bolt raised lines on 8T
92132-40614
(standard) head
Length (mm)
Nominal diameter (mm)
Welded bolt 4T Class

4T Nominal diameter
No mark
Stud bolt
Length
2 mm groove(s) on
6T
one/both edge(s)
0-14

TIGHTENING TORQUE TABLE

Standard tightening torque

Nominal Hexagon Hexagon

Pitch head bolt flange bolt
Class diameter
mm
mm

N•m kgf•cm ft•lbf N•m kgf•cm ft•lbf

6 1.0 5.4 55 48 in•lbf 5.9 60 52 in•lbf

8 1.25 13 130 9 14 145 10
10 1.25 25 260 19 28 290 21
4T
12 1.25 47 480 35 53 540 39
14 1.5 75 760 55 83 850 61
16 1.5 113 1150 83   

6 1.0 6.4 65 56 in•lbf 7.5 75 65 in•lbf

8 1.25 16 160 12 18 175 13
10 1.25 32 330 24 36 360 26
5T
12 1.25 59 600 43 65 670 48
14 1.5 91 930 67 100 1050 76
16 1.5 137 1400 101 157 1600 116

6 1.0 7.8 80 69 in•lbf 8.8 90 78 in•lbf

8 1.25 19 195 14 21 215 16
10 1.25 38 400 29 43 440 32
6T
12 1.25 72 730 53 79 810 59
14 1.5 110 1100 80 123 1250 90
16 1.5 170 1750 127 191 1950 141

6 1.0 11 110 8 12 120 9

8 1.25 25 260 19 28 290 21
10 1.25 52 530 38 58 590 43
7T
12 1.25 95 970 70 103 1050 76
14 1.5 147 1500 108 167 1700 123
16 1.5 226 2300 166   

6 1.0 12 125 9 14 145 9

8 1.25 29 300 22 32 330 24
10 1.25 61 620 45 68 690 50
8T
12 1.25 108 1100 80 123 1250 90
14 1.5 172 1750 127 196 2000 145
16 1.5 265 2700 195 299 3050 221
 0-15

PRECOATED BOLTS
(Bolts with seal lock agent coating on threads)

1. Do not use a precoated bolt as it is in either of 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 to the lower limit of the
Seal lock agent
allowable tightening torque range; if the bolt moves,
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 a specified seal lock agent to the threaded
portion of the bolt.

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 connecting the high pressure hose, hold the hose to align the fitting with the nipple and tighten
the fitting.
3. The maximum tightening torque must not exceed twice the standard tightening torque.
Tightening torque standard N•m (kgf•cm) [ft•lbf] Inside diameter
Nominal diameter
of hose
of screw Standard Tightening range mm (in)
7/16-20UNF 25 (50) [18.1] 24 to 26 (240 to 270) [17.4 to 19.5] 6 (0.24)
9/16-18UNF 49 (500) [36.2] 47 to 52 (480 to 530) [34.7 to 38.3] 9 (0.35)
3/4-16UNF 59 (600) [43.4] 56 to 62 (570 to 630) [41.2 to 45.6] 12(0.47)
7/8-14UNF 59 (600) [43.4] 56 to 62 (570 to 630) [41.2 to 45.6] 12 (0.47)
7/8-14UNF 78 (800) [57.9] 74 to 82 (740 to 840) [53.5 to 60.8] 15 (0.59)
1•1/16-12UNF 118 (1200) [86.8] 112 to 123 (1140 to 1250) [82.5 to 90.4] 19 (0.75)
1•5/16-12UNF 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)
0-16

RECOMMENDED LUBRICANT QUANTITY AND TYPES

Applicable portion Type Quantity
1.25 Liter (0.33 US gal)
The oil level shall be within a
range of 9 to 11 mm (0.354 to
Drive unit Hypoid gear oil SAE 75W-80
0.433 in) from the bottom of the
filler port.
The above value is for reference
Brake line SAE J-1703, DOT-3 Appropriate amount
Steering chains Molybdenum disulfide grease Appropriate amount
Chassis parts MP Grease Appropriate amount
Battery Distilled water Appropriate amount
 0-17

LUBRICATION CHART
CBT4•6

A A

B B 2

3 C C

II

III

IV

CBTY4

A A

B B 2

3 C C

II

III

IV

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

z: Replacement II. Inspection every 250 hours (6 weekly)
A: MP grease III. Inspection every 1000 hours (6 monthly)
B: Brake fluid (SAE J-1703, DOT-3) IV. Inspection every 2000 hours (annual)
C: Gear oil (SAE 75W-80)

1. Front wheel bearing Note:

2. Brake fluid reservoir tank In case of a hand operating condition, the
3. Differential and drive unit service interval of 170 hours or 1 month is
recommendable.
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

Inspection Period Every Every Every Every

6 weeks 3 months 6 months 12 months
Every Every Every Every
Item 250 hours 500 hours 1000 hours 2000 hours
ELECTRICAL SYSTEM
Rotation sound I ← ← ←
Looseness in the connecting parts ← ← ←
Insulation resistance M ← ←
Motor
Brush wear and sliding condition I ←
Commutator contamination, damage I ←
Brush spring wear M
Charge level I ← ← ←
Electrolyte level I ← ← ←
Electrolyte specific gravity M ← ← ←
Terminal looseness I ← ← ←
Battery Abnormality in the upper portion of the battery
I ← ← ←
case
Insulation resistance M ← ←
Voltage measurement of each battery cell after
M
charging
Contact looseness, damage, abrasion I ← ← ←
Operating condition of the auxiliary contact,
I ← ← ←
contamination, 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,
I
looseness
Operating condition and timings I ← ← ←
Microswitch
Damage and looseness of installing parts I ← ← ←
Direstion Operation condition, damage
switch or
I ← ← ←
accelerator
lever
Operation condition I ← ← ←
Controller Interior contamination, damage C ← ← ←
Motor input voltage M
Fuse Looseness I ← ← ←
 0-19

Inspection Period Every Every Every Every

6 weeks 3 months 6 months 12 months
Every Every Every Every
Item 250 hours 500 hours 1000 hours 2000 hours
Harness deterioration, champ damage and
I ← ← ←
Wiring looseness
(including Looseness in connecting parts, tapping condi-
I ← ← ←
charging tion
cord) Connecting condition and damage of the bat-
I ← ← ←
tery connector
POWER TRANSFER SYSTEM
Oil leakage I ← ← ←
Drive unit Oil level I ← ← ←
Bolt or nut looseness T
DRIVING SYSTEM
Tire inflation pressure M ← ← ←
Tire cuts, damege and abnormal wear I ← ← ←
Lim and hub nuts looseness T ← ← ←
Tire groove depth M ← ← ←
Metal chips, pebbles and other foreign matter
Wheels I ← ← ←
trapped in tire grooves
Rim and disc wheel damage I ← ← ←
Abnormal sound and looseness of front wheel
I ← ← ←
bearing
Abnormal sound and looseness of rear wheel
I ← ← ←
bearing
Cracks, damage and deformation of beam I
Front axle Looseness of axle beam in vehicle longitudinal
M* M
direction
Rear axle Cracks, damage and deformation of housing I
STEERING SYSTEM
Steering - Play and looseness I ← ← ←
wheel Function I ← ← ←
BRAKING SYSTEM
Play and depressed pedal clearance from the
M ← ← ←
Brake pedal floor plate
Braking effect I ← ← ←
Operating force I ← ← ←
Parking
Braking effect I ← ← ←
brake
Rod and cable looseness and damage I ← ← ←
Brake pipe Leak, damage and mounting condition I ← ← ←
Reservoir
Leak and fluid level I ← ← ←
tank
Master cyl-
inder and Function, wear, damage, leak and mounting
I
wheel cylin- looseness
der
 0-20
no

Inspection Period Every Every Every Every

6 weeks 3 months 6 months 12 months
Every Every Every Every
Item 250 hours 500 hours 1000 hours 2000 hours
Clearance between drum and lining M ← ← ←
Wear of shoe sliding portion and lining I

Brake drum Drum wear and damage I

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 sys-
Function and mounting condition I ← ← ←
tem
Horn Function and mounting condition I ← ← ←
Instruments Function I ← ← ←
Backup
Function and mounting condition I ← ← ←
buzzer
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,
I
Body etc.
Bolt looseness T

Note:In case of a hard operation, the service interval of 170 hours or 1 month is recommendabl e.
In case of a hard operation condition, the service interval of 170 hours or 1 month is
recommendable.
 0-21

PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS

z: Replacement

Replacement timing Every Every Every Every

6 weeks 3 months 6 months 12 months
Every Every Every Every
Item 250 hours 500 hours 1,000 hours 2,000 hours
Drive unit 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

NEW MODEL FEATURES

DEVELOPMENT OBJECTIVES
While most small tractors are driven by engines, this newly developed model is driven by a battery and is
capable of towing a load up to 4,000 kg [8,800 lbs] (CBT4 and CBTY4) and 6,000 kg [13,200 lbs] (CBT6)
for 60 minutes to satisfy the growing concern about the environment.

SELLING POINTS
1. Optimum driving position and wide opening for a smooth ingress/egress (CBT4 and 6).
The driving position and wide opening that considers frequent ingress/egress (CBTY4).
.

CBT4•6
540 mm (21.3 in)
Hip point height

Opening
420 mm (16.5 in)

CBTY4
200 mm (7.9 in)
Floor height

Opening
515 mm (20.3 in)

2. Small turning radius for lively indoor operation

Minimum turning radius: 1,775 mm [69.9 in] (CBT4 and 6)
1,600 mm [63.0 in] (CBTY4)
 0-23

3. A large capacity battery can be mounted for a longer, continuous operation.

CBT4 : 48V 300AH/6HR battery can be mounted
CBTY4 : 48V 250AH/6HR battery can be mounted
CBT6 : 48V 400AH/6hr battery can be mounted

OUTLINE OF MAJOR FUNCTIONS

1. Controller
The main circuit adopts a transistor chopper for smooth acceleration and excellent operability at low
speeds with less power consumption.
CBT4•6

Key switch

Seat switch

Acceleration sensor Controller Drive motor

&
switch

Direction switch

CBTY4

Key switch

Accelerator lever Controller Drive motor

Floor switch (OPT)

2. Return-to-neutral function
CBT4•6:
The vehicle does not move when the key switch is turned to the ON position while the direction lever is
in its forward or reverse position or the accelerator pedal is being depressed.
In such a case, first set the direction lever to the neutral position and release the accelerator pedal,
and operate the direction lever and accelerator pedal to move the vehicle.
CBTY4:
The vehicle does not move when the key switch is turned to the ON position while the accelerator lever
is in its forward or reverse position.
In such a case, first set the accelerator lever to its neutral position and operate the accelerator lever to
move the vehicle.
3. Seat switch (optional for CBT4•6)
• The driving circuit is automatically disconnected when no operator is on the operator's seat even
when the key switch is in the ON position. The vehicle does not move if the accelerator pedal is
erroneously depressed when getting into /out of the vehicle.
• The head and tail lamps automatically go out when the operator leaves the operator's seat without
turning these lamps off.
0-24

• In addition to the standard return-to-neutral function, this function prevents the vehicle from moving
while the operator is on the operator’s seat with the direction lever in its forward or reverse position
or the accelerator pedal being depressed. In such a case, first set the direction lever to the neutral
position and release the accelerator pedal, and operate the direction lever and accelerator pedal to
move the vehicle
• The hour meter interlocked with the seat switch operates when the key switch is turned to the ON
position while the operator is on the operatorÅfs seat. (Optional)
4. Floor switch (optional for CBTY4)
• The driving circuit is automatically disconnected when the floor switch is not depressed. The vehicle
does not move if the operator erroneously depresses the accelerator pedal when getting into/out of
the vehicle.
• The headlamp and taillight automatically go off when the operator leaves the operatorÅfs seat
without turning these lamps off.
• In addition to the standard return-to-neutral function, the vehicle does not move when the floor
switch is depressed with the accelerator lever in its forward or reverse position. In such a case, first
set the accelerator lever to its neutral position and operate the accelerator lever to move the vehicle.
• The hour meter interlocked with the floor switch operates when the key switch is turned to the ON
position while the operator is depressing the floor switch. (Optional)
5. Floor switch pedal (CBTY4: USA)
• The drive motor circuit switch is built in the floor switch pedal. To drive the vehicle, turn the key
switch to ON, depress the floor switch pedal and operate the accelerator lever. If the floor switch
pedal is released while driving, the drive motor circuit is cut off.
6. Floor parking pedal (CBTY4: EEC)
• The drive motor circuit switch and parking brake operating mechanism are built in the floor parking
pedal. When the floor parking pedal is not depressed, the drive motor circuit is cut off and the
parking brake becomes effective. To drive the vehicle, turn the key switch to ON and depress the
floor parking pedal.
 0-25

PERFORMANCES
1. Working hours
Battery Continuous working
Vehicle model
Voltage (V) Capacity (AH/5HR) hours
210 11 hr and 55 min
CBT4 48
280 16 hr and 12 min
160 8 hr and 56 min
165 9 hr and 14 min
CBTY4 ↑
225 12 hr and 47 min
250 14 hr and 15 min
280 9 hr and 33 min
CBT6 ↑ 365 12 hr and 36 min
370 12 hr and 47 min

*: The continuous working hours are based on Toyota's standard towing operation pattern in the
premises.
2. Towing weight (60-min. rating)
Towing weight
Vehicle model Slope
Flat road
1° 2° 3° 4°
kg 4000 1900 1000 500 200
CBT4
(lbs) (8800) (4200) (2200) (1100) (440)
kg
CBTY4 ↑ ↑ ↑ ↑ ↑
(lbs)
kg 6000 3000 1800 1100 600
CBT6
(lbs) (13200) (6600) (4000) (2400) (1300)
3. Traveling performance
Maximum traveling
Condi- speed Gradability
Vehicle model
tions %
km/h mph
W/O load 13.5 8.4 36
CBT4
W/ load 9.0 5.6 6
W/O load 13.5 8.4 36
CBTY4
W/ load 9.0 5.6 6
W/O load 18.0 11.2 32
CBT6
W/ load 13.0 8.1 4

* : The towing weight of CBT4 and CBTY4 are 2,000 kg [4,400 lbs] and that of CBT 6 is 3,000 kg
[6,600 lbs] when loaded. The gradability of CBT4 and CBTY4 is 5-minute rating and that of CBT6 is
3-minnute rating.
0-26

VEHICLE SPECIFICATIONS
Vehicle exterior views

CBT4•6

B1
B3
B2

Seat slide
120 mm (4.73 in)
h1

h4
h3

h2

L4 L3 L6

L2

L1
 0-27

CBTY4

B1
B3
B2

R
h1

h2
h3

h4

L4 L3 L5 L6

L2

L1
0-28

MAIN SPECIFICATIONS
Manufacturer TOYOTA
Model CBT4 CBTY4 CBT6
Power Type Battery
Rider Rider
Operator Position Stand up
Seated Seated
Pneumatic/Pneumatic
Tire Type Front/Rear
(Nonpunc/Nonpunc)
Wheels (x=driven) Front/Rear 2/2
3-Minute Ratings N 3920 ← 4410
Maximum Drawbar
kgf 400 ← 450
Pull
lbs 880 ← 990
60-Minute Ratings N 980 ← 1470
Rated Drawbar Pull
kgf 100 ← 150
(Towing Capacity)
lbs 220 ← 330
60-Minute Ratings Kg 4000 ← 6000
Towed Weight
lbs 8800 ← 13200
No Load km/h 13.5 ← 18
mph 8.4 ← 11.2
Speeds Travel, Max.
km/h 9 ← 13
W/load *1
mph 5.6 ← 8.1
Gradeability *2 No Load *3 % (tan θ) 36 ← 32
mm 2070 1755 2070
Overall Length w/bumper w/ hitch
in 81.5 69.1 81.5
L1
mm 2020 - 2020
Overall Length w/o bumper w/ hitch
in 79.5 - 79.5
mm 1930 1615 1930
Overall Length w/bumper w/o hitch
in 76.0 63.6 76.0
L2
mm 1880 - 1880
Overall Length w/o bumper w/o hitch
in 74.0 - 74.0
mm 210 235 210
Front Overhang w/bumper
in 8.3 9.3 8.3
L4
mm 160 - 160
Front Overhang w/o bumper
in 6.3 - 6.3
mm 360 240 360
L5 Rear Overhang
in 14.2 9.4 14.2
mm 140 ← 140
L6 Hitch Length
in 5.5 ← 5.5
mm 965 ← 965
B1 Overall Width
in 38.0 ← 38.0
mm 1250 1185 1250
h1 Overall Height
in 49.2 46.7 49.2
 0-29

mm 1825 1600 1825

Turning Radius (Outside) w/bumper
in 71.9 63.0 71.9
R
mm 1775 - 1775
Turning Radius (Outside) w/o bumper
in 69.9 - 69.9
mm 305 ← 305
h2 Height of Hitch
in 12.0 ← 12.0
mm 1360 1140 1360
L3 Wheelbase
in 53.5 44.9 53.5
mm 260 ← ←
B2 Tread Front
in 10.2 ← ←
mm 790 ← ←
B3 Tread Rear
in 31.1 ← ←
mm 80 75 80
h4 Under Clearance Center of Wheelbase
in 3.15 3.0 31.5
mm 330 200 330
h3 Floor Height
in 13.0 7.9 13.0
kg 980 975 1055
W/Battery
lbs 2160 2150 2325
Total Weight
kg 560 625 585
Without Battery
lbs 1230 1380 1290
kg 330 290 360
Front
Weight Distribution lbs 730 640 795
(With STD Battery) kg 650 685 695
Rear
lbs 1430 1510 1530
Number Front/Rear 2/2
Pneumatic 3.50-5-6PR
Front
Tires Nonpunc 3.50-5
Size
Pneumatic 4.00-8-6PR
Rear
Nonpunc 4.00-8
Service (foot) Hydraulic
Brake Parkig
Mechanical
(CBT4•6:hand CBTY4:foot)
Voltage/Capacity
STD V/AH 48/210 48/160 48/280
(6-hour rating)
Battery
kg 430 350 470
Weight (STD Capacity Type)
lbs 950 770 1035
Electric Motors Drive kw 2.6 ← 4.9
Control Type Drive Trasistor Chopper

* :Computed values
*1:Towing weight w/ load CBT4,CBTY4 :2000 kg [4400lbs]
CBT6 :3000 kg [6600lbs]
*2:Computed values.
*3:CBT4 and CBTY4 are 5-minute rating and CBT6 is 3-minute rating.
 1-1

BATTERY
1

Page
BATTERY COMPARTMENT AND
REQUIRED WEIGHT .................................................... 1-2
SERVICE STANDARD ................................................. 1-2 1
BATTERY CHARGE INDICATOR ............................. 1-3
TROUBLESHOOTING ................................................. 1-3
BATTERY ASSY ........................................................... 1-4
Removal•Installation ..................................................... 1-4
INSPECTION .................................................................. 1-6
REPLACING BATTERY PLUG TERMINAL ........... 1-9
BATTERY TRAY (CBTY4) .......................................... 1-10
REFERENCE .................................................................. 1-11
OPTIONAL BATTERY LIST ........................................... 1-11
USA RECOMMENDED BATTERIES ............................. 1-13
EUROPE RECOMMENDED BATTERIES ...................... 1-14
OPTIONAL OFF-VEHICLE CHARGER LIST ................. 1-17
 1-2

BATTERY COMPARTMENT AND REQUIRED WEIGHT

1

When the battery is to be purchased locally, always adjust the weight to satisfy the minimum required
weight as shown in the table below.
Compartment dimensions (mm) Minimum required
Model STD Side draw type (OPT) battery weight Remarks
Depth X Width Y Height Z Depth X Width Y Height Z (with case) Kg (lbs)
497 745* 594 497 745 523 390
CBT4
(19.57) (29.33) (23.39) (19.57) (29.33) (20.59) (860)
499 742 475 280
CBTY4 - - -
(19.65) (29.21) (18.70) (617)
497 745* 594 497 745 523 450
CBT6
(19.57) (29.33) (23.39) (19.57) (29.33) (20.59) (992)

*818 mm (32.20 in) for Europe models.

h
pt
De

Height

Width

SERVICE STANDARD
Specific gravity 1.280 [20°C (68°F) ]
Specific gravity 1.150 [20°C (68°F) ]
Discharge end voltage 48 V 42.5 V
Electrolyte Refined dilute sulfuric acid
Fluid to be added Distilled water
Insulation resistance 1 MΩ or more
 1-3

BATTERY CHARGE INDICATOR

10
The battery charged condition is indicated in ten levels. The
upper most LED comes on when fully charged, and the LED
moves downward as the battery is discharged. The second
lamp from the bottom comes on when about 80 % is
discharged. Charge the battery then. If 90 % is discharged,
the bottom LED and the second LED from the bottom blinks
1 alternately.
O : On : Blink 1
LED indication
Battery
10 9 8 7 6 5 4 3 2 1
discharge (%)
Green Green Green Green Green Yellow Yellow Yellow Red Red
0 to below 10 O - - - - - - - - -
10 to below 20 - O - - - - - - - -
20 to below 30 - - O - - - - - - -
30 to below 40 - - - O - - - - - -
40 to below 50 - - - - O - - - - -
50 to below 60 - - - - - O - - - -
60 to below 70 - - - - - - O - - -
70 to below 80 - - - - - - - O - -
80 to below 90 - - - - - - - - O -
90 to below 100 - - - - - - - -
100 or more - - - - - - - - - -

TROUBLESHOOTING
Plate corrosion Sulfation Plate warpage and ative substance freeing

Improper charging
Long storage Repeated overdischarge/
without operation overcharge
End of life Short circuit
between cells
Excessive charging
Defect of electrolyte
Insufficient current
Defective electrolyte
electrolyte
Overdischarge Excessive ambient
Battery defect

temperature

Crack or
Damaged Improper chipping of cell
separator water supply Imperfect
Overcharge terminal
connection

Deposition of freed Fouled terminal or

active substance connecting plug
at bottom of cell

Short circuit Electrolyte leakage and reduction Loosened or corroded connection

1-4

BATTERY ASSY
Removal•Installation
CBT4•CBT6

Removal Procedure
1 Disconnect the battery plug.
2 Open the battery hood.
3 Remove the battery ASSY. [Point 1]

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Point operation
[Point 1]
SST Removal•Installation:
SST 25009-13201-71
 1-5

CBTY4

Removal Procedure
1 Disconnect the battery plug.
2 Connect the battery carrier (OPT) to the vehicle.
3 Release the battery stopper.
4 Remove the battery ASSY. [Point 1]

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Point operation
SST [Point 1]
Removal•Installation:
SST 25009-13201-71

Caution:
Securely lock the battery carrier wheels for removal and installation.
1-6

INSPECTION
Stopper
1. Electrolyte level inspection
Open the cap, and if the white line on the red float has
White line
dropped, water should be added.
Add water until the white line appears.
Stop water addition 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 to check the level when
making a periodic inspection.
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 lignt
Normal level Off On
lnsufficient level Blinking On

Note:
Never change the installation location of the sensor.

