CE681.

book Page 1 Friday, July 30, 2010 3:34 PM

FOREWORD
This manual covers the service procedures of the 7CBT(Y)06. Please use this manual for pro-
viding quick, correct servicing of the corresponding forklift models.

This manual deals with the above models as of June 2010. Please understand that disagree-
ment 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.
CE681.book Page 1 Friday, July 30, 2010 3:34 PM

Contents

SPECIFICATIONS .......................................................................0-2

NAME AND APPEARANCE OF MAIN COMPONENTS..............0-3

FRAME NUMBER PUNCHING LOCATION ................................0-7

DEFINITION OF TERMS .............................................................0-8

MECHANICAL SECTION

1. STEERING, FRONT WHEEL ................................................1-1

2. REAR AXLE...........................................................................2-1

3. BRAKE, PARKING BRAKE (SOLENOID BRAKE) ................3-1

4. DRIVE MOTOR .....................................................................4-1

5. ACCELERATOR....................................................................5-1

ELECTRICAL SECTION

6A. DRIVE CONTROLLER (9803-0103)................................... 6A-1

6B. DRIVE CONTROLLER (0104- ).................................... 6B-1

7. CHARGER.............................................................................7-1

APPENDIX

8. MAINTENANCE STANDARDS TABLE .................................8-1

9. WIRING DIAGRAM ...............................................................9-1

0-1
CE681.book Page 2 Friday, July 30, 2010 3:34 PM

SPECIFICATIONS
Standard Specifications Table

Item Unit 7CBT06