Reference:
The consumption of electrolyte can be calculated by 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)
CBT4 24 210
CBTY4 ↑ 160
CBT6 ↑ 280
 1-7

2. Electrolyte inspection
Battery electrolyte is normal when it is transparent.
Check turbidity when inspecting the specific gravity. If it
cannot be checked clearly, put the electrolyte in a
beaker for inspection.

3. Battery electrolyte specific gravity inspection

Use a hydrometer to measure the specific gravity of the
electrolyte.
Specific gravity upon complete charging:
1.280 [20°C (68°F)] (Reference)
Specific gravity upon end of discharge:
1.150 [20°C (68°F)] (Reference)
The specific gravity of the electrolyte is expressed with
that at 20°C (68°F) as the standard.

Equation for converting specific gravity

S20=St+0.0007 (t-20)
S20: Specific gravity at 20°C
St : Specific gravity at t °C
tS : 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.
(2) Let the hydrometer float correctly without
contact with the outer tube, top or bottom, and
read the scale at 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 the hydrometer well with clear
water and store it after wiping water off with
clean cloth.
1-8

4. Insulation resistance inspection

Measure the resistance between the battery and battery
case with an insulation resistance meter
(megohmmeter).
Insulation resistance .... 1 MΩ or more

Note:
• When the insulation resistance is less than 1 MΩ,
wash the battery with water after removing it from the
vehicle.
• Fully dry the washed battery and measure the
insulation resistance again. Install the battery on the
vehicle after confirming that the insulation resistance
is 1 MΩ or more.

* Battery control table

Prepare a control table for each battery to record and maintain the inspection results.
Inspection date Specific Electrolyte Added water
Inspected cell No. Remarks Inspector
and time gravity temperature quantity
 1-9

REPLACING BATTERY PLUG TERMINAL

1. Disconnect battery plug cable one by one.

Caution:
Never disconnect more than one cable at the same time.
Fatal accident may result by short circuit.

2. Insert a screwdriver from the terminal side, push down

the spring at the bottom of the terminal and pull the
Terminal Screw driver cable to draw out the terminal.

Spring Spring

3. Strip the tip of the cable for Approx. 30 mm, solder

sufficiently and insert it to the contact portion of the new
terminal.

Note:
Be sure to prevent solder from pouring out and adhere
to the contact surface of the terminal.

Crimping method 4. When crimping cables, never bend the terminal with a
crimping tool.
Crimping tool

Pad
(To prevent the contact
piece from bending)

5. Insert the terminal to the battery plug.

Check that the tip of the terminal goes over the tip of the
Case Terminal spring and securely set in the position.

spring Cable
1-10

BATTERY TRAY (CBTY4)

Removal•Installation

Removal Procedure
1 Disconnect the battery plug.
2 Remove the battery ASSY. (See page 1-6.)
3 Remove the battery tray.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
In order to remove the battery tray, first remove the set bolts, draw out 1/3 of the tray, and hoist
with a hoist crane.
 1-11

REFERENCE
OPTIONAL BATTERY LIST
CBT4•6

Applicable
Battery specification
model
Cell
Height Weight
Mounting Voltage Capacity Manu- Length Width mm kg CBT4 CBT6
method (V) (AH/5HR) facturer Model mm mm (in) (lbs)
(in) (in)
90 158 575 390
GS VCF3C O
(3.54) (6.22) (22.64) (860)
90 158 575 425
210 KOBE VCF210A O
(3.5) (6.22) (22.64) (940)
89 157 575 440
YUASA VCF210 O
(3.50) (6.18) (22.64) (970)
90 158 575 440
GS VCF4N O O
(3.54) (6.22) (22.64) (970)
Hoisting
90 158 575 470
method 48 280 KOBE VCF280L O O
(3.54) (6.22) (22.64) (1040)
(STD)
89 157 575 450
YUASA VCF280S O O
(3.50) (6.18) (22.64) (990)
90 158 575 558
365 YUASA VCI365 O
(3.54) (6.22) (22.64) (1230)
90 158 575 582
KOBE VCI370 O
(3.54) (6.22) (22.64) (1280)
370
90 157 575 534
GS VGI370 O
(3.54) (6.18) (22.64) (1180)
94 157 500 362
216 GS VCD4BN O
(3.70) (6.18) (19.69) (800)
94 157 500 410
GS VCD5AN O O
(3.70) (6.18) (19.69) (900)
Side draw
90 158 500 414
method 48 250 KOBE VCD250 O O
(3.54) (6.22) (19.69) (910)
(OPT)
VCDH25 90 158 500 422
YUASA O O
0P (3.54) (6.22) (19.69) (930)
90 158 500 494
305 YUASA VZE305 O
(3.54) (6.22) (19.69) (1090)

*:
• The height and weight of the battery includes that of the battery case.
• Battery connector model SB175A (ANDERSON)
1-12

CBTY4

Battery specification
Cell
Height Weight Applicability
Mounting Voltage Capacity Manu- Length Width mm kg
method (V) (AH/5HR) facturer Model mm mm (in) (lbs)
(in) (in)
VCD160 90 158 468 350
KOBE O
A (3.54) (6.22) (18.43) (770)
160
89 157 468 315
YUASA VCB4P O
(3.50) (6.18) (18.43) (690)
Hoisting
90 158 468 285
method 48 165 GS VCD3A O
(3.54) (6.22) (18.43) (630)
(STD)
90 158 468 375
225 YUASA VZC225 O
(3.54) (6.22) (18.43) (830)
90 158 468 420
250 KOBE VCD250 O
(3.54) (6.22) (18.43) (930)

*:
• The height and weight of the battery includes that of the battery case.
• Battery connector model SB175A (ANDERSON)
 1-13

USA RECOMMENDED BATTERIES

CBT4•6
Applicable
Battery specification
model
Cell
Height Weight
Mounting Voltage Capacity Manu- Length Width mm kg CBT4 CBT6
method (V) (AH/6HR) facturer Model mm mm (in) (lbs)
(in) (in)
89 157 575 620
Hoisting 300 C&D 24C75-9 O
(3.50) (6.18) (22.64) (1370)
method 48
(STD) 89 157 575 653
400 EXIDE E100-9 O
(3.50) (6.18) (22.64) (1440)
89 157 445 533
Side draw 240 EXIDE E60D-9 O O
(3.50) (6.18) (17.52) (1180)
method 48
(OPT) 89 157 480 554
300 EXIDE E75L-9 O O
(3.50) (6.18) (18.90) (1220)

*:
• The height and weight of the battery includes that of the battery case.
• Battery connector model
Battery side SB350 gray (ANDERSON)
Rapid charge side SB350 gray (ANDERSON) and SB175A (ANDERSON)
Controller side SB175A (ANDERSON)

CBTY4
Battery specification
Cell
Mounting Voltage Capacity Manu- Length Width Height Weight
method (V) (AH/6HR) facturer Model mm mm mm (in) kg (lbs)
(in) (in)
Side draw
89 157
method 48 220 EXIDE E55L-9 468 (18.43) 390 (860)
(3.50) (6.18)
(STD)

*:
• The height and weight of the battery includes that of the battery case.
• Battery connector model SB175A (ANDERSON)
1-14

EUROPE RECOMMENDED BATTERIES

CBT4•6

BRITISH STANDARD COMPLIANT

Applicable
Battery specification
model
Cell
Height Weight
Mounting Voltage Capacity Manu- Length Width mm kg CBT4 CBT6
method (V) (AH/6HR) facturer Model mm mm (in) (lbs)
(in) (in)
OLD- 93 157.5 575 470
AE5 O O
HAM (3.66) (6.20) (22.64) (1040)
Hoisting
CHLO- 93.5 158 575 490
method 48 270 TLF11N O O
RIDE (3.68) (6.22) (22.64) (1080)
(STD)
95 159 575 510
VALTA 5PEC270 O O
(3.74) (6.26) (22.64) (1120)
OLD- 93 157.5 500 383
210 AE05 O O
HAM (3.66) (6.20) (19.69) (840)
CHLO- 93.5 158 500 429
Side draw ILF11N O O
RIDE (3.68) (6.22) (19.69) (950)
method 48 235
(OPT) 95 159 500 446
VALTA 5PEB235 O O
(3.74) (6.26) (19.69) (980)
OLD- 95 157.5 500 465
300 AE5 O O
HAM (3.74) (6.20) (19.69) (1030)
 1-15

DIN STANDARD COMPLIANT

Applicable
Battery specification
model
Cell
Height Weight
Mounting Voltage Capacity Manu- Length Width mm kg CBT4 CBT6
method (V) (AH/6HR) facturer Model mm mm (in) (lbs)
(in) (in)
OLD- 64.5 198 575 450
DW3 O O
HAM (2.54) (7.80) (22.64) (990)
Hoisting
CHLO- 65 198.5 575 455
method 48 240 3PZS240 O O
RIDE (2.56) (7.81) (22.64) (1000)
(STD)
65 198 575 455
VALTA 3PZS240 O O
(2.56) (7.80) (22.64) (1000)
CHLO- 65 198.5 500 381
3PZS210 O O
RIDE (2.56) (7.81) (19.69) (840)
Side draw 210
65 198 500 369
method 48 VALTA 3PZS210 O O
(2.56) (7.80) (19.69) (810)
(OPT)
OLD- 64.5 198 500 395
219 DVH3 O O
HAM (2.54) (7.80) (19.69) (870)

*:
• The height and weight of the battery includes that of the battery case.
• Battery connector model
Battery side CONNECTEUR 160A FEMALE 50 mm2 (REELS FRANCE)
Controller side CONNECTEUR 160A MALE 50 mm2 (REELS FRANCE)
1-16

CBTY4

BRITISH STANDARD COMPLIANT

Battery specification
Cell
Mounting Voltage Capacity Manu- Length Width Height Weight
method (V) (AH/6HR) facturer Model mm mm mm (in) kg (lbs)
(in) (in)
Hoisting
OLD- 77 159 468 380
method 48 216 AE4
HAM (3.03) (6.26) (18.43) (840)
(STD)

DIN STANDARD COMPLIANT

Battery specification
Cell
Mounting Voltage Capacity Manu- Length Width Height Weight
method (V) (AH/6HR) facturer Model mm mm mm (in) kg (lbs)
(in) (in)
Hoisting
OLD- 47 198 468 290
method 48 160 DW2
HAM (1.85) (7.80) (18.43) (640)
(STD)

*:
• The height and weight of the battery includes that of the battery case.
• Battery connector model
Battery side CONNECTEUR 160A FEMALE 50 mm2 (REELS FRANCE)
Controller side CONNECTEUR 160A MALE 50 mm2 (REELS FRANCE)
 1-17

OPTIONAL OFF-VEHICLE CHARGER LIST

Battery Supply Applicable model
Applicable battery
Manufacturer voltage voltage Charger Model
CBT4 CBTY4 CBT6 (AH)
(V) (V)
SG3-69-35JBY-2 - O - 160, 165
SG3-69-45JBY-2 O O - 210
GS 48 200
SG3-69-60JBY-2 O - O 280
SG3-69-80JBY-2 - - O 365, 370
ZTC48-40AD - O - 160, 165
ZTC48-45AD O O - 210
YUASA 48 200
ZTC48-54AD O - O 280
ZTC48-80AD - - O 365, 370

Note:
1. On-vehicle chargers are not available.
2. For North America and Europe, off-vehicle chargers are also not available.
Note the battery specifications when purchasing a charger from a local supplier.
 2-1

CONTROLLER
2

Page
CONTROLLER ............................................................... 2-2
GENERAL ....................................................................... 2-2
SPECIFICATIONS .......................................................... 2-2
COMPONENTS ............................................................... 2-3 2
CONTROL PANEL ASSY ............................................... 2-5
Removal•Installation ..................................................... 2-5
INSPECTION .................................................................. 2-8
DISASSEMBLY .............................................................. 2-17
REASSEMBLY ............................................................... 2-18
OCL (OVERCURRENT LIMIT) VALUE .......................... 2-20
DIRECTION SWITCH (CBT4•6) ................................. 2-21
REMOVAL•INSTALLATION ........................................... 2-21
DISASSEMBLY•INSPECTION•REASSEMBLY ............. 2-22
ACCELERATOR BOX ASSY (CBTY4) .................... 2-24
REMOVAL•INSTALLATION ........................................... 2-24
DISASSEMBLY•INSPECTION•REASSEMBLY ............. 2-25
ACCELERATION POTENTIOMETER
ADJUSTMENT (CBT4•6) ............................................. 2-27
 2-2

CONTROLLER
GENERAL
2

The controller on the CBT(Y) 4•6 uses a power transistor as the chopper main circuit element.
The chopper uses pulse width control (PWM control) in which the ON time increases as the accelerator
pedal is depressed.
The chopper frequency, however, is switched over between approx. 400 Hz for traveling and approx. 90
Hz for plugging. The SG board in the controller has a main transistor short-circuit detection circuit, which
opens the contactor upon detection of main transistor short-circuit to ensure safety by preventing the
vehicle from getting out of control, as well as the regulated power supply circuit, forward/reverse contactor
closing circuit, chopping frequency setting circuit and overcurrent limiting (OCL) circuit for maintaining the
traveling performance.

SPECIFICATIONS
F1 (for drive circuit) 175 A
Fuses F4 (for lamp circuit) 10 A
F5 (for control circuit) 10 A
Transistor TMD (for traveling) 1D600 A-030
DAD (drive circuit absorber) ERE24-02
Diodes DF1 (DMD flywheel) SR170L-4S
DF2 (DMD flywheel) SR170L-4S
Capacitor CAD (drive circuit absorber) JS201156QP-4 20 µF
MF (for forward traveling) MZ11A 46 V
Contactors
MR (for reverse traveling) MZ11A 46 V
R1 MFS40N150K
Resistors
RAD (drive circuit absorber) MFS40N1R8K
 2-3

COMPONENTS
2401

2
2-4

MF/MR contactor 2403

 2-5

CONTROL PANEL ASSY

Removal•Installation
CBT4•6
CBT4

CBT6

6
2-6

Removal Procedure
1 Disconnect the battery plug.
2 Remove the battery hood (See page 10-11).
3 Remove the rear cover.
4 Remove the control panel top cover.
5 Disconnect the wiring from the control panel ASSY.
6 Remove the control panel ASSY. [Point 1]

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
• Before connecting the battery plug, check any omission or insufficient tightening of cable connections. If
loose, elements in the control panel may be damaged.
• Check the wiring after installation for any incorrect connection.
• Tightening torque of control panel wiringT = 8.83 ~ 10.79 N•m (90 - 110 kgf•cm) [6.51 - 7.96 ft•lbf]

Point Operation
[Point 1]
Removal:
First remove two mounting bolts from the lower side.

Set bolt

Installation:
Place the controller ASSY on the stopper and install the
Set bolt
upper set bolts first

Stopper
 2-7

CBTY4
4

2 3

Removal Procedure
1 Disconnect the battery plug.
2 Remove the controller cover.
3 Disconnect the wiring from the control panel ASSY.
4 Remove the control panel ASSY.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
• Before connecting the battery plug, check any omission or insufficient tightening of cable connections. If
loose, elements in the control panel may be damaged.
• Check the wiring after installation for any incorrect connection.
• Tightening torque of control panel wiringT = 8.83 ~ 10.79 N•m (90 - 110 kgf•cm) [6.51 - 7.96 ft•lbf]
2-8

INSPECTION
Some components can be inspected after removal from the vehicle while others cannot be inspected if
removed.
Since the battery voltage must be applied to the SG board, it must be inspected on the vehicle.
The explanation here is mainly for inspection after removing the control panel ASSY from the vehicle.

1. Insulation resistance measurement (Be sure to measure before starting control panel inspection).
(1) Disconnect the battery plug and measure the insulation resistance between the controller side of
the battery plug and the body.
Measurement terminals Between controller side of battery plug and body
The resistance should be as high as possible, but it varies greatly
Standard with the vehicle operating conditions, working site and weather (1 MΩ
or more).

2. CAD (Drive circuit absorber capacitor)

(1) Inspection procedure
After discharging CAD with a resistor of around 100 Ω, disconnect the CAD wiring.
Inspection portion Measurement terminals Circuit tester range
CAD Both terminals of CAD Ω×1k

Standard
Bring the tester probes into contact with the CAD terminals. The pointer once deflects to the 0 Ω side,
then gradually returns to the infinity side, and finally indicates ∞ Ω as the capacitor is charged by the
tester current.

CAD
 2-9

3. TMD (drive circuit main transistor)

(1) Inspection procedure
Disconnect the TMD wiring.
Inspection portion Measurement terminals Standard Circuit tester range
C- — E+ ∞Ω Ω×1k
Between C and E
C+ — E- Approx. 25 Ω Ω×1
B- — C+ Approx. 14 Ω Ω×1
TMD Between B and C
B+ — C- ∞Ω Ω×1k
B- — E+ Approx. 45 Ω Ω×1
Between B and E
B+ — E- Approx. 70 Ω Ω×1

4. DF1/DF2 (flywheel diode)

(1) Inspection procedure
Disconnect the DF1/DF2 wiring.
Inspection portion Measurement terminals Standard Circuit tester range
Anode (-) -
Forward direction Approx. 10 Ω Ω×1
Cathode (+)
DF1•DF2
Anode (+) -
Reverse direction ∞Ω Ω×1k
Cathode (-)

DF1 DF2
2-10

5. DAD (drive circuit absorber diode)

(1) Inspection procedure
Disconnect the DAD wiring.

Inspection portion Measurement terminals Standard Circuit tester range

Forward direction Anode (-) - Cathode (+) Approx. 10 Ω Ω×1k
DAD
Reverse direction Anode (+) - Cathode (-) ∞Ω Ω×1

6. MF/MR (Forward/reverse contactor)

(1) Inspection procedure
Measure the MF/MR coil resistance after disconnecting one side of the MF/MR coil wiring.

Inspection portion Measurement terminals Standard Circuit tester range

MF•MR coil Both terminals of each coil °
105 Ω (20 C) Ω×1

MR MF MF • MR connector
 2-11

7. R1
(1) Inspection procedure
Disconnect one side of R1 wiring.

Inspection portion Measurement terminals Standard Circuit tester range

R1 Both terminals of R1 15 Ω Ω×1

8. RAD (Drive circuit absorber resistor)

(1) Inspection procedure
Disconnect one side of RAD wiring.

Inspection portion Measurement terminals Standard Circuit tester range

RAD Both terminals of RAD 1.8 Ω Ω×1
2-12

9. SG (printed circuit board) inspection

Measure the applied voltage at the SG connector.
Precautions on SG inspection
• Be sure to measure the voltage to determine whether the source of the problem is in the SG or
elsewhere.
• During inspection, make sure that the front wheels are lifted off the ground.
• The voltage must be measured with the power supplied, but be sure to disconnect the battery plug
before disconnecting the SG connector.
Inspection portion Measurement terminals Circuit tester range
Each terminal of SG connectors CN101, 102 and 103 (+) - N1
SG DC50 V
(-)

Basic conditions for inspection (measurement)

CBT4•6 : Battery plug ON, key switch ON, and SWAC ON (with the accelerator pedal fully depressed)

CBTY4 : Measure the voltage with the battery plug ON and key switch ON.
 2-13

Standards
CBT4•6

CN101
Terminal No. Wire color Connected to Conditions Standard (V)
LSD ON, DSF/DSR ON, SWAC
1 GR Accelerator (VRAD) Approx. 7.0
ON
LSD ON, DSF/DSR ON, SWAC
2 GL Accelerator (VRAD) Approx. 1 ~ 4.5
ON, accelerator Min. ~ Max.
LSD ON, DSF/DSR ON, SWAC
3 V Accelerator (VRAD) Approx. 0.3
ON
Direction switch
4 O LSD ON, DSR ON Approx. 48
(DSR)
Direction switch
5 G LSD ON, DSF ON Approx. 48
(DSF)
6 BR Seat relay (DRY) LSD ON, DSF/DSR ON Approx. 1.0
7 - Unused - -
Accelerator switch LSD ON, DSF/DSR ON, SWAC
8 P (SWAC) Approx. 0.3
ON
9 - Unused - -
10 - Unused - -
11 BR Seat relay (DRY) LSD ON, DSF/DSR ON Approx. 48

CN102
Terminal No. Wire color Connected to Conditions Standard (V)
1 L Controller (N1) - 0
2 B Controller (R1) - Approx. 48
LSD ON, DSF/DSR ON, SWAC
3 Y-0 Controller (TMDB) 0 ~ Approx. 1.5
ON, accelerator Min. ~ Max.
4 - Unused - -
LSD ON, DSF/DSR ON, SWAC Approx. 48 ~
5 O Controller (R1)
ON, accelerator Min. ~ Max. 2.5
6 P Controller (CSD+) - 0
LSD ON, DSF/DSR ON, SWAC Approx. 48 ~
7 R-G Controller (P8)
ON, accelerator Min. ~ Max. 1.0
LSD ON, DSF/DSR ON, SWAC
8 R-B Controller (P5) Approx. 48
ON, accelerator Min.
LSD ON, DSF/DSR ON, SWAC
9 R-L Controller (R7) Approx. 48
ON, accelerator Min.
LSD ON, DSF/DSR ON, SWAC
10 BR Controller (P6) Approx. 48
ON, accelerator Min.
11 R Controller (P2) - Approx. 48
12 - Unused - -
13 - Unused - -
14 W - 0
2-14

CN103
Terminal No. Wire color Connected to Conditions Standard (V)
2 - Unused - -
3 - Unused - -
4 L Controller (N1) - 0
5 - Unused - -
6 Y-G Controller (M-) LSD ON, DSF/DSR ON Approx. 48
7 W-R Controller (MR+) LSD ON, DSR ON Approx. 48
8 W-L Controller (MF+) LSD ON, LSAF ON Approx. 48
9 - Unused - -
10 - Unused - -
 2-15

CBTY4

CN101
Terminal No. Wire color Connected to Conditions Standard (V)
1 GR Accelerator (VRAD) DSF/DSR ON Approx. 7.0
DSF/DSR ON, accelerator
2 GL Accelerator (VRAD) Approx. 1 ~ 4.5
Min. ~ Max.
3 V Accelerator (VRAD) DSF/DSR ON Approx. 0.3
Direction switch
4 O DSR ON Approx. 48
(DSR)
Direction switch
5 G DSF ON Approx. 48
(DSF)
6 BR Seat relay (DRY) DSF/DSR ON Approx. 1.0
7 - Unused - -
Accelerator switch
8 P DSF/DSR ON Approx. 0.3
(SWAC)
9 - Unused - -
10 - Unused - -
11 BR Seat relay (DRY) DSF/DSR ON Approx. 48

CN102
Terminal No. Wire color Connected to Conditions Standard (V)
1 L Controller (N1) - 0
2 B Controller (R1) - Approx. 48
DSF/DSR ON, accelerator
3 Y-0 Controller (TMDB) 0 ~ Approx. 1.5
Min. ~ Max.
4 - Unused - -
DSF/DSR ON, accelerator Approx. 48 ~
5 O Controller (R1)
Min. ~ Max. 2.5
6 P Controller (CSD+) - 0
DSF/DSR ON, accelerator Approx. 48 ~
7 R-G Controller (P8)
Min. ~ Max. 1.0
DSF/DSR ON, accelerator
8 R-B Controller (P5) Approx. 48
Min.
DSF/DSR ON, accelerator
9 R-L Controller (R7) Approx. 48
Min.
DSF/DSR ON, accelerator
10 BR Controller (P6) Approx. 48
Min.
11 R Controller (P2) - Approx. 48
12 - Unused - -
13 - Unused - -
14 W - 0
2-16

CN103
Terminal No. Wire color Connected to Conditions Standard (V)
2 - Unused - -
3 - Unused - -
4 L Controller (N1) - 0
5 - Unused - -
6 Y-G Controller (M-) DSF/DSR ON Approx. 48
7 W-R Controller (MR+) DSR ON Approx. 48
8 W-L Controller (MF+) LSF ON Approx. 48
9 - Unused - -
10 - Unused - -
 2-17

DISASSEMBLY
The control panel rarely requires overhaul. In most cases, defective parts are replaced after identifying the
cause of trouble by inspection.
Therefore, perform correct operation by referring to the components diagrams, assembly drawing and
internal connection diagram.

MF

RAD

MR

TMD
SG

DAD
CAD
R1

DF2

P
DF1

Precautions for Parts Replacement

• Tighten bar and harness mounting nuts and screws to the specified torques. Looseness or omission of
tightening will cause troubles.
• When a bar or harness is to be disconnected, be sure to note the mounting position or put a tag.
Reinstall or reconnect it correctly later by referring to the memo or tag. Wrong installation or connection
may cause another trouble.
• Parts coated with silicone grease should be recoated before installation. Omission of silicone grease
application may cause overheating.
• After reassembly, make sure that the non-contact portion of a bar or wiring is not in erroneous contact.
2-18

REASSEMBLY
Reassembly diagram

MF MR

P5

R1
P6 P7

CAD
RAD

TMD
DAD
P1

P2
N1
DF1 DF2

Control Panel Parts Tightening Torques

Tightening portion Tightening torque N•m (kgf•cm) [ft•lbf]
M5 Mounting screw 1.96~2.94 (20~30) [1.45~2.17]
Transistor TMD M8 Collector terminal 9.81~11.8 (100~120) [7.24~8.68]
M4 Base terminal 1.27~1.67 (13~17) [0.94~1.23]
DF1 M5 Mounting screw 1.96~2.94 (20~30) [1.45~2.17]
Diode DF2 M5 Cathode terminal 1.96~2.94 (20~30) [1.45~2.17]
DAD M6 Mounting stud 2.45~3.43 (25~35) [1.81~2.53]
Capacitor CAD M4 Mounting screw 0.98~1.96 (10~20) [0.72~1.45]
Contactor MF/MR M5 Mounting screw 1.96~2.94 (20~30) [1.45~2.17]
External
M8 11~15 (112~153) [8.10~11.07]
terminal
 2-19

Control Panel Internal Wiring Diagram

B R-B

View A R-G
P

View B L

B R Y Y BR Y-O R-L

O W-O W- O Y Y

R1 W- Y
RAD
B Y
W- Y
Y

View A View B

Light Sky
Color Black White Red Green Yellow Purple Blue Gray Brown green Pink Orange blue
Symbol B W R G Y V L GR BR LG P O SL
2-20

OCL (OVERCURRENT LIMIT) VALUE

1. Drive circuit OCL value measurement
In the operating state, lock the drive wheels (rear wheels) and connect an ammeter and a shunt as
illustrated below to measure the locking current of the drive motor.

OCL value : Approx. 290 A

Ammeter : 50 mmV, 750 A
F1 Shunt : 50 mmV, 500 A

DF2 DF1

Shunt

MA P7 P6
MF
(F) (E)
RAD

DAD RAD

P9
TMD

CSD

If the OCL value does not satisfy the standard, inspect the drive motor. If no abnormality of the drive motor
is found, the SG board is defective.
 2-21

DIRECTION SWITCH (CBT4•6)

REMOVAL•INSTALLATION

Removal Procedure
1. Disconnect the battery plug.
2. Disconnect the direction switch wiring.
3. Remove the direction switch.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
2-22

DISASSEMBLY•INSPECTION•REASSEMBLY

2
2

Disassembly Procedure
1 Remove the plate.
2 Remove the microswitch. [Point 1]
3 Remove the head.
4 Remove the cam.

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
 2-23

Point Operation
[Point 1]
Reassembly:

1. Install the microswitch in the correct position.

DSFO DSBU
(OPT) (OPT)

DSF DSR

2. When replacing the microswitch, perform wiring

according to the wire colors in the illustration.
STD DSF
NC
NO COM
45 51 G B O
NC
46
NO DSR COM

OPT
NCDSFO
NO COM 120
43
R W-O
NC W-BR
COM
NO DSBU 103

Inspection
After reassembling the direction switch, check each switch
for continuity before installation.
DSFO Standards Lever position
(OPT) DSBU
DSR
(OPT)
Inspection portion Neutral Forward Reverse
DSF
DSF ∞Ω 0Ω ∞Ω
DRR ∞Ω ∞Ω 0Ω
DSFO(OPT) ∞Ω 0Ω ∞Ω
DSBU(OPT) ∞Ω ∞Ω 0Ω
2-24

ACCELERATOR BOX ASSY (CBTY4)

REMOVAL•INSTALLATION

5 4

Removal Procedure
1. Disconnect the battery plug.
2. Open the front protector cover.
3. Remove the accelerator lever knob.
4. Disconnect the accelerator box ASSY wiring.
5. Remove the accelerator box ASSY.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
 2-25

DISASSEMBLY•INSPECTION•REASSEMBLY

3
4

Disassembly Procedure
1 Remove the accelerator box cover.
2 Remove the microswitch.
3 Remove the variable resistor.
4 Remove the accelerator lever.

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
2-26

Inspection
Check the continuity in the accelerator ASSY.
Circuit tester
Inspection portion Measurement terminals
range
DSF CN26(2)45 - CN26(9)50
Ω
DSR CN26(2)45 - CN26(9)50
DSFO CN26(5)43 - CN26(6)120
Ω
DSB CN26(5)43 - CN26(7)103
VRAD(between 50 and 53) CN26(9)50 - CN26(10)53
VRAD(between 50 and 52) CN26(9)50 - CN26(8)52 Ω×1k
VRAD(between 52 and 53) CN26(8)52 - CN26(10)53

Standard
Lever
position Slightly tilted position Fully tilted position
Free
Inspection (front and reverse travel) (front and reverse travel)
portion
DSF ∞Ω 0Ω 0Ω
DSR ∞Ω 0Ω 0Ω
DSFO ∞Ω 0Ω 0Ω
DSB ∞Ω 0Ω 0Ω
VRAD(between 50 and 53) 2.5kΩ 2.5kΩ 2.5kΩ
VRAD(between 50 and 52) The resistance changes between 0 and 2.5kΩ as the lever is tilted.
VRAD(between 52 and 53) The resistance changes between 2.5 and 0kΩ as the lever is tilted.

When not operated When operated

Note:
When a connection, such as DSF, DSR, VRAD, is
changed, refer to the wire color on the left to prevent
wrong connection.
 2-27

ACCELERATION POTENTIOMETER
ADJUSTMENT (CBT4•6)
1. Operate the accelerator pedal and inspect if the switch
51 is turned on and off.
64 Measurement terminals Forward
Stan- When the pedal is not operated ∞Ω
dard When the pedal is operated 0 (continuity)

2. Adjust installation of the acceleration potentiometer.

Setscrew (1) Insert a 1.5 mm (0.06 in) thickness gauge between
the acceleration link stopper and the accelerator
bracket.
(2) Temporarily install the potentiometer so that the
acceleration switch (SWAC) is turned on.
Thickness (3) Inspect the acceleration switch (SWAC) ON and OFF
gauge inserting
position switching points.
When a 1 mm (0.04 in) thickness gauge is inserted:
OFF
When a 2.0 mm (0.08 in) thickness gauge is inserted:
ON
(4) After completing switch ON/OFF adjustment, apply
sealant (08833-76002-71 (08833-00080)) to the
threaded portion of the setscrew.
Standard for accelarator pedal adjustment ACCELERATOR PEDAL STOPPER ADJUSTMENT

The accelerator pedal stopper is added on the CBT4 and

CBT6 models.
A Inspect and adjust the pedal stopper height A.
Standard: 46~47 mm (1.81~1.85 in)

A:46~47 mm (1.81~1.85 in)

 3-1

ELECTRICAL SYSTEM TROUBLESHOOTING

3

Page
BEFORE TROUBLESHOOTING ............................... 3-2
GENERAL ....................................................................... 3-4
TROUBLESHOOTING REFERENCE ....................... 3-4
TRAVELING SYSTEM TROUBLESHOOTING ...... 3-5
OTHER TROUBLESHOOTING .................................. 3-18 3
3-2

BEFORE TROUBLESHOOTING
3

CONNECTOR HANDLING
1. Disconnect the battery plug before connecting or
disconnecting each connector or terminal.
2. When disconnecting a connector, do not pull it at the
harness but hold the connector itself and pull it after
unlocking it.
To connect, push the connector fully until it is locked in
position.

3. Bring a tester probe into contact with a connector

terminal from the rear side of the coupler (harness side).
4. If insertion from the rear side is impossible, as in the
case of a waterproof connector, bring the tester probe
carefully into contact with the terminal so as not to cause
deformation of 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 any trouble occurs, first inspect the connectors and
wire harness of the related circuit according to the following
procedure:
Continuity check
1. Disconnect the connectors at both ends of the
corresponding harness.
2. Measure the resistance between corresponding
terminals of the connectors at both ends.
Standard: 10 Ω or less
Note:
Measure while lightly shaking the wire harness up and
down and sideways.
Reference
Open circuit at the wire harness occurs rarely partway
through a vehicle wiring but mostly at connectors.
Inspect especially the sensor connectors with sufficient care.
 3-3

Short circuit check

1. Disconnect the connectors at both ends of the
corresponding harness.
2. Measure the resistance between the corresponding
connector terminal and N1. Always inspect the
connectors at both ends.
Standard: 1 MΩ or more.
Note:
Measure while lightly shaking the wire harness up and
down and sideways.
3. Measure the resistance between a terminal
corresponding to the connector terminal and N1. Always
inspect the connectors at both ends.
3
Standard: 1 MΩ or more.

Note:
The wiring may short-circuit due to pinching by the body
or defective clamping.

Visual and contact pressure checks

• Disconnect the connectors at both ends of the
corresponding harness.
• Visually inspect that there is neither rust nor foreign matter
trapped at connector terminals.
• Inspect that there is no loosening or damage at the locked
portion. Also, lightly pull the wire harness from the
connector to check that it does not come off.

• Insert a male terminal same as that of the terminal to a

female connector and check the extracting force.
Defective contact may exist at a terminal where the
extracting force is less than that of other terminals.
Note:
Even if there is rust or foreign matter trapped at the
terminal, or the contact pressure between male and
female terminals is low, abnormal contact condition may
be changed to normal by disconnecting and
reconnecting the connector. In that case, repeat
connector connection and disconnection several times.
If defect is perceived even once, terminal contact may be
defective.
3-4

GENERAL
This troubleshooting section is provided for checking the cause of electrical system troubles for quick
repairs. Use a circuit tester, megger and other measuring instruments for checking errors.

This manual is edited on assumption of mechanics who have mastered handling of measuring
instruments, are capable of reading circuit and connection diagrams correctly and can perform actual
measurements according to connector diagrams.

Please use attached wiring, connection and connector diagrams.

TROUBLESHOOTING REFERENCE

Inspection 1. NG
Drive circuit fuse (F1) check Replace F1.
(∞ Ω)
OK (0 Ω)

Inspection 2.
CN101-9 (43) NG
Voltage check Short circuit between
↔

CN103-2 (N1) (0 V) P2 and N1

OK (48 V)
Measurement with a circuit tester
P2 wiring discontinuity

Repair or replace it.

Potential level No.

Inspection 2.
CN101-9 (43) Tester probe (+)
Voltage check
↔

CN103-2 (N1) Tester probe (-)

Pin No.
Connector No.
 3-5

TRAVELING SYSTEM TROUBLESHOOTING

1. The vehicle does not move at all (MF•MR fails to be closed).

Off • F5open
Is the battery charge indicator on? • SWK defect
• Wiring defect
On

Inspection 1.
CN101-6 (116) NG (0 V) •SDM defect
CN101-11 (116) •RDM defect
Voltage check • Wiring defect
3
↔

N1

OK (battery voltage)

Inspection 2.
CN101-5 (45)
NG (0 V) • DSF,DSR defect
CN101-4 (46)
Voltage check • Wiring defect
↔

N1

OK (battery voltage)

Inspection 3. NG (other than standard)

• TMD defect
TMD continuity check

OK (standard)

Inspection 4.
NG (other than 105 Ω)
MF/MR coil continuity check • MF,MR coil defect

OK (105 Ω)

• PBSG defect
3-6

Inspection 1.
Voltage check between drive controller and N1
Battery plug ON, key switch ON, seat switch ON
CN101-6 (116) (+)  N1 (-)
Measurement terminals
CN101-11(116) (+)  N1 (-)
Circuit tester range DC50 V
Standard Battery voltage (48 V)

OK (battery voltage) → To inspection 2

NG (0 V) → F5 open, SWK defect, wiring defect

Inspection 2.
Voltage check between DSF/DSR and N1
Battery plug ON, key switch ON, seat switch ON, DSF(R) ON
CN101-5 (45) (+)  N1(-) (DSF ON)
Measurement terminals
CN101-4 (46) (+)  N1(-) (DSR ON)
Circuit tester range DC50V
Standard Battery voltage (48 V)

OK (battery voltage) → To inspection 3

NG (0 V) → DSF/DSR defect, wiring defect

Inspection 3.
TMD continuity check
See p2-9.
OK (standard) → Go to Inspection 4
NG (other than standard) → TMD defect

Inspection 4.
MF/MR coil continuity check
See p2-10.
OK (105 Ω) → PBSG defect
NG (other than standard) → MF, MR coil defect
 3-7

2. The vehicle does not move at all (MF•MR can be closed).

Inspection 1. NG
Drive circuit fuse (F1) check F1 fuse defect (open)
(∞ Ω)

OK (0Ω)

Inspection 2.
P8 OK Inspection 3.
NG MF/MR
Voltage check DMD continuity
↔

contactor contact vi-

N1 (0V) sual check check

NG OK (0 Ω) NG
OK (battery voltage) Defective contact DCMD wiring defect (∞ Ω)

Inspection 4. NG (other than standard) DCMD defect

DF1/DF2 check DF1/DF2 defect

OK (forward: approx. 10 Ω, reverse: ∞ Ω)

IInspection 5. NG
Shunt wiring check Shunt wiring defect

OK

Inspection 6. NG (other than standard)

TMD continuity check TMD defect

OK (standard)

Inspection 7. NG
Accelerator sensor individual check Accelerator sensor defect (open)
(∞ Ω)
OK (CBT4•6:The resistance is approx. 2.6 kΩ max. or varies between approx. 0.5 kΩ and 1.7 kΩ
according to the accelerator operation.
CBTY4:The resistance is approx. 2.5 kΩ max. or varies between approx. 0 Ω and 1.5 kΩ
according to the accelerator operation.)

Inspection 8. NG Wiring defect between CN101 and

Accelerator sensor wiring check (∞ Ω) accelerator sensor

OK (standard)

(A)
3-8

(A)

Inspection 9. NG
PBSG check PBSG defect
(0 V)

OK (battery voltage)

Inspection 10. NG
R1 check R1 defect (open)
(∞ Ω)

OK (approx. 45 Ω)

Inspection 11. NG
TMD base wiring check TMD base wiring defect
(∞ Ω)

OK (0 Ω)

PBSG defect
 3-9

Inspection 1.
Drive circuit fuse (F1) check
Battery plug OFF
Measurement terminals Both terminals of F1
Circuit tester range Ω×1
Standard 0Ω

F1

OK (0 Ω) → To inspection 2
NG (∞ Ω) → F1 fuse defect (open)

Inspection 2.
P8 - N1 voltage check
Jack up the rear end of the vehicle to lift the rear wheels off the ground.
Battery plug ON, key switch ON, DSF (DSR) ON
Measurement terminals P8+  N1-
Circuit tester range DC50 V
Standard Battery voltage (48 V)

P8 P8

N1
N1

OK (battery voltage) → To inspection 4

NG (0 V) → To inspection 3 after visual inspection of MF/MR contact
3-10

Inspection 3.
DCMD armature coil continuity check
Battery plug OFF
Measurement terminals DCMD terminal A - terminal B
Circuit tester range Ω×1
Standard 0Ω

CBT4•6 CBTY4

OK (0 Ω) → DCMD wiring defect

NG (∞ Ω) → DCMD defect (coil open or floating brush)

Inspection 4.
DF1/DF2 check
See page 2-9.
OK (standard range) → Go to Inspection 5
NG (other than standard) → DF1/DF2 defect

Inspection 5.
Shunt wiring check
Battery plug OFF
Inspect the following:
(1) Check the shunt wiring (TMD emitter, N1 terminal) for any looseness.
(2) Check the CN102 shunt signal cable for any discontinuity or looseness.

OK → To inspection 6
NG → Shunt wiring defect
 3-11

Inspection 6.
DF1/DF2 check
See page 2-8.
OK (standard) → To inspection 7
NG (other than standard) → TMD defect

Inspection 7.

CBT4•6
Accelerator sensor check
Battery plug OFF, CN11 disconnection, accelerator pedal operation
Between 51 and 53 CN11-1 (51)  CN11-4 (53)
Measurement terminals Between 51 and 52 CN11-1 (51)  CN11-3 (52)
Between 51 and 64 CN11-1 (51)  CN11-2 (64)
Circuit tester range Ω×1k , Ω×1
Between 51 and 53 Approx. 2.6 kΩ
Varies between approx. 0.5 kΩ ~
Standard Between 51 and 52
approx. 1.7 kΩ
Between 51 and 64 0Ω

CN11

OK (standard) → To inspection 8
NG (∞Ω) → Accelerator sensor defect (open)

CBTY4
Battery plug OFF, terminal CN1 disconnection and accelerator lever operation.
Between 51 and 53 CN1-9 (51)  CN1-10 (53)
Measurement terminal
Between 51 and 52 CN1-9 (51)  CN1-8 (52)
Tester range Ω×1k
Between 51 and 53 Approx. 2.5 kΩ
Standard
Between 51 and 52 Varies between 0 Ω ~ approx. 1.5 kΩ
3-12

5 4 3 2 1 1 2 3 4 5
10 9 8 7 6 CN1 6 7 8 9 10
TAB REC
NO P C J NO P C J
1 116 G-L LS- 1 116 BR J13
2 45 V DSF 2 45 G CN101-5
3 3
4 46 G DSR 4 46 O CN101-4
5 43 B-Y LSCOM 5 43 L J1
6 120 Y-G DSFO 6 120 P CN41-3
7 103 G-W DSB 7 103 LG J9
8 52 GW VRAD 8 52 LG CN101-2
9 51 L-W VRAD- 9 51 V CN101-3
CN1 10 53 W-B VRAD+ 10 53 GR CN101-1

OK (standard) → Go to inspection 8
NG (∞Ω) → Accelerator sensor defect (open)

Inspection 8.
Accelerator sensor check
Battery plug OFF, CN101 disconnection, accelerator pedal (CBT4•6) or accelerator lever (CBTY4)
operation.
Between 51 and 53 CN101-3 (51)  CN101-1 (53)
Measurement terminals Between 51 and 52 CN101-3 (51)  CN101-2 (52)
Between 51 and 64 CN101-3 (51)  CN101-8 (64)
Circuit tester range Ω×1k , Ω×1
Between 51 and 53 Approx. 2.6 kΩ
Varies between approx. 0.5 kΩ ~
CBT4•6 Between 51 and 52
approx. 1.7 kΩ
Between 51 and 64 0Ω
Standard
Between 51 and 53 Approx. 2.5 kΩ
Varies between approx. 0 kΩ ~
CBTY4 Between 51 and 52
approx. 1.5 kΩ
- -

CN101

OK (standard) → To inspection 9
NG (∞ Ω) → Wiring defect between CN101 and accelerator sensor
 3-13

Inspection 9.
PBSG check
Battery plug ON, key switch ON
Measurement terminals CN102-5 (34)+  N1-
Circuit tester range DC50 V
Standard Battery voltage (48 V)

N1
CN102

OK (battery voltage) → To inspection 10

NG (0 V) → PBSG defect
3-14

Inspection 10.
R1 check
Battery plug OFF, CN102 disconnection
Measurement terminals CN102-2 (35)  CN102-5 (34)
Circuit tester range Ω×1
Standard Approx. 45 Ω

CN102

OK (Approx. 45 Ω) → To inspection 11
NG (∞ Ω) → R1 defect (open)

Inspection 11.
TMD base wiring check
Battery plug OFF, CN102 disconnection
Measurement terminals CN102-3 (92)  TMD base terminal
Circuit tester range Ω×1
Standard 0Ω

CN102

B(Base)

OK (0 Ω) → PBSG defect
NG (∞ Ω) → TMD base wiring defect
 3-15
1. The vehicle does not move at all (MF/MR closes but detaches immediately).

Inspection 1. NG (other than standard)

TMD defect
TMD continuity check

OK (standard)

Inspection 2. NG
P8 wiring check P8 wiring defect
(∞ Ω)

OK (0 Ω)

SG defect

Inspection 1.
TMD continuity check
See page 2-9.
OK (standard) → To inspection 2
NG (other than standard) → TMD defect

Inspection 2.
P8 wiring check Battery plug OFF
Battery plug OFF Check
Check the following:Check P8 wiring (CN102 ~ TM collector) for any looseness or discontinuity.

P8

OK (0 Ω) → PBSG defect
NG (∞ Ω) → P8 wiring (CN102 ~ TM collector) defect
3-16

2. Normal speed control fails (The vehicle moves but the speed does not rise or no torque is output).

Inspection 1.
CN101-2 (52) NG
NG (other than standard) Inspection 2. Accelerator
Voltage check
↔

Accelerator sensor sensor defect

N1 (∞ Ω)
check

OK (battery voltage) OK (standard)

Inspection 4. NG Inspection 3. NG
Shunt wiring Accelerator sensor
Shunt wiring check Accelerator sensor
(∞ Ω) defect wiring defect
wiring check (∞ Ω)
OK (approx. 55.4 Ω)
OK (CBT4•6: Approx. 2.6 kΩ max. and
IInspection 5. NG varies between approx. 0.5 kΩ and 1.7 kΩ
P8 wiring according to the pedal operation.
P8 wiring check
(∞ Ω) defect CBTY4: Approx. 2.5 kΩ max. and varies
OK (0 Ω) between approx. 0 kΩ and 1.5 kΩ according
to the pedal operation.)
Inspection 6. NG
DF1,DF2 continuity check DF1,DF2 defect
(other than standard)
OK (standard) PBSG defect

PBSG defect

Inspection 1.
CN101-2 (52) - N1 voltage check
Battery plug ON, key switch ON, DSF (DSR) ON, accelerator pedal operation slowly to its stroke
end (CBT4•6)
Slowly operate the accelerator lever fully to the forward or reverse travel side with the battery plug
ON and key switch ON. (CBTY4)
Measurement terminals CN101-2 (52)+  N1-
Circuit tester range DC10 V
The voltage varies between approximately 1.0 V
Standard and 4.5 V according to the accelerator pedal (CBT
4•6) or accelerator lever (CBTY4) operation.

CN101 N1

OK (standard) → To inspection 4
NG (other than standard) → To inspection 2
 3-17

Inspection 2.
Accelerator sensor check
See inspection 7 in "2. The vehicle does not move at all (MF•MR can be closed)."
OK (standard) → To inspection 3
NG (∞ Ω) → Accelerator sensor defect

Inspection 3.
Accelerator sensor wiring check
See inspection 8 in "2. The vehicle does not move at all (MF•MR can be closed)."
OK (standard) → PBSG defect
NG (∞ Ω) → Accelerator sensor wiring defect

Inspection 4.
Shunt wiring check
See inspection 5 in "2. The vehicle does not move at all (MF•MR can be closed)."
OK → To inspection 5
NG → Shunt wiring defect

Inspection 5.
P8 wiring check
See inspection 2 in "3. The vehicle does not move at all (MF•MR closes but immediately
detaches)."
OK (0 Ω) → To inspection 6
NG (∞ Ω) → P8 wiring defect

Inspection 6.
DF1/DF2 continuity check
See page 2-9.
OK (standard) → PBSG defect
NG (other than standard) → DF1/DF2 defect
3-18

OTHER TROUBLESHOOTING
(1) MF (MR) closes but the vehicle moves in one direction only.
• Operate the accelerator pedal (CBT4•6) or accelerator lever (CBTY4) in the non-moving
direction, and perform troubleshooting for "2. The vehicle does not move at all (MF/MR can be
closed)."
(2) F1 fuse is blown frequently.
• Check the brake for any dragging.
• Check any loosening of F1 fuse connection.
• Check the drive motor commutator for roughening and coil for shorting between layers.
• Check any short circuit of DF1 or DF2.
(3) Electrical shock occurs.
• Defective insulation
(4) Excessive plugging.
• P2,P5 wiring discontinuity or defective contact
• PBSG defect
(5) The vehicle stops suddenly from time to time.
• Defective contact at terminals, connectors or TMD base wiring
 4-1

MOTOR
4

Page
DRIVE MOTOR .............................................................. 4-2
GENERAL ....................................................................... 4-2
SPECIFICATIONS .......................................................... 4-2
COMPONENTS ............................................................... 4-3
DRIVE MOTOR ASSY .................................................... 4-4
Removal•Installation ..................................................... 4-4
DISASSEMBLY•INSPECTION•REASSEMBLY ............. 4-6 4
 4-2

DRIVE MOTOR
4

GENERAL

CBT4•CBTY4

Terminal A
Terminal F

Terminal B

Terminal E

CBT6

Terminal B
Terminal E Terminal F

Terminal A

SPECIFICATIONS
Vehicle model
CBT4•CBTY4 CBT6
Item
Type DC series motor, self-ventilated type
Nominal voltage V 48
Rated output kW 2.6 4.9
Insulation class F
14×40×32 12.5×30×27
Brush size (thickness x width x length) mm (in)
(0.55×1.75×1.26) (0.49×1.18×1.06)
Number of brushes 4
 4-3

COMPONENTS
CBT4•CBTY4 1401

4
4-3-a

CBT6 1401
 4-4

DRIVE MOTOR ASSY

Removal•Installation
CBT4•6
T=N•m (kgf•cm) [ft•lbf]

4
T=156.8~215.6
(1600~2200)
[115~160]

Removal Procedure
1 Remove the rear axle ASSY W/drive motor (See steps 1 to 13 on page 5-5).
2 Remove the drive motor ASSY from the rear axle ASSY. [Point 1]

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Point Operation
SST
[Point 1]
Removal•installation:
SST 09010-10260-71
4-5

CBTY4
T=N•m (kgf•cm) [ft•lbf]
Through bolt T=156.8~215.6 (1600~2200) [115~160]

Reamer bolt T=156.8~215.6 (1600~2200) [115~160]

Removal Procedure
1 Remove the rear axle ASSY W/drive motor (See steps 1 to 15 on page 5-8).
2 Remove the drive motor ASSY from the rear axle ASSY. [Point 1]

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Point Operation
SST
[Point 1]
Removal•installation:
SST 09010-10260-71
 4-6

DISASSEMBLY•INSPECTION•REASSEMBLY

3
2

1
7

5 6

Disassembly Procedure
1 Remove the brush cover.
2 Remove the brushes. [Point 1]
3 Remove bracket No. 1. [Point 2]
4 Remove the armature ASSY. [Point 3]
5 Remove bracket No.2. [Point 4]
6 Remove the brush holder from bracket No.2.
7 Remove the yoke ASSY. [Point 5]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
4-7

Note:
Perform the following inspections before disassembly and after reassembly.
• Measure the insulation resistance between each motor wiring and motor body.
Standard: 1 MΩ or more (with a 500-VDC megger)
• Inspect the field coil for continuity by measurement between terminals E and F.
Standard: 0Ω (circuit tester range × 1Ω)

Point Operations
[Point 1]
Inspection:
Inspect the brushes for wear and trace of contact.
CBT4•CBTY4
Standard: 32 mm (1.26 in)
Limit: 14 mm (0.55 in)
CBT6
Standard: 27 mm (1.06 in)
Limit: 13 mm (0.51 in)

[Point 2]
Disassembly:
Put match marks on bracket No.1 and the yoke, and
bracket No.2 and the yoke.

[Point 3]
Disassembly•Reassembly:
Remove the armature ASSY and field coils without
damaging them.

Disassembly:
SST 09950-76013-71
(SST 09950-40010)

SST
 4-8

Reassembly:
Bracket No.1 side bearing
SST 09608-76003-71
SST (SST09608-04031)

Reassembly:
Bracket No.2 side bearing
SST(2) SST 09950-76018-71 ....(1)
(SST 09950-60010)
SST 09950-76020-71 ....(2)
SST(1) (SST09950-70010)

Inspection:
If the commutator surface is roughened, correct it with
sandpaper (about #600).
If heavily roughened, correct with a lathe.
Commutator outside diameter
CBT4•CBTY4 Standard: 80 mm (3.15 in)
Limit: 75 mm (2.95 in)
CBT6 Standard: 100 mm (3.94 in)
Limit: 97 mm (3.82 in)

Inspection:
After commutator correction, undercut the mica portion.
Undercut amount
CBT4•CBTY4
Undercut
Standard: 1.0 mm (0.04 in)
Limit: 0.3 mm (0.01 in)
CBT6
Mica Standard: 1.0 mm (0.04 in)
Limit: 0.5 mm (0.02 in)

Inspection:
Measure the insulation resistance of the armature coil.
Standard: 1 MΩ or more
4-9

Inspection:
Measure the commutator runout.
Limit: 0.03 mm (0.001 in)

[Point 1]
Inspection:
Install the armature ASSY and brushes. Set a spring scale
on a brush spring and measure the spring force on the
instant when the spring leaves from the brush.
CBT4•CBTY4
Standard: 10.3 ~ 13.2 N (1,050 ~ 1,350 gf)
[2.32 ~ 2.98 lbf]
CBT6
Standard: 9.26 ~ 11.32 N (945 ~ 1,155 gf)
[2.09 ~ 2.55 lbf]
Inspection:
Measure the insulation resistance between the brush
holder and bracket No.2.
Standard: 1 MΩ or more

[Point 4]
Inspection:
Inspect the field coil continuity.
Measurement terminals: E and F
Standard: 0Ω (circuit tester range × 1Ω)

Inspection:
Measure the field coil insulation resistance.
Point to be measured: Between yoke and terminal E•F
Standard: 1 MΩ or more
 5-1

DRIVE UNIT
5

Page
GENERAL ....................................................................... 5-2
SPECIFICATIONS ......................................................... 5-2
COMPONENTS .............................................................. 5-3
DRIVE UNIT ASSY ........................................................ 5-5
REMOVAL•INSTALLATION ........................................... 5-5
DISASSEMBLY•INSPECTION•REMOVAL .................... 5-10
DIFFERENTIAL CASE ASSY .................................... 5-14
5
DISASSEMBLY•INSPECTION•REASSEMBLY ............. 5-14
 5-2

GENERAL
5

SPECIFICATIONS
Vehicle model
CBT4•CBTY4 CBT6
Item
Total reduction ratio 23.078 13.254
Number of drive gear teeth 15 23
Number of reduction gear teeth Large: 67 Small: 12 Large: 59 Small: 12
Number of ring gear teeth 62
Differential oil quantity l 1.25
 5-3

COMPONENTS
3305

5
5-4

4101
 5-5

DRIVE UNIT ASSY

REMOVAL•INSTALLATION
CBT4•6
T=N•m (kgf•cm) [ft•lbf]

6 14

6 T=144~156.8
(1468~1599)
[106~115] 6 15 5
17 9

18 13

19
T=156.8~215.6
20 (1600~2200)
16 [115~160]
21
7
T=29.4~44.1
(300~450)
[21.7~32.5] T=88.2~117.6
(899~1199)
[65.0~86.7]

10

T=156.8~215.6
(1600~2200)
[115~160]

T=88.2~117.6
10 (899~1199) 12
[65.0~86.7]

T=29.4~44.1
(300~450)
[21.7~32.5]

21

20

19

18
17
13
7 6
T=144~156.8
(1468~1599)
[106~115]
5-6

Removal Procedure
1. Disconnect the battery plug.
2. Chock the front wheels.
3. Remove the battery hood (See page 10-11).
4. Remove the rear cover.
5. Remove the tire cover.
6. Loosen hub nuts, hoist the vehicle at the drawbar bracket, and support the frame with wooden blocks.
7. Remove the rear wheels.
8. Drain differential oil.
9. Disconnect the brake piping. [Point 1]
10. Disconnect the parking brake cable.
11. Disconnect the drive motor wiring.
12. Support the drive unit with a wooden block.
13. Remove the rear axle ASSY W/drive motor.
14. Remove chocks from front wheels, hoist the vehicle and move it forward.
15. Lower the rear side of the vehicle onto wooden blocks and chock the front wheels.
16. Remove the drive motor from the rear axle ASSY (See page 4-4).
17. Remove the brake drum.
18. Remove the rear axle shaft (See page 7-6).
19. Remove the rear axle housing end.
20. Remove the brake ASSY.
21. Remove the rear axle bracket.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
Apply sealant (08833-76001-71 (08833-00070)) to the rear axle shaft set bolts.

Point Operation
[Point 1]
Installation:
Bleed air from the brake system (See page 9-18).
 5-7

CBTY4
T=N•m (kgf•cm) [ft•lbf]

8 16

T=29.4~44.1
8 17 18
(300~450) 4
T=144~156.8 T=156.8~215.6
[21.7~32.5]
(1468~1599) (1600~2200)
8 [115~160]
[106~115]
15

T=156.8~215.6
(1600~2200)
[115~160]
14

20
19 21 23 15
9 T=88.2~117.6 22 T=156.8~215.6
(899~1199) (1600~2200)
[65.0~86.7] [115~160] 13

4
T=156.8~215.6 T=144~156.8
15 (1600~2200) (1468~1599)
[115~160] [106~115]
T=29.4~44.1 8
T=156.8~215.6
(300~450)
14 (1600~2200)
[115~160] [21.7~32.5]
21

23 20
15 T=88.2~117.6
T=156.8~215.6 22 (899~1199) 19
(1600~2200) [65.0~86.7]
[115~160] 9
5-8

Removal Procedure
1. Disconnect the battery plug.
2. Chock the front wheels.
3. Remove the toe board.
4. Disconnect the parking brake cable.
5. Remove the battery ASSY.
6. Disconnect the controller wiring.
7. Remove the battery hood.
8. Loosen hub nuts, hoist the vehicle at the drawbar bracket, and support the frame with wooden blocks.
9. Remove the rear wheels.
10. Drain differential oil.
11. Disconnect the brake piping. [Point 1]
12. Disconnect the drive motor wiring.
13. Support the drive unit with a wooden block.
14. Remove the rear axle bracket through bolt.
15. Remove the rear axle bracket reamer bolt. [Point 2]
16. Remove chocks from front wheels, hoist the vehicle and move it forward.
17. Lower the rear side of the vehicle onto wooden blocks and chock the front wheels.
18. Remove the drive motor from the rear axle ASSY (See page 4-5).
19. Remove the brake drum.
20. Remove the rear axle shaft (See page 7-6).
21. Remove the rear axle housing end.
22. Remove the brake ASSY.
23. Remove the rear axle bracket.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
Apply sealant (08833-76001-71 (08833-00070)) to the rear axle shaft set bolts.

Point Operations
[Point 1]
Installation:
Bleed air from the brake system (See page 9-19).
 5-9

[Point 2]
Removal:
SST 09310-23320-71

SST
5-10

DISASSEMBLY•INSPECTION•REMOVAL
T=N•m (kgf•cm) [ft•ldf]

T=68.6~88.2
(700~900)
[50.6~65.1]

T=39.2~58.5
(400~597)
[28.9~43.2]

Disassembly Procedure
1. Remove the rear axle housing. [Point 1]
2. Remove the gear case LH. [Point 2]
3. Remove the drive gear. [Point 3]
4. Remove the reduction gear. [Point 4]
5. Remove the differential case ASSY.

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Note:
Apply sealant (08833-76001-71 (08833-00070) to the rear axle housing set bolts.
 5-11

Point Operations
[Point 1]

5mm Reassembly:
(0.20in) Apply liquid gasket on the mating surfaces of the gear
case and axle housing.
Liquid gasket: 08826-76002-71 (08826-00090)

Disassembly:
Remseal using a screwdriver.
Reassembly:
Install the oil seal.
SST 09950-76018-71 ....(1)
(SST 09950-60010)
SST 09950-76020-71 ....(2)
(SST 09950-70010)
SST (1)

SST (2)

[Point 2]
Reassembly:
Starting area
Apply liquid gasket on the mating surface with the gear
Liquid gasket
case.
Liquid gasket: 08826-76002-71 (08826-00090)

[Point 3]

[Point 3]
Disassembly:
SST
Bearing LH side
SST 09950-76013-71 (SST 09950-40010)

Reassembly:
Bearing LH side
SST (2) SST 09950-76018-71 ....(1)
(SST 09950-60010)
SST 09950-76020-71 ....(2)
(SST 09950-70010)
SST (1)
 5-12
Disassembly: Bearing RH side

Disassembly:
SST (2) Bearing RH side
SST 09950-76013-71 ....(1)
SST (1) (SST 09950-40010)
SST 09950-76018-71 ....(2)
(SST 09950-60010)

Reassembly:
SST Bearing RH side
SST 09608-76005-71 (SST 09608-06041)

[Point 4]

[Point 4]
Disassembly:
Bearing RH/LH side
SST
SST 09950-76013-71 (SST 09950-40010)

Reassembly:
Bearing LH side
SST 09110-30200-71

SST

Reassembly:
Bearing LH side
SST (2) SST 09950-76018-71 ....(1)
(SST09950-60010)
SST 09950-76020-71 ....(2)
(SST 09950-70010)

SST (1)
 5-13

Disassembly:
Remove the reduction gear.
SST 09950-76013-71 (SST 09950-40010)

SST

Reassembly:
Install the reduction gear.
SST 09110-30200-71

SST
5-14

DIFFERENTIAL CASE ASSY

DISASSEMBLY•INSPECTION•REASSEMBLY
T=N•m (kgf•cm) [ft•ldf]

2 1

T=90.1~102.9
(919~1049)
[66.5~75.9]

Disassembly Procedure
1. Remove the ring gear. [Point 1]
2. Remove the side bearings. [Point 2]
3. Remove the straight pin. [Point 3]
4. Remove the pinion shaft, pinion gear, pinion thrust washer, side gear and side gear thrust washer.
[Point 4]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Note:
• When installing the thrust washer, side gear and pinion, make sure that they are free from dust
or cutting chips.
• Apply a generous amount of hypoid gear oil to each sliding and rotating part.
• Apply sealant (08833-76001-71 (08833-00070)) to the ring gear mounting bolt.
 5-15

Point Operations
[Point 1]
Disassembly•reassembly:
Provide match marks on the differential case and ring
gear.
Disassembly•reassembly:
Using a plastic hammer, lightly tap the outer periphery of
the ring gear for disassembly and reassembly.
Match mark

[Point 2]
Disassembly:
SST 09950-76013-71 ....(1)
SST (1)
(SST 09950-40010)
SST 09950-76018-71 ....(2)
(SST 09950-60010)
SST (2)

Reassembly:
SST 09370-20270-71

SST

[Point 3]
Disassembly:
Using a chisel, undo the staking from the outer periphery
of the pin hole of the differential case.
Reassembly:
After installing the straight pin, stake the outer periphery of
the pin hole.

Disassembly•reassembly:
Using a pin punch, drive the straight pin out.
 5-16

[Point 4]
Align the holes
Reassembly:
Align the pinion shaft fixing hole with the hole in the case.

Inspection:
To adjust the backlash of the side gear to within the standard
range and to enable smooth rotation, install thrust washers of
equal thickness on both the left and right sides.
Secure the pinion on the differential case side, and inspect
the backlash.
Standard: 0.05 ~ 0.20 mm (0.002 ~ 0.008 in)
<Reference> Thrust washer types
Thickness mm (in)
0.6 (0.024)
0.7 (0.028)
0.8 (0.031)
0.9 (0.035)
1.0 (0.039)
5
 6-1

FRONT AXLE
6

Page
GENERAL ....................................................................... 6-2
SPECIFICATIONS ......................................................... 6-2
COMPONENTS .............................................................. 6-3
FRONT AXLE ................................................................. 6-5
REMOVAL•INSTALLATION ........................................... 6-5

6
 6-2

GENERAL
6

SPECIFICATIONS
Front Axle
Vehicle mode
CBT4•6 CBTY4
Iteml
Front axle type Center-supported laterally rocking type
Minimum turning radius mm (in) 1775 (69.9) 1600 (63.0)

Tires and Rims

Tire pressure kPa
Type Tire size Rim size
(kgf/cm2)
CBT4•6 Pneumatic 3.50-5-6PR 3.00SP DT 700 (7.0)
CBTY4 Non-puncture (OPT) 3.50-5 ↑ 
 6-3

COMPONENTS
4201

6
6-4

4401
 6-5

FRONT AXLE
REMOVAL•INSTALLATION
Note:
The front axle hub can be disassembled with the front axle ASSY mounted on the vehicle. This
manual describes the front axle removal/installation procedure in sequence.

CBT4•6

T=N•m (kgf•cm) [ft•lbf]

3
3

2 T=34.3~68.6
(350~700)
[25.3~50.6]

5
2 T=34.3~68.6
(350~700)
[25.3~50.6]

8
7
9
10 11
11
10
9
7
6 8
6-6

CBTY4

T=N•m (kgf•cm) [ft•lbf]

3
3 1

2 T=34.3~68.6
(350~700)
[25.3~50.6]

2 T=34.3~68.6
5 (350~700)
[25.3~50.6]

8
7
9
10
11
11
10
9
7
6 8
 6-7

Removal Procedure
1 Chock the rear wheels and apply the parking brake.
2 Loosen the front wheel hub nuts.
3 Jack up the front side of the wheel and support the frame with wooden blocks.
4 Turn the steering wheel fully clockwise or counterclockwise.
5 Chock the front and rear side of the front wheels, and remove the rocking pin.
6 Jack up the front side of the vehicle further, and remove the front axle ASSY.
7 Remove the front wheels.
8 Remove the hub caps. [Point 1]
9 Remove the front axle hubs. [Point 2]
10 Remove the inner bearing and oil seal. [Point 3]
11 Remove the bushing.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Point Operations
[Point 1]
Reassembly:
Fill grease in the hub cap before installation.
Reassembly:
Tap the cap flange portion for installation.
6-8

[Point 2]
Disassembly:
STT Remove the bearing outer race.
SST 09700-30200-71

Bearing outer race

Reassembly:
Install the bearing outer races.
SST 09950-76020-71 ....(1)
(SST 09950-70010)
SST 09950-76018 .........(2)
SST(1) SST(1)
(SST 09950-60010)
SST(2) SST(2)

Inner side Outer side

Reassembly:
Measure the front axle hub starting force.
1. Temporarily tighten the castle nut to a torque of 0.98 N•m
(10 kgf•cm) [0.72 ft•lbf]
2. While tapping the outer periphery of the axle hub,
retighten the castle nut.
3. Set a spring scale on a hub bolt, and measure the starting
force.
Standard: 14.7 ~ 34.3 N (1.5 ~ 3.5 kgf) [3.3 ~ 7.7 lbf]

[Point 3]
Disassembly:
SST 09950-76013-71 (SST 09950-40010)

SST

Reassembly:
SST 09608-76005-71 (SST 09608-06041)

SST
 7-1

REAR AXLE
7

Page
GENERAL ....................................................................... 7-2
SPECIFICATIONS ......................................................... 7-3
COMPONENTS .............................................................. 7-3
REAR AXLE SHAFT ..................................................... 7-6
REMOVAL•INSTALLATION ........................................... 7-6

7
 7-2

GENERAL
7
 7-3

SPECIFICATIONS
Rear Axle
Vehicle model
CBT4•6 CBTY4
Items
Rear axle type Semi-floating type
Suspension type Frame fixed type
Axle shaft diameter mm (in) 35.0 (1.38)
Axle shaft diameter (spline portion) mm (in) 32.809 (1.29)

Tires and Rims

Air pressure kPa
Type Tire size Rim size
(kgf/cm2)
Pneumatic 4.00-8-6PR (I) 8×3.00D DT 700 (7.0)
CBT4•6
CBTY4 Non-puncture
4.00-8 ↑ 
(OPT)

COMPONENTS
CBT4•6
4301 7
7-4

CBTY4

4301
 7-5

4403

7
7-6

REAR AXLE SHAFT

REMOVAL•INSTALLATION
CBT4•6

T=29.4~44.1
(300~450)
[21.7~32.5]

5 3

7 7
7
7

2 6

T=144~156.8
(1468~1599)
1 [106~115]

CBTY4

T=29.4~44.1
(300~450)
[21.7~32.5]

5 3

77
7
7

1 T=144~156.8
(1468~1599)
[106~115]
 7-7

Removal Procedure
1 Chock the front wheels.
2 Support the vehicle rear side with wooden blocks.
3 Jack up the vehicle and remove the rear wheels.
4 Drain differential oil.
5 Remove the brake drum.
6 Remove the axle shaft.
7 Remove the snap ring, spacer, bearing and keep plate from the axle shaft. [Point 1]

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Apply sealant (08833-76001-71 (08833-00070)) to the axle shaft set bolt.

Point Operation
[Point 1]
Removal•installation:
SST
SST 09420-23001-71
 8-1

STEERING
8

Page
GENERAL ....................................................................... 8-2
SPECIFICATIONS ......................................................... 8-4
COMPONENTS .............................................................. 8-5
STEERING WHEEL•MAST JACKET ....................... 8-10
REMOVAL•INSTALLATION ........................................... 8-10
DISASSEMBLY•INSPECTION•REASSEMBLY ............. 8-14
STEERING CHAIN•SPROCKET ............................... 8-16
REMOVAL•INSTALLATION ........................................... 8-16
STEERING CHAIN TENSION ADJUSTMENT ....... 8-24

8
8-2

GENERAL
CBT4•6
 8-3

CBTY4

8
8-4

Steering chain and sprocket

Sprocket No. 3 Sprocket No. 1

Chain No. 1

Sprocket No. 2

Sprocket No. 4
Chain No. 2

SPECIFICATIONS
Item Vehicle model CBT4•6, CBTY4
Number of teeth 38
Sprocket No. 1 Tooth profile S
Tooth width mm (in) 7.2 (0.28)
Number of teeth 50
Sprocket No. 2 Tooth profile S
Tooth width mm (in) 9.0 (0.35)
Number of teeth 12
Sprocket No. 3/4 Tooth profile S
Tooth width mm (in) 7.2 (0.28)
Number of links 48
Overall length mm (in) 609.6 (24)
Chain No. 1
Pitch mm (in) 12.7 (0.5)
Roller diameter mm (in) 7.92 (0.31)
Number of links 56
Overall length mm (in) 711.2 (28)
Chain No. 2
Pitch mm (in) 12.7 (0.5)
Roller diameter mm (in) 7.92 (0.31)
 8-5

COMPONENTS
CBT4•6
4501

8
8-6

CBTY4
4501
 8-7

CBT4•6

4502
8-8

CBTY4

4502
 8-9

4506
8-10

STEERING WHEEL•MAST JACKET

REMOVAL•INSTALLATION
CBT4•6
T=N•m (kgf•cm) [ft•lbf]

T=25~45
(255~459)
[18.4~33.2]
2

11 5 4

10

A 9
8 7

Removal Procedure
1 Disconnect the battery plug.
2 Remove the steering wheel. [Point 1]
3 Disconnect the wiring to the turn signal switch and direction switch.
4 Remove the turn signal switch cover.
5 Remove the turn signal switch.
6 Remove the direction switch.
7 Remove front cover No. 2.
8 Remove front cover No. 1.
9 Remove four front protector set bolts. [Point 2]
10 Remove the mast jacket set bolt.
11 Remove the mast jacket W/steering shaft. [Point 3]

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
Fill the A portion with about 7 cc of MP grease before installation.
 8-11

Point Operations
[Point 1]
SST
Removal:
SST 09950-76001-71 (SST 09950-50010)

[Point 2]
Removal:
Remove only the set bolts on the left and right sides.

[Point 3]
Removal:
Match mark Provide match marks on the steering shaft and sprocket
No. 3 shaft.

Removal•installation:
Loosen the set bolt on the front side of the front protector
slightly, and remove/install with the front protector
inclined.

Caution:
Excessive loosening of the mounting bolt may cause the
front protector to fall. Carefully prevent over-loosening.
8-12

CBTY4
T=N•m (kgf•cm) [ft•lbf]

T= 25~45
(255~459)
[18.4~33.2]

A
2

Removal Procedure
1 Remove the steering wheel. [Point 1]
2 Open the front protector cover.
3 Remove the plate W/steering shaft. [Point 2]

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
Fill the A portion with about 7 cc of MP grease before installation.

Point Operations
[Point 1]
SST Removal:
SST 09950-76001-71 (SST 09950-50010)
 8-13

[Point 2]
Removal:
Provide match marks on the steering shaft and sprocket
No. 3 shaft.
Match mark
8-14

DISASSEMBLY•INSPECTION•REASSEMBLY
CBT4•6

6
3 5

Disassembly Procedure
1 Remove the steering shaft.
2 Remove the universal joint.
3 Remove the steering shaft.
4 Remove the bushing.
5 Remove the bracket w/bearing.
6 Remove the bearing from the bracket.
7 Remove the grommet.

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Note:
Apply MP grease to each sliding contact portion before installation.
 8-15

CBTY4

3
5
6
5
5
4

5
4

Disassembly Procedure
1 Remove the steering shaft.
2 Remove the universal joint.
3 Remove the steering shaft.
4 Remove the steering shaft w/bearing.
5 Remove the Iower bearing and spacer.
6 Remove the upper bearing.

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Note:
Apply MP grease to each sliding contact portion before installation.
8-16

STEERING CHAIN•SPROCKET
REMOVAL•INSTALLATION
CBT4•6
T=N•m (kgf•cm) [ft•lbf]

3
2

T= 29.4~49 (300~500) [21.7~36.2]

10 T= 4.9~9.8 (50~100) [3.6~7.2] 18

7

11
8 20
12
21
14
19
9
11

20
16

6
17

6 15

6
16
13

13
 8-17

Removal Procedure
1 Disconnect the battery plug.
2 Remove the front axle ASSY (See page 6-5).
3 Remove the front cover and bumper (See page 10-9).
4 Remove the mast jacket w/steering shaft with the steering wheel installed (See page 8-10).
5 Remove the front protector (See page 10-16).
6 Remove the steering chain tension adjusting bolt and adjust plate set bolt.
7 Remove steering chain No. 1.
8 Remove sprocket No. 1.
9 Remove steering chain No. 2.
10 Remove sprocket No. 2.
11 Remove the steering bracket and upper bearing. [Point 1]
12 Remove the lower bearing.
13 Remove the stopper.
14 Remove sprocket No. 3. [Point 2]
15 Remove the adjust plate w/idle shaft.
16 Remove the idle shaft and lower bearing from the adjust plate. [Point 3]
17 Remove the upper bearing. [Point 4]
18 Remove sprocket No. 4.
19 Remove the plate w/steering shaft.
20 Remove the steering shaft and lower bearing from the plate. [Point 5]
21 Remove the upper bearing. [Point 6]

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
• Apply chassis grease on the steering chain and sprocket before installing the steering chain.
• Adjust the chain tension after steering chain installation (See page 8-24).
8-18

Point Operations
[Point 1]
Removal:
Support the steering bracket with a wooden block.

Wooden block

[Point 2]
Removal:
SST 09950-76013-71 (SST 09950-40010)

SST

Installation:
SST 09381-41950-71

SST

[Point 3]
Removal:
SST 09700-30200-71

SST

Installation:
Install the lower bearing on the adjust plate. After installing
the idle shaft by driving it to the bottom of the adjust plate,
reverse the bracket and install the lower bearing using the
SST SST.
SST 09381-41950-71
 8-19

[Point 4]
Installation:
SST 09381-41950-71

SST

[Point 5]
Removal:
SST 09700-30200-71
SST

Installation:
SST Install the lower bearing on the plate. After installing the
steering shaft by driving it to the bottom of the plate,
reverse the bracket and install the lower bearing using the
SST.
SST 09700-30200-71

[Point 6]
Installation:
SST 09700-30200-71

SST
8-20

CBTY4
T=N•m (kgf•cm) [ft•lbf]

1
2

T= 29.4~49 (300~500) [21.7~36.2]

12
T= 4.9~9.8 (50~100) [3.6~7.2] 9 20

13
10 22
14
23
16
21
11
13

22
18

8
19

8 17

8
18
15
15
 8-21

Removal Procedure
1 Disconnect the battery plug.
2 Remove the front axle ASSY (See page 6-6).
3 Remove the front protector cover.
4 Remove the parking brake cover.
5 Remove the steering wheel w/steering shaft.
6 Remove the reservoir tank.
7 Remove the front protector (See page 10-17).
8 Remove the steering chain tension adjusting bolt and adjust plate set bolt.
9 Remove steering chain No. 1.
10 Remove sprocket No. 1.
11 Remove steering chain No. 2.
12 Remove sprocket No. 2.
13 Remove the steering bracket and upper bearing. [Point 1]
14 Remove the lower bearing.
15 Remove the stopper.
16 Remove sprocket No. 3. [Point 2]
17 Remove the adjust plate w/idle shaft.
18 Remove the idle shaft and lower bearing from the adjust plate. [Point 3]
19 Remove the upper bearing. [Point 4]
20 Remove sprocket No. 4.
21 Remove the plate w/steering shaft.
22 Remove the steering shaft and lower bearing from the plate. [Point 5]
23 Remove the upper bearing. [Point 6]

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
• Apply chassis grease on the steering chain and sprocket before installing the steering chain.
• Adjust the chain tension after steering chain installation (See page 8-24).
8-22

Point Operations
[Point 1]
Removal:
Support the steering bracket with a wooden block.

Wooden block

[Point 2]
Removal:
SST 09950-76013-71 (SST 09950-40010)

SST

Installation:
SST 09381-41950-71

SST

[Point 3]
Removal:
SST 09700-30200-71

SST

Installation:
Install the lower bearing on the adjust plate. After installing
the idle shaft by driving it to the bottom of the adjust plate,
reverse the bracket and install the lower bearing using the
SST SST.
SST 09381-41950-71
 8-23

[Point 4]
Installation:
SST 09381-41950-71

SST

[Point 5]
Removal:
SST 09700-30200-71
SST

Installation:
SST Install the lower bearing on the plate. After installing the
steering shaft by driving it to the bottom of the plate,
reverse the bracket and install the lower bearing using the
SST.
SST 09700-30200-71

[Point 6]
Installation:
SST 09700-30200-71

SST
8-24

STEERING CHAIN TENSION ADJUSTMENT

Adjusting bolt

Loosen the adjust plate set bolt, and adjust the steering chain tension to within the standard range by
turning the adjusting bolt.
Standard A = 1~3.5 mm (0.04~0.138 in)
Pushing force F = 9.8~19.6 N (1~2 kgf) [2.2~4.4 lbf]
 9-1

BRAKE
9

Page
GENERAL ....................................................................... 9-2
SPECIFICATIONS ......................................................... 9-4
COMPONENTS .............................................................. 9-5
SERVICE BRAKE .......................................................... 9-16
DISASSEMBLY•INSPECTION•REASSEMBLY ............. 9-16
BRAKE AIR BLEEDING .............................................. 9-20
BRAKING FORCE
INSPECTION•ADJUSTMENT ................................. 9-22
MASTER CYLINDER .................................................... 9-23
REMOVAL•INSTALLATION ........................................... 9-23
DISASSEMBLY•INSPECTION•REASSEMBLY ............. 9-25
PARKING BRAKE ......................................................... 9-28
9
REMOVAL•INSTALLATION ........................................... 9-28
NOTES FOR MAINTENANCE ........................................ 9-31
ADJUSTMENT ................................................................ 9-32
PARKING BRAKE CABLE ......................................... 9-33
REMOVAL•INSTALLATION ........................................... 9-33
BRAKE PEDAL ADJUSTMENT ................................ 9-36
STOP LAMP SWITCH .................................................. 9-38
 9-2

GENERAL
Service Brake
9
 9-3

Parking Brake
CBT4•6

CBTY4
9
9-4

Master Cylinder
CBT4•6

CBTY4

SPECIFICATIONS
Vehicle model
CBT4•6 CBTY4
Item
Foot brake type hydraulic internal expanding duo servo brake
Parking brake type Internal expanding mechanical brake
Brake drum inside diameter mm (in) 203.2 (8)
Brake lining material Resin mold (asbestos-free)
Brake lining dimensions
mm (in) 4.0×34×195 (0.16×1.34×7.68)
Thickness × Width × Length
Wheel cylinder bore mm (in) 19.05 (0.75)
Master cylinder bore mm (in) 15.87 (0.62)
Applicable oil SAEJ-1703 DOT-3
 9-5

COMPONENTS
CBT4•6
4601

9
9-6

CBTY4
4601
 9-7

CBT4•6
4701
9-8

CBTY4
4701
 9-9

CBTY4 (USA)

Floor Switch Pedal Components

4701

Bush

Collar

Limit switch

Return spring
Bolt

Switch bracket
Bolt

Stopper bolt
Pedal bracket
9-10

CBTY4 (EU)

Floor Parking Brake Pedal Components

4701

Bolt
Pedal

Bush

Collar

Cap
Clevis

Clevis

Spring bracket
Spring

Rod

Switch
Pedal bracket
 9-11

CBT4•6
4702
9-12

CBTY4
4702
 9-13

CBT4•6
4714
9-14

CBTY4
4714
 9-15

4715
9-16

SERVICE BRAKE
DISASSEMBLY•INSPECTION•REASSEMBLY

13
6
7

14

10 5
8

Disassembly Procedure
1 Chock the front wheels.
2 Remove each rear wheel.
3 Remove the brake drum. [Point 1]
4 Remove the hold-down spring. [Point 2]
5 Remove the link, actuator lever, actuator spring, and pawl lever. [Point 3]
6 Remove the shoe return springs. [Point 4]
7 Remove the strut lever. [Point 5]
8 Remove the adjustor spring and adjusting screw. [Point 6]
9 Remove the brake shoe. [Point 7]
10 Disconnect the parking brake cable.
11 Drain brake fluid.
12 Disconnect the brake pipe.
13 Remove the wheel cylinder ASSY. [Point 8]
14 Remove the backing plate.
 9-17

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Note:
• Check there is no grease or oil on the inner surfaces of the brake lining and brake drum before
reassembly.
• Before installing the brake drum, adjust the outside diameter of the installed brake shoe to the
following dimension (approx. 1 mm (0.04 in) smaller than the brake drum bore) by tightening the
adjusting screw.Installed brake shoe outside diameter: 202.2 mm (7.96 in)
• Apply sealant (08833-76001-71 (08833-00070) ) to the axle shaft set bolt before tightening.
• Bleed air from the brake system after reassembly (See page 9-20).
• Adjust the brake performance after reassembly. For adjustment, make the vehicle travel in the
forward and reverse directions repeatedly and depress the brake pedal each time.
• The tightening torque for each part is as follows:
Unit: N•m (kgf•cm) [ft•lbf]
Hub bolt set nut 88.2~157 (900~1600) [65.0~116]
Axle shaft set bolt 29.4~44.1 (300~450) [21.7~32.6]
Backing plate self-lock nut 88.2~118 (900~1200) [65.0~86.8]
Wheel cylinder set bolt 4.22~6.18 (43~63) [3.11~4.56]

Point Operations
[Point 1]
Inspection:
Measure the brake drum inside diameter.
Standard: 203.2 mm (8 in)
Limit: 205.0 mm (8.07 in)

[Point 2]
Disassembly•reassembly
SST 09510-31960-71

SST
9-18

Inspection:
Measure the free length of the hold-down spring.
Standard: 20 mm (0.79 in)
Limit: 18 mm (0.71 in)

[Point 3]
Inspection:
Measure the free length of the actuator spring.
Standard: 30 mm (1.18 in)
Limit: 27 mm (1.06 in)

Reassembly:
Apply grease onto the contact surfaces between the brake
shoe, the actuator lever and the sleeve.

Grease

SST
[Point 4]
Disassembly:
SST 09717-76001-71 (SST 09717-20010)

Inspection:
Measure the free length of the shoe return spring.
Standard: 81.7 mm (3.22 in)
Limit: Replace if there is any clearance in the coil.
 9-19

Reassembly:
SST 09718-76001-71 (SST 09718-20010)

SST

[Point 5]
Inspection:
Measure the free length of the strut-to-shoe spring.
Standard: 20 mm (0.79 in)
Limit: 18 mm (0.71 in)

[Point 6]
Inspection:
Measure the free length of the adjustor spring.
Standard: 60 mm (2.36 in)
Limit: Replace the spring if there is any clearance
in the coil.

Reassembly:
Apply grease to the threaded portion of the adjusting
screw and fill the cap with grease.

[Point 7]
Inspection:
Measure the brake lining thickness.
Standard: 3.95 mm (0.15 in)
Limit: 1.0 mm (0.04 in)
9-20

Reassembly:
Before installing the brake shoe, apply grease to the
illustrated portions (6 places in contact with the shoe and
rim as well as the anchor pin).

[Point 8]
Inspection:
Measure the clearance between the wheel cylinder and
piston.
Limit: 0.18 mm (0.007 in)

BRAKE AIR BLEEDING

Note:
While bleeding air from the brake system, add brake
fluid so as not to let the fluid level in the reservoir tank
become insufficient.
CBT4•6
1. Bleed air from the brake master cylinder.
(1) Pump the brake pedal several times to compress the
air in the piping and hold it depressed.
(2) Loosen the breather plug to bleed the air in the piping
with the brake fluid, and tighten the plug immediately
before the fluid flow stops.
(3) Repeat steps (1) and (2) above until no air bubble is
seen in the discharged fluid.

2. Bleed air from the breather plug at the center on the rear
side.
(1) Perform air bleeding in the same way as in step 1
above.
 9-21

3. Bleed air from the wheel cylinders RH and LH.

(1) Perform air bleeding in the same way as in 1 above
for each of the cylinders RH and LH.

4. Add brake fluid to the specified level.

(1) Add brake fluid through the filter provided at the
reservoir tank.
(2) Add brake fluid to the shouldered portion of the
reservoir tank.
Shouldered Filter

CBTY4
1. Bleed air from the breather plug at the rear on the right
side.
(1) Pump the brake pedal several times to compress the
air in the piping and hold it depressed.
(2) Loosen the breather plug to bleed the air in the piping
with the brake fluid, and tighten the plug immediately
before the fluid flow stops.
(3) Repeat steps (1) and (2) above until no air bubble is
seen in the discharged fluid.

2. Bleed air from the wheel cylinders RH and LH.

(1) Perform air bleeding in the same way as in 1 above
for each of the cylinders RH and LH.

3. Add brake fluid to the specified level.

(1) Add brake fluid through the filter provided at the
reservoir tank.
(2) Add brake fluid to the shouldered portion of the
reservoir tank.
Shouldered Filter
9-22

BRAKING FORCE INSPECTION•ADJUSTMENT

1. Inspect the braking force by means of a brake tester or a traveling test.
Braking distance (no load) CBT4•CBTY4 CBT6
Initial speed of braking km/h (mph) 13.5 (8.4) 18 (12.4)
Braking distance m (in) 5 (197) or less
2. Adjust the braking force.
(1) Repeat traveling in the forward and reverse directions and adjust the brake shoe clearance. The
adjusting screw makes automatic adjustment when the brake pedal is depressed in reverse
traveling.
(2) If the braking force is insufficient, remove and inspect the brake drum. Check for an adjuster
malfunction, a lining contact defect or foreign matter on the lining or a brake fluid leakage.
(3) When the brake shoe is replaced with a new one, repeat traveling in the forward and reverse
directions to get a good fit.
 9-23

MASTER CYLINDER
REMOVAL•INSTALLATION
CBT4•6

Removal Procedure
1 Remove the push rod clevis pin.
2 Disconnect the piping.
3 Remove the brake master cylinder.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
• See the brake pedal adjustment section (page 9-36) for the adjustment after installation.
• Perform air bleeding after installation (See page 9-20).
9-24

CBTY4

Removal Procedure
1 Remove the toe board.
2 Remove the push rod clevis pin.
3 Disconnect the piping.
4 Remove the brake master cylinder.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
• See the brake pedal adjustment section (page 9-37) for the adjustment after installation.
• Perform air bleeding after installation (See page 9-20).
 9-25

DISASSEMBLY•INSPECTION•REASSEMBLY
CBT4•6
T=N•m (kgf•cm) [ft•lbf]

T=8.83~12.75
T=34.32~53.94 (90~130)
(350~550) [6.51~9.41]
[25.3~39.8]
T=51.98~82.38
(530~840)
[38.3~60.8]

Removal Procedure
1 Turn the boot up, remove the snap ring and then the push rod. [Point 1]
2 Remove the piston.
3 Remove the fluid inlet elbow. [Point 2]
4 Remove the outlet plug and valve.

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Note:
Apply rubber grease on the piston cup before reassembly.
9-26

Point Operations
[Point 1]
Reassembly:

107 mm (4.21in)
Temporarily set the pushrod length to the illustrated
dimension, and adjust it after installation.
Reference value: 107 mm (4.21 in)

[Point 2]
Inspection:
Check the filter for clogging.

Filter
 9-27

CBTY4
T=N•m (kgf•cm) [ft•lbf]
T=39.2~68.6
(300~700)
[21.7~50.6]

T=107.87~176.52
(1100~1800)
[79.6~130.2]

Removal Procedure
1 Remove the master clevis.
2 Remove the push rod. [Point 1]
3 Pull out the piston, cylinder cup, return spring and inlet valve together.
4 Remove the outlet check valve.

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Note:
Clean each part with new brake fluid and apply brake fluid before installing the parts.

Point Operation
[Point 1]
Reassembly:
Temporarily set the pushrod length to the illustrated
dimension, and adjust it after installation.
Reference value: 84.5 mm (3.33 in)

84.5 mm (3.33 in)

9-28

PARKING BRAKE
REMOVAL•INSTALLATION
CBT4•6

1.3

Removal Procedure
1 Chock the wheels, and release the parking brake.
2 Remove the parking brake cable adjusting nut.
3 Remove the parking brake ASSY.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
Adjust the parking brake after installation (See page 9-31).
 9-29

CBTY4

1• 5 4

3 2

Removal Procedure
1 Chock the wheels, and release the parking brake.
2 Remove the front protector cover.
3 Remove the parking brake cover.
4 Remove the parking brake cable adjusting nut.
5 Remove the parking brake ASSY.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
Adjust the parking brake after installation (See page 9-31).
9-30

CBTY4 (EEC)

Removal Procedure
1 Chock the wheels.
2 Remove the toe board.
3 Loosen the parking brake cable set nut.
4 Depress the floor parking brake pedal and release the tension of the parking brake cable.
5 Remove the parking brake cable from the clevis.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
Adjust the parking brake after installation (See page 9-31)
 9-31

NOTES FOR MAINTENANCE

CBT4•6

Parking brake
adjusting nut

CBTY4 Parking brake

adjusting nut

A C
C

D
D

CBTY4 (EEC) Release the parking brake

1. The parking brake cable adjusting nut must be adjusted to apply tension to the parking cable when the
parking brake lever is retracted.
2. Apply MP grease to portion A in the illustration.
3. Adjust the wire as follows:
CBT4•CBT6•CBTY4 (EEC)
B: 88.5~91.5 mm (3.48~3.60 in)
CBTY4 (Except in EEC)
Adjust both dimension Cs to the same value (listed below). Do the same for the dimension Ds.
C: 9 mm (0.35 in) (Reference)
D: 7 mm (0.28 in) (Reference)
4. Upon completion of the above installation, check there is no brake dragging.
9-32

ADJUSTMENT
(1.97 in)
50 mm CBT4•6

Make adjustment so that the pawl is in mesh with the 3rd to

5th notch of the sector when the parking lever operating force
at the illustrated position is 147 N (15 kgf) [33 lbf].

CBTY4

Make adjustment so that the pawl is in mesh with the 3rd to

5th notch of the sector when the parking lever operating force
at the illustrated position is 350~400 N (35.7~40.8 kgf)
[78.7~90.0 lbf].

CBTY4 (EEC)
B
Adjusting nut
Adjust the spring length (Dimension C) to set the pedal
height (Dimension A) and limit switch roller clearance
(Dimension B) in the figure as follows:
Dimension A Standard: 212~217 mm (8.35~8.54 in)
A

Dimension B Standard: 9.5~10.5 mm (0.37~0.41 in)

Dimension C Standard: 119~121 mm (4.69~4.76 in)

C
 9-33

PARKING BRAKE CABLE

REMOVAL•INSTALLATION
CBT4•6

11

11
10

1
3

6 8 1

Removal Procedure
1 Chock the wheels and release the parking brake.
2 Disconnect the battery plug.
3 Remove the toe board (See page 10-18).
4 Remove front cover No. 2.
5 Remove front cover No. 1.
6 Unload the battery.
7 Remove the rear cover.
8 Remove the tire cover LH.
9 Remove the parking brake cable adjusting nut.
10 Remove the parking brake cable set pin.
11 Remove the parking brake cable.
9-34

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
After installation, perform parking brake cable adjustment (See page 9-31).
 9-35

CBTY4

6 10 7

5 4

8 1 3 1

Removal Procedure
1 Chock the wheels and release the parking brake.
2 Disconnect the battery plug.
3 Remove the toe board.
4 Open the front protecter cover.
5 Remove the parking brake cover.
6 Remove the parking brake cable adjusting nut.
7 Remove the parking brake cable set pin.
8 Remove the LH under cover.
9 Remove the parking brake set claw.
10 Remove the parking brake cable.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
After installation, perform parking brake cable adjustment (See page 9-31).
9-36

BRAKE PEDAL ADJUSTMENT

CBT4•6
Stop lamp switch

Stopper bolt

Push rod

C
D

B
A
E

Toe board

1. Adjust the brake pedal height and play.

(1) Adjust the stopper bolt length (dimension C) so that the brake pedal height (dimensions A and B)
satisfy the values shown below.
(2) Adjust the master cylinder push rod length so that the brake pedal play (dimension D) satisfies the
value shown below.
(3) Upon completion of the above installation, check the depressed pedal height (dimension E).
Unit :mm (in)
A B C D E
151~156 (5.94~6.14) 156~161 (6.14~6.33) 13 (0.51) 5~10 (0.20~0.40) 112 (4.41) or more

A: Dimension without pad

B: Dimension with pad
C: Stopper bolt length
D: Pedal play
E: Depressed pedal height (with pad)

Push Rod Play

1. Always provide the push rod play.

G = 1~2 mm (0.04~0.08 in)
107 mm (4.21 in)
G
 9-37

CBTY4
D

Toe board

Stop lamp switch

Push rod C Stopper bolt

1. Adjust the brake pedal height and play.

(1) Adjust the stopper bolt length (dimension C) so that the brake pedal height (dimensions A and B)
satisfy the values shown below.
(2) Adjust the master cylinder push rod length so that the brake pedal play (dimension D) satisfies the
value shown below.
(3) After the adjustment, depress the pedal with a force of 600 N (61.2 kgf) [134.9 lbf] and check the
depressed pedal height (dimension E).
Unit :mm (in)
A B C D E
60~65 (2.36~2.56) 65~70 (2.56~2.76) 10 (0.40) 5~10 (0.20~0.40) 20 (0.79) or more

A: Dimension without pad

B: Dimension with pad
C: Stopper bolt length
D: Pedal play
E: Depressed pedal height (with pad)

Push Rod Play

1. Always provide the push rod play.

G = 1~2 mm (0.04~0.08 in)
84.5 mm (3.33 in)
G
9-38

STOP LAMP SWITCH

FOOT BRAKE
CBT4•6

1. Adjust the brake pedal play (See page 9-36).

Standard: 5 ~ 10 mm (0.20 ~ 0.40 in)

2. Adjust protrusion of the limit switch roller (dimension A in

the illustration).

3. Operate the brake pedal to check the limit switch for

continuity.

Standard: Pedal not depressed : OFF (∞ Ω)

Pedal depressed : ON (0 Ω)

4. Adjust the brake pedal arm and limit switch ON/OFF

timing.
Standard:
The switch is turned ON when the brake pedal
A

stroke is in a range of 1~3 mm (0.04~0.12 in)

(dimension B in the illustration).
B

5. If the standard is not satisfied, adjust the limit switch

protrusion (dimension A in the illustration).

CBTY4

1. Adjust the brake pedal play (See page 9-37).

Standard: 5 ~ 10 mm (0.20 ~ 0.40 in)

2. Adjust protrusion of the limit switch roller (dimension A in

the illustration).

3. Operate the brake pedal to check the limit switch for

continuity.

Standard: Pedal not depressed : OFF (∞ Ω)

Pedal depressed : ON (0 Ω)

B
4. Adjust the brake pedal arm and limit switch ON/OFF
timing.
Standard:
The switch is turned ON when the brake pedal
stroke is in a range of 1~3 mm (0.04~0.12 in)
(dimension B in the illustration).

A 5. If the standard is not satisfied, adjust the limit switch

protrusion (dimension A in the illustration).
 9-39

Floor Switch Pedal (USA)

REMOVAL•INSTALLATION

Removal Procedure
1 Remove the toe board.
2 Disconnect the limit switch wiring.
3 Remove the pedal bracket and floor switch pedal as a unit.
Installation Procedure
The installation procedure is the reverse of the removal procedure.

Adjustment
1. Adjust the stopper bolt length (Dimension B) to set the
pedal height (Dimension A) in the figure as follows:
Dimension A Standard: 123~128 mm (4.84~5.04 in)
A

Dimension B Reference:17 mm (0.67 in)

2. Depress the brake pedal and check the limit switch

continuity.
Standard: Pedal not depressed: OFF (∞ Ω)
C Pedal depressed: ON (0 Ω)

3. If the standard is not satisfied, adjust the limit switch

roller clearance (Dimension C).
Dimension C Standard: 1~2 mm (0.04~0.08 in)
 10-1

BODY•FRAME
10

Page
LAYOUT AROUND DRIVER'S SEAT ...................... 10-2
COMPONENTS .............................................................. 10-3
DRAWBAR•DRAWBAR LEVER (OPT: CBT4•6) .. 10-8
DISASSEMBLY•INSPECTION•REASSEMBLY ............. 10-8
STOPPER BOLT ADJUSTMENT ................................... 10-8
BUMPER (OPT: CBT4•6) ............................................ 10-9
REMOVAL•INSTALLATION ........................................... 10-9
BATTERY TRAY (CBTY4) .......................................... 10-10
REMOVAL•INSTALLATION ........................................... 10-10
BATTERY HOOD .......................................................... 10-11
REMOVAL•INSTALLATION ........................................... 10-11
INSTRUMENT PANEL ................................................. 10-13
GENERAL ....................................................................... 10-13
BATTERY CHARGE INDICATOR .................................. 10-15 10
BATTERY CHARGE INDICATOR & HOUR METER
(OPT)................................................................................ 10-15
HOUR METER
(OPT: FOR VEHICLE W/SEAT
OR FLOOR SWITCH) ......................................... 10-15
FRONT PROTECTOR .................................................. 10-16
REMOVAL•INSTALLATION ........................................... 10-16
TOE BOARD ................................................................... 10-18
REMOVAL•INSTALLATION ........................................... 10-18
FUSES .............................................................................. 10-19
INSTALLED POSITIONS ................................................ 10-19
NAMES (PROTECTED CIRCUITS)
AND CAPACITIES .......................................................... 10-20
 10-2

LAYOUT AROUND DRIVER'S SEAT

10

CBT4•6
Battery Charge
Battery Charge Indicator & Hour
Steering Wheel Key Switch Indicator Meter (Option)

Light Control Switch Direction Switch

Turn Signal Switch
(Option) Horn Button Hour Meter (Option)
Rear View Mirror
(Option) Hazard Lamp Switch (Option)

Pen Stand (Option)

Turn Signal Lamp
(Option)

Brake Pedal

Accelerator Pedal
Fuse

Hood Grip

Binder (Option)

Driver's Seat Auxiliary box (Option)

CBTY4

Rear View Mirror Battery Charge

Indicator Accelerator lever

Hour Meter
(Option)
Steering Wheel
Turn Signal Switch
(Option)

Horn Button

Pen Stand (Option)

Turn Signal Lamp
(Option) Assist Grip

Hazard Lamp Switch

(Option)

Key Switch Light Control Switch

 10-3

COMPONENTS
CBT4

5101

CBT6
5101
10
10-4

CBTY4
5101
 10-5

CBT4•6
5201

CBTY4
5201
10
10-6

5301
 10-7

CBT4•6
5308

CBTY4
5308
10-8

DRAWBAR•DRAWBAR LEVER (OPT: CBT4•6)

DISASSEMBLY•INSPECTION•REASSEMBLY

5
2

Disassembly Procedure
1. Remove the plates.
2. Remove the drawbar.
3. Remove the drawbar lever.
4. Remove the lever bracket.
5. Remove the drawbar bracket.

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
When the drawbar is disassembled, adjust the stopper bolt after reassembly.

STOPPER BOLT ADJUSTMENT

1. Make adjustment by turning the stopper bolt so that the

Stopper bolt drawbar height when the drawbar lever is thrown is as
shown at left.

2. Lock the stopper bolt by tightening the lock nut.

(0 in)
0 mm
 10-9

BUMPER (OPT: CBT4•6)

REMOVAL•INSTALLATION

Disassembly Procedure
1. Remove the bumper.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
10-10

BATTERY TRAY (CBTY4)

REMOVAL•INSTALLATION

Disassembly Procedure
1 Remove the battery.
2 Remove the battery tray. [Point 1]

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Point Operation
[Point 1]

Removal:
Draw out 1/3 of the tray from the vehicle and hoist the
battery tray.
 10-11

BATTERY HOOD
REMOVAL•INSTALLATION
CBT4•6

2 7 8

6
3

Disassembly Procedure
1 Disconnect the battery plug.
2 Open the battery hood.
3 Disconnect the seat switch wiring.
4 Remove the driver's seat.
5 Disconnect the damper on the frame side.
6 Disconnect the stay on the frame side.
7 Close the battery hood.
8 Remove the battery hood.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
10-12

CBTY4

5
4

Disassembly Procedure
1 Disconnect the battery plug.
2 Remove the battery hood cover.
3 Remove the battery.
4 Remove the battery tray (See page 10-10).
5 Remove the controller (See page 2-7).
6 Remove the battery hood.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
 10-13

INSTRUMENT PANEL
GENERAL
CBT4•6

Installation bolt Battery charge indicator Battery charge indicator &

(at 4 places indicated by *) hour meter (Option)

Instrument panel *

*
*

Pen stand (Option)

Hour meter (Option)

*
Key switch Hazard lamp switch (Option)

Light control switch

Sub-harness
Fuse
Sub-harness
Hour meter (Option)
Sub-harness

W
Y To main harness

To main harness

Hazard lamp switch (Option)

To main harness

To main harness

L
G-R

G-Y
GR

Note:
Disconnect the battery plug and disconnect each electrical part wiring before removing the
instrument panel.
10-14

CBTY4

Battery charge indicator &

hour meter (Option)

Hour meter (Option) Turn signal switch

Battery charge indicator (Option)
Hour meter (Option)
W Accelerator lever
Y

O Horn button

Hazard lamp switch (Option)

L
G-R

G-Y
GR

Key switch Hazard lamp switch (Option)

Light control switch

 10-15

BATTERY CHARGE INDICATOR

The battery charged condition is indicated in ten levels. The

upper most LED comes on when fully charged, and the LED
Green
moves downward as the battery is discharged. The second
Yellow lamp from the bottom in red comes on when about 70 % is
Red discharged. Charge the battery then. If 80 % is discharged,
the bottom LED and the second LED from the bottom blinks
alternately.

BATTERY CHARGE INDICATOR &

HOUR METER (OPT)
Red Yellow Green
BATTERY CHARGE

The electrical charge in the battery is indicated in ten levels.

The rightmost lamp comes on when fully charged, and the
lighting lamp moves to the left as the battery is discharged.
The second lamp from the left lights in red when about 70%
is discharged. Charge the battery then. If 80% is discharged
the leftmost lamp and the second lamp from the left light
alternately.

HOUR METER

When the key switch is turned ON, the meter counts in

intervals of 1/10 hour (6 minutes).

HOUR METER
(OPT: FOR VEHICLE W/SEAT OR FLOOR
SWITCH)

When the operator turns ON the key switch, the meter counts
in intervals of 1/10 hour (6 minutes).
10-16

FRONT PROTECTOR
REMOVAL•INSTALLATION
CBT4•6

5 4

10

3 2 9

Removal Procedure
1 Disconnect the battery plug.
2 Remove front cover No. 2.
3 Remove front cover No. 1.
4 Remove the instrument panel (See page 10-13).
5 Remove the steering wheel w/mast jacket (See page 8-10).
6 Remove the parking brake lever with the wire.
7 Disconnect the wiring from each electrical part.
8 Unclamp the wiring.
9 Disconnect the brake pipe from the brake master cylinder.
10 Remove the front protector.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
Bleed air from the brake system after installation (See page 9-20).
 10-17

CBTY4

Removal Procedure
1 Disconnect the battery plug.
2 Remove the front protector cover.
3 Remove the parking brake cover.
4 Remove the steering wheel w/mast jacket (See page 8-12).
5 Remove the reservoir tank.
6 Disconnect the wiring from each electrical part.
7 Unclamp the wiring.
8 Remove the front protector.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
10-18

TOE BOARD
REMOVAL•INSTALLATION

1 3

2 4 2

Removal Procedure
1 Disconnect the battery plug.
2 Remove the toe board set bolts.
3 Disconnect the accelerator potentiometer wiring. [Point 1]
4 Remove the toe board.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Point Operation
[Point 1]

Removal:
Tilt the toe board and disconnect the accelerator
potentiometer wiring.

Accelerator
potentiometer
 10-19

FUSES
INSTALLED POSITIONS
CBT4•6

The F1 fuse is installed under the controller inside the rear cover. The F4 and F5 fuses are installed on the
right side of the parking brake on the instrument panel. The F1 fuse is the module type while the F4 and F5
fuses are of the glass tube type.

F1

F4

F5
10-20

CBTY4

The F1 fuse is installed under the controller inside the controller cover. The F4 and F5 fuses are mounted
on the right side in the front protector cover. The F1 fuse is the module type while the F4 and F5 fuses are
of the glass tube type.

F4
F1
F5

NAMES (PROTECTED CIRCUITS) AND CAPACITIES

Name Protected circuit Capacity
F1 Drive circuit 175 A
F4 Lamp circuit 10 A
F5 Control circuit 10 A
 11-1

APPENDIX
11

Page
SST LIST ......................................................................... 11-2
SERVICE STANDARDS LIST .................................... 11-5
CONNECTOR DIAGRAMS ......................................... 11-9
CONNECTING DIAGRAM ........................................... 11-18
WIRING DIAGRAM ....................................................... 11-21

11
 11-2

SST LIST
11

Section
Illustration Part No. Part Name
1 2 3 4 5 6 7 8 9 10

09010-10260-71 Motor hook O

Countershaft
09110-30200-71 remover & O O
replacer

Reamer bolt
09310-23320-71 O
remover

Drive pinion
09370-20270-71 bearing O
replacer

HST pump
09381-41950-71 bearing O
replacer

Bearing
09420-23001-71 O
remover

Brake hold
down spring
09510-31960-71 O
remover &
replacer
 11-3

Section
Illustration Part No. Part Name
1 2 3 4 5 6 7 8 9 10

Front hub &

09608-76003-71 drive pinion
O
(09608-04031) bearing tool
set

Axle hub &

09608-76005-71 drive pinion
O O
(09608-06041) bearing tool
set

Spring pin
09700-30200-71 O O
tool remover

Brake shoe
09717-76001-71
return spring O
(09717-20010)
remover

Brake shoe
11
09718-76001-71
return spring O
(09718-20010)
remover

09950-76001-71
Puller C set O
(09950-50010)

09950-76013-71
Puller B set O O O O
(09950-40010)
11-4

Section
Illustration Part No. Part Name
1 2 3 4 5 6 7 8 9 10

09950-76018-71 Replacer A
O O O
(09950-60010) set

09950-76020-71
Handle set O O O
(09950-70010)

Battery
25009-13200-71 O
hanger
 11-5

SERVICE STANDARDS LIST

BATTERY
Item All models
Specific gravity in fully charged state (reference) (at 20 °C) 1.280
Specific gravity in fully discharged state (reference) (at 20 °C) 1.150
Discharge end voltage V 42.5
Insulation resistance MΩ 1 or more

CONTROLLER
Item All models
Drive controller
FD (drive circuit fuse) A 175
FLP (lamp circuit fuse) A 10
FCC (control circuit fuse) A 10
Insulation resistance MΩ 1 or more
The pointer deflects once when
the tester probes are brought into
contact with the CSADV termi-
CAD (circuit tester range × 1 k) Ω nals, then returns to the ∞ side
gradually, and finally indicates ∞
Ω (as the capacitor is charged by
the current from the circuit tester).
C [-] - E [+] ∞
C [+] - E [-] Approx. 25
B [-] - C [+] Approx. 14
TMD continuity (circuit tester range × 1 k) Ω
B [+] - C [-] ∞
B [-] - E [+] Approx. 45 11
B [+] - E [-] Approx. 70
Forward Approx. 10
DF1-DF2 continuity (circuit tester range × 1 k) Ω
Reverse ∞
Forward Approx. 10
CSADV continuity (circuit tester range × 1 k) Ω
Reverse ∞
R1 continuity (circuit tester range × 1) Ω 15
RSAD continuity (circuit tester range × 1) Ω 1.8
CFW•CRV coil resistance (circuit tester range × 1) Ω 105 (at 20°C)

ACCELERATOR POTENTIOMETER
Item CBT4•6
Clearance between pedal stopper and toe board mm Switch OFF 1.0 [0.04]
[in] Switch ON 2.0 [0.08]
11-6

DIRECTION SWITCH
Item CBT4•6
Limit switch continuity (circuit tester range × 1 k) Ω See page 2-22.

ACCELERATOR BOX ASSY

Item CBTY4
Limit switch continuity (circuit tester range × 1 k) Ω See page 2-25.

BRAKE LIMIT SWITCH

Item All models
Limit switch ON dimension See page 9-35.

DRIVE MOTOR
Item CBT4•CBTY4 CBT6
Armature coil insulation resistance MΩ 1 or more ←
Field coil insulation resistance MΩ 1 or more ←
Brush holder insulation resistance MΩ 1 or more ←
Standard 80 (3.15) 100 (3.94)
Commutator outside diameter mm (in)
Limit 75 (2.95) 97 (2.95)
Commutator runout mm (in) Limit 0.03 (0.001) ←
Standard 1.0 (0.04) ←
Undercut mm (in)
Limit 0.3 (0.012) 0.5 (0.02)
Standard 32 (1.26) 27 (1.06)
Brush length mm (in)
Limit 14 (0.55) 13 (0.51)
10.3 ~ 13.2 9.26 ~ 11.32
Brush pressure N (kg) [lbf] (1050 ~ 1350) (945 ~ 1155)
[2.32 ~ 2.98] [2.08 ~ 2.55]

DRIVE UNIT
Item All models
Ring gear backlash mm (in) Standard 0.05 ~ 0.20 (0.002 ~ 0.08)
Tightening torque N•m (kgf•cm) [ft•lbf]
156.8 ~ 215.6 (1600 ~ 2200)
Axle bracket set bolt Standard
[115 ~ 160]
90.1 ~ 102.9 (919 ~ 1049)
Ring gear set bolt Standard
[66.5 ~ 75.9]
68.6 ~ 88.2 (700 ~ 900)
Front axle housing set bolt Standard
[50.6 ~ 65.1]
 11-7

FRONT AXLE
Item CBT4•6 CBTY4
Center pin outside diameter mm (in) Standard 19.8 (0.78) ←
Support pin bushing bore mm (in) Limit 31.0 (1.22) ←
Front axle hub starting force (On the hub bolt)
Standard 0.98(10) [0.72] ←
N•m (kgf•cm) [ft•lbf]
Minimum turning radius 1775 (69.9) 1600 (63.0)
Tightening torque N•m (kgf•cm) [ft•lbf]
18.63 ~ 30.40
Castle nut Standard (190 ~ 310) ←
[13.74 ~ 22.42]

REAR AXLE
Item All models
Tightening torque N•m (kgf•cm) [ft•lbf]
29.4 ~ 44.1 (300 ~ 450)
Rear axle shaft set bolt Standard
[21.7 ~ 32.5]

WHEEL
Item Tire size Air pressure
Pneumatic 3.50-5-6PR 700 kPa
Front
Non-puncture 3.50-5 
Pneumatic 4.00-8-6PR 700 kPa
Rear
Non-puncture 4.00-8 
Tightening torque N•m (kgf•cm) [ft•lbf]
34.0 ~ 68.6 (350 ~ 700)
Front wheel hub nut Standard
[25.31 ~ 50.63]
144.0 ~ 156.8 (1470 ~ 1600)
Rear wheel hub nut Standard
[106.3 ~ 115.7]

STEERING
Item All models
Steering gear ratio 38:50
Steering wheel rotation (lock-to-lock) 4.7 turns
Steering chain play 1.0 ~ 3.5 (0.04 ~ 0.138)
Tightening torque N•m (kgf•cm) [ft•lbf]
76.0 ~ 114.0 (775 ~ 1160)
Steering chain adjust plate set bolt Standard
[56.1 ~ 83.9]
76.0 ~ 114.0 (775 ~ 1160)
Plate set bolt Standard
[56.1 ~ 83.9]
11-8

BRAKE
Item CBT4•6 CBTY4
Front 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 (3.22) ←
Shoe return spring mm (in) Clearance
Limit between ←
coils
Standard 20 (0.79) ←
Strut-to-shoe spring mm (in)
Limit 18 (0.71) ←
Standard 60 (2.36) ←
Adjuster spring mm (in) Clearance
Limit between ←
coils
Standard 3.95 (0.16) ←
Brake lining thickness mm (in)
Limit 1.0 (0.04) ←
Wheel cylinder to piston clearance mm (in) Limit 0.18 (0.007) ←
Standard 203.2 (8.00) ←
Brake drum bore mm (in)
Limit 205.0 (8.07) ←
Parking Brake
Number of notches until parking brake lever application 3~5 ←
Brake Pedal
65 ~ 70
Pedal height above toe board (w/pad) mm (in) 156 ~ 161 (6.14 ~ 6.34)
(2.56 ~ 2.76)
Pedal play mm (in) 5 ~ 10 (0.20 ~ 0.40) ←
20 (0.79) or
Depressed pedal height mm (in) 112 (4.41) or more
more
Push rod play mm (in) 1 ~ 2 (0.04 ~ 0.08) ←
Tightening torque N•m (kgf•cm) [ft•lbf]
4.22 ~ 6.18
Wheel cylinder set bolt Standard (43 ~ 63) ←
[3.11 ~ 4.56]
88.2 ~ 118
Backing plate set nut Limit (900 ~ 1200) ←
[65.0 ~ 86.8]

BRAKE LIMIT SWITCH

Item All models
Limit switch ON dimension SSTL 5 ~ 10
(brake pedal operating dimension) mm (in) (0.20 ~ 0.40)
 11-9

CONNECTOR DIAGRAMS
CBT4•CBT6

3 2 1
6 5 4
CN1 1 2 3
4 5 6
2 1
4 3
CN8 1 2
3 4
TAB REC TAB REC
NO P C J NO P C J NO P C J NO P C J
1 116 O DSF, DSR 1 116 BR CN28-1 1 117 - T 1 117 SL CN5-1
2 120 B DSFO 2 120 P CN41-3 2 104 - B 2 104 V CN5-2
3 103 G DSB 3 103 LG CN33-4 3 102 - HM 3 102 O CN5-4
4 46 W-O DSR 4 46 O CN104-4 4 102 - HS 4 102 O CN5-4
5 45 W-BR DSF 5 45 G CN104-5
6 43 R DSFO, DSB 6 43 L J1
2 1
4 3
CN9 1 2
3 4
2 1 1 2
TAB REC
6 5 4 3 CN2 3 4 5 6 NO P C J NO P C J
1 1
TAB REC 2 41 - SWK 2 41 Y CN5-3
NO P C J NO P C J 3 3
1 41 L SWH(+) 1 41 Y J2 4 43 - SWK 4 43 L CN5-6
2 48 B SWH(-) 2 48 P HORN
3 110 W SWF(B) 3 110 GR CN12-1
4 108 Y SWF(R) 4 108 L LF-R
4 3 2 1 CN11 1 2 3 4
5 109 G SWF(L) 5 109 G-Y LF-L
6 6 TAB REC
NO P C J NO P C J
1 51 - E2 1 51 V CN104-3
1 2 3
3
6
2
5
1
4
CN3 4 5 6
2
3
64
52
-
-
IDL
VTA
2
3
64
52
P
LG
CN104-6
CN104-2
4 54 - VC 4 54 GR CN104-1
TAB REC
NO P C J NO P C J
1 N1 W CN7-1, HM 1 N1 W N1 TERMINAL
1 1
2 43 L CN7-6 2 43 L J1
3 41 Y CN7-4, HM 3 41 Y J2 2 CN12 2
4 4
5 47 G-Y CN7-2 5 47 G-Y HM-ST
6 49 O HM 6 49 O HM-ST
TAB REC
NO P C J NO P C J
1 110 - FRY 1 110 GR CN2-3
2 41 - FRY 2 41 Y J2
1 2 3
3
6
2
5
1
4
CN5 4 5 6
1 1
NO P C
TAB
J NO P C
REC
J 3 2
CN13 2 3
1 117 SL CN8-1 1 117 SL CN28-2 TAB REC
2 104 V CN8-4 2 104 V CN33-1 NO P C J NO P C J
3 41 Y CN9-2 3 41 Y CN23-3 1 110 GR SWHZ 1 110 GR J8
4 102 O CN8-3, CN8-4 4 102 O CN14-2 2 109 G-Y SWHZ 2 109 G-Y J7
5 5 3 108 L SWHZ 3 108 L J3
6 43 L CN9-4 6 43 L CN42-2

2 1 CN14 2 1
2 1 CN6 2 1
TAB REC
TAB REC NO P C J NO P C J
NO P C J NO P C J 1 N1 - LH 1 N1 W J12
1 101 R LSST 1 101 R CN23-4 2 102 - LH 2 102 O CN5-4
2 111 SL LSST 2 111 Y CN33-3

1 1
4 3 2 1 1 2 3 4 CN17
8 7 6 5 CN7 5 6 7 8
2 2
TAB REC
TAB REC NO P C J NO P C J
NO P C J NO P C J 1 122 R CHI 1 122 Y CN41-2
1 N1 - COM(-) 1 N1 W CN3-1 2 N1 B CHI 2 N1 W J12
2 47 - LOW V 2 47 G-Y CN3-5
3 3
1 1
4
5
41 - HIGH V 4
5
41 Y CN3-3
2
CN18 2
6 43 - ETI(+) 6 43 L CN3-2
TAB REC
7 7
NO P C J NO P C J
8 8
1 103 - BZ 1 103 LG J9
2 N1 - BZ 2 N1 W J12
11-10

1 1
2 1 CN23 1 2
3 4 2
CN60 2
4 3
TAB REC TAB REC
NO P C J NO P C J NO P C J NO P C J
1 P1 B F5 1 P1 B P1 TERMINAL 1 43 L RF 1 43 L J1
2 P1 B F4 2 P1 B J11 2 N1 W CN61 2 N1 W J12
3 41 Y F5 3 41 Y CN5-3
4 101 R F4 4 101 R CN6-1 1 1
2
CN61 2
3 2 1
6 5 4
CN28 1 2 3
4 5 6 NO P C
TAB
J NO P C
REC
J
1 130 R FC 1 130 GR RF
TAB REC 2 N1 B FC 2 N1 W CN60
NO P C J NO P C J
1 116 BR DRY 1 116 BR CN1-1
5 4 3 2 1 1 2 3 4 5
2
3
117
115
SL
G
DRY
DRY
2
3
117
115
SL
G
CN5-1
CN42-1 12 11 10 9 8 7 6 CN101 6 7 8 9 10 11 12
4 43 L DRY 4 43 L J1 TAB REC
5 101 R DRY 5 101 R J4 NO P C J NO P C J
6 N1 W DRY 6 N1 W J12 1 54 - POTA+ 1 54 GR CN104-1
2 52 - POTA 2 52 LG CN104-2
3 51 - POTA- 3 51 V CN104-3
2 1
4 3
CN33 1 2
3 4
4 46 - DSR 4 46 O CN104-4
5 45 - DSF 5 45 G CN104-8
TAB REC 6 116 - LSD 6 116 BR CN104-5
NO P C J NO P C J 7 7
1 104 G LT-L 1 104 V CN5-2 8 64 ACL SW 8 64 P CN104-6
2 N1 B COM 2 N1 W J12 9 9
3 111 W LST-L 3 111 Y CN6-2 10 10
4 103 R LBU-L 4 103 LG CN1-3 11 116 - LSD 11 116 BR J13
12 12

2 1
4 3
CN34 1 2
3 4
CN102 CN103
TAB REC 6 5 4 3 2 1 4 3 2 1
NO P C J NO P C J 14 13 12 11 10 9 8 7 10 9 8 7 6 5
1 104 G LT-R 1 104 V J8 TAB TAB
2 N1 B COM 2 N1 W J12 NO P C J NO P C J
3 111 W LST-R 3 111 Y J10 1 N1 L N1 1
4 103 R LBU-R 4 103 LG J9 2 34 B R1 2
3 92 Y-O TMDB 3
3 2 1 CN41 1 2 3 4
5 35 O R1
4 N1
5
L N1

TAB REC 6 73 P CSD+ 6 1 Y-G M-

NO P C J NO P C J 7 P8 R-G P8 7 3 W-R MR+
1 130 - L 1 130 L CHICR 8 P5 R-B P5 8 2 W-L MF+
2 122 - E 2 122 Y CN17-1 9 P7 R-L P7 9
3 120 - B 3 120 P CN1-2 10 P6 BR P6 10
11 P2 R P2
12 75 - STDT
1
2
CN42 1
2
13 76 - STDT
14 74 W CSD-
TAB REC
NO P C J NO P C J
1 115 - LSD 1 115 G CN28-3
4 3 2 1
8 7 6 5
CN104 1 2 3 4
5 6 7 8
2 43 - LSD 2 43 L CN5-6
TAB REC
NO P C J NO P C J
1 1
2
CN50 2
1 53 GR CN101-1 1 53 GR CN11-4
2 52 LG CN101-2 2 52 LG CN11-3
TAB REC 3 51 V CN101-3 3 51 V CN11-1
NO P C J NO P C J 4 46 O CN101-4 4 46 O CN1-4
1 107 - LSB 1 107 P CN51-2 5 116 BR CN101-6 5 116 BR J5
2 N1 - LSB 2 N1 W J12 6 64 P CN101-8 6 64 P CN11-2
7 7
8 45 G CN101-6 8 45 G CN1-5
1 1
2
CN51 2
TAB REC
NO P C J NO P C J
1 43 - SWLSB 1 43 L J1
2 107 - SWLSB 2 107 P CN50-1
 11-11

Main harness joint

CN3-2 CN28-5 CN34-3

CHMS CN1-6 CN13-2 LF-LR

CN51-1 J1 CN28-4 J4 J7 J10

CN5-6 CN42-2 CN6-1 CN23-4 LF-L CN2-5 CN6-2 CN33-3

CN70-2
43, L 101, R 109, G-Y 111, Y

CN2-1 CN13-1 CN70-1

CN3-3 CN12-2 CN104-5 CHMS
CN23-2 CN70-3

J2 J5 J8 J11

CN23-3 CN5-3 CN28-1 CN1-1 CN2-3 CN12-1 P1 TERMINAL CN23-1

41, Y 116, BR 110, GR P1, B

CN34-1 CN18-1 CN70-4

CN13-3 LF-RR CHMCR CN34-4 CN28-6 CN18-2
CN33-2 CN17-2
LF-LR CN50-2
J3 J6 J9 LF-L J12 CN14-1
LF-RR CN34-2
CN2-4 CN33-1 CN33-4 LF-R HORN
LF-R CN5-2 CN1-3
N1 TERMINAL
108, L 104, V 103, LG
N1, W

CN101-11

J13

CN104-5 CN101-6

116, BR
11-12

CBT4•CBT6 (EEC)

3 2 1
6 5 4
CN1 1 2 3
4 5 6
2 1
4 3
CN8 1 2
3 4
TAB REC TAB REC
NO P C J NO P C J NO P C J NO P C J
1 116 O DSF, DSR 1 116 BR CN28-1 1 117 - T 1 117 SL CN5-1
2 120 B DSFO 2 120 P CN41-3 2 104 - B 2 104 V CN5-2
3 103 G DSB 3 103 LG CN33-4 3 102 - HM 3 102 O CN5-4
4 46 W-O DSR 4 46 O CN104-4 4 102 - HS 4 102 O CN5-4
5 45 W-BR DSF 5 45 G CN104-5
6 43 R DSFO, DSB 6 43 L J1
2 1
4 3
CN9 1 2
3 4
2 1 1 2
TAB REC
6 5 4 3 CN2 3 4 5 6 NO P C J NO P C J
1 1
TAB REC 2 41 - SWK 2 41 Y CN5-3
NO P C J NO P C J 3 3
1 41 L SWH(+) 1 41 Y J2 4 43 - SWK 4 43 L CN5-6
2 48 B SWH(-) 2 48 P HORN
3 110 W SWF(B) 3 110 GR CN12-1
4 108 Y SWF(R) 4 108 L LF-R
4 3 2 1 CN11 1 2 3 4
5 109 G SWF(L) 5 109 G-Y LF-L
6 6 TAB REC
NO P C J NO P C J
1 51 - E2 1 51 W CN105-1
1 2 3
3
6
2
5
1
4
CN3 4 5 6
2
3
64
52
-
-
IDL
VTA
2
3
64
52
R
G
CN105-4
CN105-3
4 54 - VC 4 54 L CN105-2
TAB REC
NO P C J NO P C J
1 N1 W CN7-1, HM 1 N1 W N1 TERMINAL
1 1
2 43 L CN7-6 2 43 L J1
3 41 Y CN7-4, HM 3 41 Y J2 2 CN12 2
4 4
5 47 G-Y CN7-2 5 47 G-Y HM-ST
6 49 O HM 6 49 O HM-ST
TAB REC
NO P C J NO P C J
1 110 - FRY 1 110 GR CN2-3
2 41 - FRY 2 41 Y J2
1 2 3
3
6
2
5
1
4
CN5 4 5 6
1 1
NO P C
TAB
J NO P C
REC
J 3 2
CN13 2 3
1 117 SL CN8-1 1 117 SL CN28-2 TAB REC
2 104 V CN8-4 2 104 V CN33-1 NO P C J NO P C J
3 41 Y CN9-2 3 41 Y CN23-3 1 110 GR SWHZ 1 110 GR J8
4 102 O CN8-3, CN8-4 4 102 O CN14-2 2 109 G-Y SWHZ 2 109 G-Y J7
5 5 3 108 L SWHZ 3 108 L J3
6 43 L CN9-4 6 43 L CN42-2

2 1 CN14 2 1
2 1 CN6 2 1
TAB REC
TAB REC NO P C J NO P C J
NO P C J NO P C J 1 N1 - LH 1 N1 W J12
1 101 R LSST 1 101 R CN23-4 2 102 - LH 2 102 O CN5-4
2 111 SL LSST 2 111 Y CN33-3

1 1
4 3 2 1 1 2 3 4 CN17
8 7 6 5 CN7 5 6 7 8
2 2
TAB REC
TAB REC NO P C J NO P C J
NO P C J NO P C J 1 122 R CHI 1 122 Y CN41-2
1 N1 - COM(-) 1 N1 W CN3-1 2 N1 B CHI 2 N1 W J12
2 47 - LOW V 2 47 G-Y CN3-5
3 3
1 1
4
5
41 - HIGH V 4
5
41 Y CN3-3
2
CN18 2
6 43 - ETI(+) 6 43 L CN3-2
TAB REC
7 7
NO P C J NO P C J
8 8
1 103 - BZ 1 103 LG J9
2 N1 - BZ 2 N1 W J12
 11-13

1 1
2 1 CN23 1 2
3 4 2
CN60 2
4 3
TAB REC TAB REC
NO P C J NO P C J NO P C J NO P C J
1 P1 B F5 1 P1 B P1 TERMINAL 1 43 L RF 1 43 L J1
2 P1 B F4 2 P1 B J11 2 N1 W CN61 2 N1 W J12
3 41 Y F5 3 41 Y CN5-3
4 101 R F4 4 101 R CN6-1 1 1
2
CN61 2
3 2 1
6 5 4
CN28 1 2 3
4 5 6 NO P C
TAB
J NO P C
REC
J
1 130 R FC 1 130 GR RF
TAB REC 2 N1 B FC 2 N1 W CN60
NO P C J NO P C J
1 116 BR DRY 1 116 BR CN1-1
2 117 SL DRY 2 117 SL CN5-1
3 115 G DRY 3 115 G CN42-1
2 1
4 3
CN62 1 2
3 4
4 43 L DRY 4 43 L J1
5 101 R DRY 5 101 R J4 TAB REC
6 N1 W DRY 6 N1 W J12 NO P C J NO P C J
1 45 G CN106-1 1 45 G CN1-5
2 46 R CN106-2 2 46 O CN1-4
2 1
4 3
CN33 1 2
3 4
3 116 W CN106-3 3 116 BR J5
4 116 L CN106-4 4 116 BR J5
TAB REC
NO P C J NO P C J 5 4 3 2 1 1 2 3 4 5
1 104 G LT-L 1 104 V CN5-2 12 11 10 9 8 7 6 CN101 6 7 8 9 10 11 12
2 N1 B COM 2 N1 W J12
3 111 W LST-L 3 111 Y CN6-2 TAB REC
4 103 R LBU-L 4 103 LG CN1-3 NO P C J NO P C J
1 54 - POTA+ 1 54 L CN105-2
2 52 - POTA 2 52 G CN105-3
2 1
4 3
CN34 1 2
3 4
3
4
51
46
-
-
POTA-
DSR
3
4
51
46
W
R
CN105-1
CN106-2
5 45 - DSF 5 45 G CN106-1
TAB REC
6 116 - LSD 6 116 L CN106-4
NO P C J NO P C J
7 7
1 104 G LT-R 1 104 V J8
8 64 ACL SW 8 64 R CN105-4
2 N1 B COM 2 N1 W J12
9 9
3 111 W LST-R 3 111 Y J10
10 10
4 103 R LBU-R 4 103 LG J9
11 116 - LSD 11 116 W CN106-3
12 12
3 2 1 CN41 1 2 3
TAB REC CN102 CN103
NO P C J NO P C J
6 5 4 3 2 1 4 3 2 1
1 130 - L 1 130 L CHICR
2 122 - E 2 122 Y CN17-1
14 13 12 11 10 9 8 7 10 9 8 7 6 5
3 120 - B 3 120 P CN1-2 TAB TAB
NO P C J NO P C J
1 N1 L N1 1
1
2
CN42 1
2
2 34 B R1 2
3 92 Y-O TMDB 3
4 4 N1 L N1
TAB REC
5 35 O R1 5
NO P C J NO P C J
6 73 P CSD+ 6 1 Y-G M-
1 115 - LSD 1 115 G CN28-3
7 P8 R-G P8 7 3 W-R MR+
2 43 - LSD 2 43 L CN5-6
8 P5 R-B P5 8 2 W-L MF+
9 P7 R-L P7 9
1 1
2
CN50 2
10
11
P6
P2
BR
R
P6
P2
10

12 75 - STDT
TAB REC
13 76 - STDT
NO P C J NO P C J
14 74 W CSD-
1 107 - LSB 1 107 P CN51-2
2 N1 - LSB 2 N1 W J12

1 1
2
CN51 2
TAB REC
NO P C J NO P C J
1 43 - SWLSB 1 43 L J1
2 107 - SWLSB 2 107 P CN50-1
11-14

4 3 2 1 CN104 1 2 3 4 Main harness joint

8 7 6 5 5 6 7 8
TAB REC CN3-2
NO P C J NO P C J CHMS CN1-6 CN13-2 LF-LR
1 53 GR CN101-1 1 53 GR CN11-4
2 52 LG CN101-2 2 52 LG CN11-3
3 51 V CN101-3 3 51 V CN11-1 CN51-1 J1 CN28-4 J7
4 46 O CN101-4 4 46 O CN1-4
5 116 BR CN101-6 5 116 BR J5
CN5-6 CN42-2 LF-L CN2-5
6 64 P CN101-8 6 64 P CN11-2
7 7 CN70-2 109, G-Y
8 45 G CN101-6 8 45 G CN1-5 43, L

CN2-1 CN13-1
CN3-3 CN12-2
2 1
4 3
CN105 1 2
3 4
TAB REC J2 J8
NO P C J NO P C J
1 51 W CN101-3 1 51 W CN11-1
2 54 L CN101-1 2 54 L CN11-2 CN23-3 CN5-3 CN2-3 CN12-1
3 52 G CN101-2 3 52 G CN11-3
41, Y 110, GR
4 64 R CN101-8 4 64 R CN11-4

CN18-1
CN13-3 LF-RR CHMCR CN34-4
2 1
4 3
CN106 1 2
3 4
TAB REC J3 J9
NO P C J NO P C J
1 45 G CN101-5 1 45 G CN62-1
2 46 R CN101-4 2 46 R CN62-2 LF-R CN2-4 CN1-3 CN33-4
3 116 W CN101-11 3 116 W CN62-3 108, L 103, LG
4 116 L CN101-6 4 116 L CN62-4
CN28-5 CN34-3

J4 J10

CN6-1 CN23-4 CN6-2 CN33-3

101, R 111, Y

CN62-3 CN70-1
CN62-4 CHMS
CN23-2 CN70-3

J5 J11

CN28-1 CN1-1 P1 TERMINAL CN23-1

116, BR P1, B

CN34-1 CN70-4
CN28-6 CN18-2
CN33-2 CN17-2
LF-LR CN50-2
J6 LF-L J12 CN14-1
LF-RR CN34-2
CN33-1 LF-R HORN
CN5-2
N1 TERMINAL
104, V
N1, W

CN101-11

J13

CN104-5 CN101-6
116, BR
 11-15

CBTY4

5 4 3 2 1
10 9 8 7 6
CN1 1 2 3 4 5
6 7 8 8 10
2 1
4 3
CN8 1 2
3 4
TAB REC TAB REC
NO P C J NO P C J NO P C J NO P C J
1 116 R-L VRAD 1 116 BR J13 1 117 - B 1 117 SL CN5-1
2 45 W DSF 2 45 G CN101-5 2 104 - T 2 104 V CN5-2
3 3 3 102 - HM 3 102 O CN5-4
4 46 G DSR 4 46 O CN101-4 4 102 - HS 4 102 O CN5-4
5 43 B-Y VBKY 5 43 L J1
6 120 Y-R DSFO 6 120 P CN41-3
7
8
103
52
R-W
GR
DSB
ACCEL
7
8
103
52
LG
LG
J9
CN101-2
2 1
4 3
CN9 1 2
3 4
9 51 L-R SG GND 9 51 V CN101-3 TAB REC
10 53 R-B ACCEL+ 10 53 GR CN101-1 NO P C J NO P C J
1 1
2 41 - SWK 2 41 Y CN5-3
1 1
2
CN2 2
3 3
4 43 - SWK 4 43 L CN5-6
TAB REC
NO P C J NO P C J
1 1
1 41
2 48
L
B
SWH(+)
SWH(-)
1 41
2 48
Y
P
J2
HORN 3 2
CN11 2 3
TAB REC
NO P C J NO P C J
1 2 3
3
6
2
5
1
4
CN3 4 5 6
1 110 GR SWF 1 110 GR J8
2 108 L SWF 2 108 L J3
TAB REC 3 109 G-Y SWF 3 109 G-Y J7
NO P C J NO P C J
1 N1 W CN7-1, HM 1 N1 W N1 TERMINAL
2 43 L CN7-6 2 43 L J1 1 1
3 41 Y CN7-4, HM 3 41 Y J2 2 CN12 2
4 4
5 47 G-Y CN7-2 5 47 G-Y HM-ST
6 49 O HM 6 49 O HM-ST TAB REC
NO P C J NO P C J
1 110 - FRY 1 110 GR J8
1 2 3
3
6
2
5
1
4
CN5 4 5 6
2 41 - FRY 2 41 Y J2

TAB REC 1 1
NO P C J NO P C J 3 2
CN13 2 3
1 117 SL CN8-1 1 117 SL CN28-2
2 104 V CN8-2 2 104 V J6 TAB REC
3 41 Y CN9-2 3 41 Y J2 NO P C J NO P C J
4 102 O CN8-3, CN8-4 4 102 O CN14-2 1 110 GR SWHZ 1 110 GR J8
5 5 2 109 G-Y SWHZ 2 109 G-Y J7
6 43 L CN9-4 6 43 L J1 3 108 L SWHZ 3 108 L J3

2 1 CN6 1 2 2 1 CN14 1 2

TAB REC TAB REC

NO P C J NO P C J NO P C J NO P C J
1 101 R LSST 1 101 R J4 1 N1 - LH 1 N1 W J12
2 111 SL LSST 2 111 Y J10 2 102 - LH 2 102 O CN5-4

4 3 2 1 1 2 3 4 1 1
8 7 6 5 CN7 5 6 7 8 2
CN17 2
TAB REC TAB REC
NO P C J NO P C J NO P C J NO P C J
1 N1 - COM (-) 1 N1 W CN3-1 1 122 R CHI 1 122 Y CN41-2
2 47 - LOW V 2 47 G-Y CN3-5 2 N1 B CHI 2 N1 W J12
3 3
4 41 - HIGH V 4 41 Y CN3-3
1 1
5 5
2
CN18 2
6 43 - ETI (+) 6 43 L CN3-2
7 7 TAB REC
8 8 NO P C J NO P C J
1 103 - BZ 1 103 LG J9
2 N1 - BZ 2 N1 W J12
11-16

2 1 CN23 1 2 2 1 CN42 1 2
4 3 3 4
TAB REC TAB REC
NO P C J NO P C J
NO P C J NO P C J
1 115 - LSD 1 115 G CN28-3
1 P1 B F5 1 P1 B J11
2 43 - LSD 2 43 L J1
2 P1 B F4 2 P1 B J11
3 41 Y F5 3 41 Y J2
4 101 R F4 4 101 R J4 1 1
2
CN50 2
TAB REC
3 2 1
6 5 4
CN28 1 2 3
4 5 6 NO P C J NO P C J
1 107 - LSB 1 107 P CN51-2
TAB REC 2 N1 - LSB 2 N1 W J12
NO P C J NO P C J
1 116 BR DRY 1 116 BR J13
1 1
2
3
117
115
SL
G
DRY
DRY
2
3
117
115
SL
G
CN5-1
CN42-1 2
CN51 2
4 43 L DRY 4 43 L J1
TAB REC
5 101 R DRY 5 101 R J4
NO P C J NO P C J
6 N1 W DRY 6 N1 W J12
1 43 - SWLSB 1 43 L J1
2 107 - SWLSB 2 107 P CN50-1

2 1
4 3
CN33 1 2
3 4
TAB REC
NO P C J NO P C J 5 4 3 2 1 1 2 3 4 5
1 104 G LT-L 1 104 V J6
12 11 10 9 8 7 6 CN101 6 7 8 9 10 11 12
2 N1 B COM 2 N1 W J12
3 111 W LST-L 3 111 Y J10 TAB REC
4 103 R LBU-L 4 103 LG J9 NO P C J NO P C J
1 53 - ACCEL+ 1 53 GR CN1-10
2 52 - ACCEL 2 52 LG CN1-8
3 51 - SG GND 3 51 V CN1-9
2 1
4 3
CN34 1 2
3 4 4 46 - DSR 4 46 O CN1-4
5 45 - DSF 5 45 G CN1-2
TAB REC 6 116 - DRY 6 116 BR J13
NO P C J NO P C J 7 7
1 104 G LT-R 1 104 V J6 8 8
2 N1 B COM 2 N1 W J12 9 9
3 111 W LST-R 3 111 Y J10 10 10
4 103 R LBU-R 4 103 LG J9 11 116 - DRY 11 116 BR J13
12 12

3 2 1 CN41 1 2 3
TAB REC
NO P C J NO P C J
1 131 - L 1 131 L CH
2 2
3 120 - B 3 120 P CN1-6
 11-17

CN102 Main harness joint

6 5 4 3 2 1 CN3-2
14 13 12 11 10 9 8 7 CHMS CN1-5 CN13-2 LF-LR
TAB
NO P C J
1 N1 L N1 CN51-1 J1 CN28-4 J7
2 34 B R1
3 92 Y-O TMDB
4 CN5-6 CN42-2 LF-L CN11-3
5 35 O R1
6 73 P CSD+ 43, L 109, G-Y
7 P8 R-G P8
8 P5 R-B P5
9 P7 R-L P7 CN2-1 CN13-1
CN3-3 CN12-2
10 P6 BR P6
11 P2 R P2
12
13 J2 J8
14 74 W CSD-

CN23-3 CN5-3 CN11-1 CN12-1

CN103
4 3 2 1 41, Y 110, GR
10 9 8 7 6 5
TAB CN18-1
NO P C J CN13-3 LF-RR CH CN34-4
1
2
3 J3 J9
4 N1 L N1
5
6 1 Y-G M- LF-R CN11-2 CN1-7 CN33-4
7 3 W-R CFW+
8 2 W-L CRV+
9
108, L 103, LG
10
CN28-5 CN34-3

J4 J10

CN6-1 CN23-4 CN6-2 CN33-3

101, R 111, Y

CN23-2
CN101-11 CHMS

J13 CN101-6 J11

CN28-1 CN1-1 P1 TERMINAL CN23-1

116, BR P1, B

CN34-1
CN28-6 CN18-2
CN33-2
LF-LR CN50-2
J6 LF-L J12 CN14-1
LF-RR CN34-2
CN33-1 LF-R HORN
CN5-2
N1 TERMINAL
104, V N1, W
 11-18
CONNECTING DIAGRAM
CBT4•CBT6
BATTERY CAPACITY HOUR METER
INDICATOR BCI

SWHZ
LSST SWLSB HM
(101, R) HM
COM
CN6 CN7 TAB
LF-R

(109, G-Y)
(110, GR)
(110, GR)
REC

(108, L)
NO
LH

REC
TAB
NC
(111, Y)

(N1, W)
(49, O)
(41, Y)

G
R
CN14 CN51
SWH TAB
REC
TAB
REC TAB
CN13

(108, L)

(N1, W)
CN3 REC
TAB
SWD REC
LF-L
F5 F4 SWF
CN5 CN9
G
R

TAB TAB
REC CN2 REC CN1

REC

REC
SWk

TAB

TAB
TAB CN41
REC CN23 DRY
(101, R)

REC
TAB
(109, G-Y)

(N1, W)

(115, G)
FRY
(117, SL)
CN8
(43, L)

REC
TAB
HM-
ST
(N1, W) SWL
(116, BR)
HOUR METER CONNECTOR
HM-
CN28 TAB
ST CN12

REC
REC

TAB
CHI ACCEL
TAB
CN17 CHICR
(N1, W)
REC CHIME CONNECTOR,
REVERSE TAB
H CN11
CHICR REC

(48, P)

CBT6
RF FC

TAB
REC
LT-L CN61
LST-L BATT
LT-R
LST-R LBU-L
LBU-R CN60 TAB CP

TAB
TAB REC CN102 E
REC CN33 P5
TAB
CN34 P6 P7 A

TAB
REC CN103 DMD
REC
F
CN42 F1

P1

P2
TAB
B
LF-LR CN101 N1
LF-RR LSB TAB
CN104 REC
BZ LSD
G
R

REC
TAB
G
R

CN50 TAB
TAB REC CN18
REC
(109, G-Y)

(N1, W)

DRIVER’S SEAT
(N1, W)
(108, L)
 11-19
CBT4•CBT6 (EEC)

BATTERY CAPACITY HOUR METER

INDICATOR BCI

SWHZ
LSST SWLSB HM
(101, R) HM
COM
CN6 CN7 TAB
LF-R

(109, G-Y)
(110, GR)
(110, GR)
REC

(108, L)
NO
LH

REC
TAB
NC
(111, Y)

(N1, W)
(49, O)
(41, Y)

G
R
CN14 CN51
SWH TAB
REC
TAB
REC TAB
CN13

(108, L)

(N1, W)
CN3 REC
TAB
SWD REC
LF-L
F5 F4 SWF
CN5 CN9
G
R

TAB TAB
REC CN2 REC CN1

REC

REC
SWk

TAB

TAB
CN62
TAB CN41
CN23

REC
TAB
REC (101, R) DRY

REC
TAB
(109, G-Y)

(N1, W)

(115, G)
FRY
(117, SL)
CN8
(43, L)

REC
TAB
HM-
ST
(N1, W) SWL
(116, BR)
HOUR METER CONNECTOR
HM-
CN28 TAB
ST CN12

REC
REC

TAB
CHI ACCEL
TAB
CN17 CHICR
(N1, W)
REC CHIME CONNECTOR,
REVERSE TAB
H CN11
CHICR REC

(48, P)

CBT6
RF FC

TAB
REC
LT-L CN61
LST-L BATT
LT-R
LST-R LBU-L
LBU-R CN60 TAB CP

TAB
TAB REC CN102 E
REC CN33 P5
TAB
CN34 P6 P7 A

TAB
REC CN103 DMD
REC
F
CN42 F1
P1

P2
TAB
B
LF-LR CN101 N1
LF-RR LSB TAB
CN104 REC
BZ LSD CN105
G
R

REC
TAB
G
R

REC

CN50
TAB

TAB
TAB REC CN18
REC
(109, G-Y)

REC
(N1, W)

TAB

DRIVER’S SEAT
(N1, W)
(108, L)

CN106
 11-20
CBTY4

BATTERY CAPACITY HOUR METER SWLSB SWH SWHZ

BCI
LH INDICATOR

(109, G-Y)
(110, GR)
(110, GR)

(108, L)
LF-L HM HM
SWF ACCEL
(front) CN7
TAB
REC
TAB
CN14 LF-R
G
R

(N1, W)
REC

(49, O)
(41, Y)
FRY CN51 CN13 (front)
TAB
CN3 TAB TAB
CN2
TAB TAB CN1 REC DRY
REC REC REC REC REC

REC
TAB
(101, R)

G
R
TAB
(109, G-Y)

(N1, W)

REC (115, G)
(N1, W)
CN12 (117, SL)

H (48, P)
(43, L)
(N1, W)
CN5 CN9 F4, F5

(108, L)

(N1, W)
(116, BR)

REC

REC
SWk

TAB

TAB
TAB
CHIME CONNECTOR CN8 REC
REC (103, LG) (131, L)
CN23

REC
CN17(F)

TAB
TAB SWL TAB
CN28
CH CH REC

REC
TAB REC
CHI
CN41
(43, L)

REC
TAB
CN42
(115, G) E

REC
TAB
LSD A
DMD
LF-LR LF-RR (101, R) F
CN6
(rear) (rear) B
(111, Y)
REC
TAB

LT-L LT-R LSST BATT

G

G
R

LST-L LST-R
LBU-L LBU-R CN18(R)
REC
(109, G-Y)

TAB HOUR METER CONNECTOR

(N1, W)

(N1, W)
(108, L)

CN33 CN34
TAB TAB
(49, O) (47, G-Y)
PBSG
BZ HM- HM-

TAB
REC REC
ST ST CN102
P5
REC TAB
P6 P7

TAB
CN103

F1

P1

P2
TAB
REC CN50
CN101 N1
TAB
REC

LSB
 11-21
WIRING DIAGRAM
CBT4•CBT6
F1 175A P2

OPT SEAT SW
P1 STD (Ex. OPT SEAT SW)

SWK
(P1, B) 10A (43, L)
F5 (41, Y)

F4 (101, R) ACCEL

VRAD
10A CBT6
LSD
LSST CBT4

SWAC
FRY
SWLSB
SWL B
DSF DSR

(53, GR)
(110, GR)

(115, G)
T HS HM OPT SEAT SW

(111, Y)
RA
DF2 DF1
(104, V) (A)

(116, BR)

(116, BR)

(52, LG)
(45, G)

(46, O)

(64, P)

(51, V)
(54, Y)
DSB DSFO DMD
(B)
BATT (P2, R)

ACC SW

ACCEL

ACCEL+

SG GND
FWD

REV
(102, O)
48V (P7, R-L)
LST-L P5
(P5, R-B)
DRY
LT-L (P6, BR)
LH
LST-R

(103, LG)

(120, P)
SWF

(107, P)
LT-R P7 P6

(116, BR)

(117, SL)
(34, B) MR MF
SWHZ (E) (F)

R1 P8
PBSG

(109, G-Y)
CHICR RAD

(108, L)
(131, L)
R1

(122, Y)
SWH
R1 DAD
(35, O) RAD

SA RF
P9
HM-ST

HM-ST

LBU-L LSB (P8, R-G)

CAD
(92, Y-O)

(130, GR)
TMD

LBU-R
(47, G-Y)

LF-L

(3, W-R)
LF-R

(9, W-L)

(2, W-L)
CHI

(1, Y-G)

(74, W)

(73, P)
(48, P)

(49, O)

(N1, L)
FC
BZ
BCI HM HM LF-LR LF-RR MF MR CSD
H
(N1, W)

CBT6
(N1)

N1

BCI BATTERY CAPACITY INDICATOR HM METER, HOUR LSST LIMIT SWITCH, STOP LAMP LST-L LAMP, STOP LH
BATT BATTERY HM-ST HOUR METER START CONNECTOR LSD LIMIT SWITCH, DEADMAN LST-R LAMP, STOP RH
H HORN
F1 FUSE, DRIVE BZ BUZZER SWAC SWITCH, ACCEL LBU-L LAMP, BACK-UP LH
F4 FUSE, LAMP CHI CHIME SWK SWITCH, KEY LBU-R LAMP, BACK-UP RH
F5 FUSE, CONTROL CIRCUIT CHICR CHIME CONNECTOR, REVERSE SWH SWITCH, HORN LSB LAMP, STROBO
SWL SWITCH, LIGHT DAD DIODE, ABSORBER, DRIVE
DMD MOTOR, DRIVE FRY RELAY, FLASHER SWF SWITCH, FLASHER RAD RESISTER, ABSORBER, DRIVE
DRY RELAY, SEAT SWHZ SWITCH, HAZARD CAD CAPACITOR, ABSORBER, DRIVE
TMD TRANSISTOR, MAIN, DRIVE SWLSB SWITCH, LAMP, STROBO
LH LAMP, HEAD MF CONTACTOR, FORWARD
SA SURGE ABSORBER DSF DIRECTION SWITCH, FORWARD MR CONTACTOR, REVERSE
VRAD VARI-OHM, ACCEL, DRIVE DSR DIRECTION SWITCH, REVERSE LT-L LAMP, TAIL LH
CSD CURRENT SENSOR, DRIVE DSFO DIRECTION SWITCH, FORWARD OPTIONAL LT-R LAMP, TAIL RH FC FAN, CONTROL UNIT
DSB DIRECTION SWITCH, BACK-UP RF RESISTOR, FAN
DF1 DIODE, FLY-WHEEL, NO1 LF-L LAMP, FLASHER LH RA RESISTOR, ACCEL
DF2 DIODE, FLY-WHEEL, NO2 LF-R LAMP, FLASHER RH PBSG PRINT BOARD, SG
LF-LR LAMP, FLASHER LH (REAR)
LF-RR LAMP, FLASHER RH (REAR)
 11-22

CBT4•CBT6 (EEC)
F1 175A P2

P1

SWK
(P1, B) 10A (43, L)
F5 (41, Y)

F4 (101, R) ACCEL

VRAD
10A CBT6
LSD
LSST CBT4

SWAC
FRY
SWLSB
SWL B
DSF DSR

(53, GR)
(110, GR)

(115, G)
T HS HM

(111, Y)
RA
DF2 DF1
(A)
(104, V)

(116, W)

(116, L)

(51, W)
(45, G)

(52, G)
(46, R)

(64, R)

(54, L)
DSB DSFO DMD
(B)
BATT (P2, R)

ACC SW

ACCEL

ACCEL+

SG GND
FWD

REV
(102, O)
48V (P7, R-L)
LST-L P5
(P5, R-B)
DRY
LT-L (P6, BR)
LH
LST-R

(103, LG)

(120, P)
SWF

(107, P)
LT-R P7 P6

(116, BR)

(117, SL)
(34, B) MR MF
SWHZ (E) (F)

R1 P8
PBSG

(109, G-Y)
CHICR RAD

(108, L)
(131, L)
R1

(122, Y)
SWH
R1 DAD
(35, O) RAD

SA RF
P9
HM-ST

HM-ST

LBU-L LSB (P8, R-G)

CAD
(92, Y-O)

(130, GR)
TMD

LBU-R
(47, G-Y)

LF-L

(3, W-R)
LF-R

(9, W-L)

(2, W-L)
CHI

(1, Y-G)

(74, W)

(73, P)
(48, P)

(49, O)

(N1, L)
FC
BZ
BCI HM HM LF-LR LF-RR MF MR CSD
H
(N1, W)

CBT6
(N1)

N1

BCI BATTERY CAPACITY INDICATOR HM METER, HOUR LSST LIMIT SWITCH, STOP LAMP LST-L LAMP, STOP LH
BATT BATTERY HM-ST HOUR METER START CONNECTOR LSD LIMIT SWITCH, DEADMAN LST-R LAMP, STOP RH
H HORN
F1 FUSE, DRIVE BZ BUZZER SWAC SWITCH, ACCEL LBU-L LAMP, BACK-UP LH
F4 FUSE, LAMP CHI CHIME SWK SWITCH, KEY LBU-R LAMP, BACK-UP RH
F5 FUSE, CONTROL CIRCUIT CHICR CHIME CONNECTOR, REVERSE SWH SWITCH, HORN LSB LAMP, STROBO
SWL SWITCH, LIGHT DAD DIODE, ABSORBER, DRIVE
DMD MOTOR, DRIVE FRY RELAY, FLASHER SWF SWITCH, FLASHER RAD RESISTER, ABSORBER, DRIVE
DRY RELAY, SEAT SWHZ SWITCH, HAZARD CAD CAPACITOR, ABSORBER, DRIVE
TMD TRANSISTOR, MAIN, DRIVE SWLSB SWITCH, LAMP, STROBO
LH LAMP, HEAD MF CONTACTOR, FORWARD
SA SURGE ABSORBER DSF DIRECTION SWITCH, FORWARD MR CONTACTOR, REVERSE
VRAD VARI-OHM, ACCEL, DRIVE DSR DIRECTION SWITCH, REVERSE LT-L LAMP, TAIL LH
CSD CURRENT SENSOR, DRIVE DSFO DIRECTION SWITCH, FORWARD OPTIONAL LT-R LAMP, TAIL RH FC FAN, CONTROL UNIT
DSB DIRECTION SWITCH, BACK-UP RF RESISTOR, FAN
DF1 DIODE, FLY-WHEEL, NO1 LF-L LAMP, FLASHER LH RA RESISTOR, ACCEL
DF2 DIODE, FLY-WHEEL, NO2 LF-R LAMP, FLASHER RH PBSG PRINT BOARD, SG
LF-LR LAMP, FLASHER LH (REAR)
LF-RR LAMP, FLASHER RH (REAR)
 11-23
CBTY4

F1 175A P2

P1

SWK
(P1, B) 10A
F5 (41, Y) (43, L)

F4 (101, R) ACCEL
VRAD
10A
LSD
LSST
SWLSB FRY

SWL B
DSF DSR

(110, GR)

(115, G)
T HS HM

(111, Y)
DF2 DF1
(A)
(104, V)

(116, BR)

(116, BR)

(53, GR)
(52, LG)
(45, G)

(46, O)

(51, V)
DSB DSFO DMD
DRY (B)
BATT (P2, R)

ACCEL

ACCEL+

SG GND
FWD

REV
48V
(102, O)

(P7, R-L)
LST-L P5
(P5, R-B)

(107, P)
LT-L (P6, BR)
LH

(116, BR)

(117, SL)
LST-R

(103, LG)

(120, P)
SWF

LT-R P7 P6
(34, B) MR MF
SWHZ (E) (F)

R1 P8
PBSG

(109, G-Y)
CHICR RAD

(108, L)
(131, L)
R1

(122, Y)
SWH
R1 DAD RAD
(35, O)

SA
P9
HM-ST

HM-ST

LBU-L LSB (P8, R-G)

CAD
(92, Y-O)
TMD

LBU-R
(47, G-Y)

(3, W-R)
LF-L LF-R

(9, W-L)

(2, W-L)
CHI

(1, Y-G)

(74, W)
(N1, L)

(73, P)
(48, P)

(49, O)

BZ
BCI HM HM LF-LR LF-RR MF MR CSD
H
(N1, W)

(N1)

N1

BCI BATTERY CAPACITY INDICATOR HM METER, HOUR LSST LIMIT SWITCH, STOP LAMP LST-L LAMP, STOP LH
BATT BATTERY HM-ST HOUR METER START CONNECTOR LSD LIMIT SWITCH, DEADMAN LST-R LAMP, STOP RH
H HORN
F1 FUSE, DRIVE BZ BUZZER SWK SWITCH, KEY LBU-L LAMP, BACK-UP LH
F4 FUSE, LAMP CHI CHIME SWH SWITCH, HORN LBU-R LAMP, BACK-UP RH
F5 FUSE, CONTROL CIRCUIT CHICR CHIME CONNECTOR, REVERSE SWL SWITCH, LIGHT LSB LAMP, STROBO
SWF SWITCH, FLASHER
DMD MOTOR, DRIVE FRY RELAY, FLASHER SWHZ SWITCH, HAZARD DAD DIODE, ABSORBER, DRIVE
DRY RELAY, SEAT SWLSB SWITCH, LAMP, STROBO RAD RESISTER, ABSORBER, DRIVE
TMD TRANSISTOR, MAIN, DRIVE CAD CAPACITOR, ABSORBER, DRIVE
LH LAMP, HEAD
SA SURGE ABSORBER DSF DIRECTION SWITCH, FORWARD MF CONTACTOR, FORWARD
VRAD VARI-OHM, ACCEL, DRIVE DSR DIRECTION SWITCH, REVERSE LT-L LAMP, TAIL LH MR CONTACTOR, REVERSE
CSD CURRENT SENSOR, DRIVE DSFO DIRECTION SWITCH, FORWARD OPTIONAL LT-R LAMP, TAIL RH
DSB DIRECTION SWITCH, BACK-UP PBSG PRINT BOARD, SG
DF1 DIODE, FLY-WHEEL, NO1 LF-L LAMP, FLASHER LH
DF2 DIODE, FLY-WHEEL, NO2 LF-R LAMP, FLASHER RH
LF-LR LAMP, FLASHER LH (REAR)
LF-RR LAMP, FLASHER RH (REAR)
 Published by

1st Printing: Jan. 2004

Pub. No. CE654-1

Printed in Japan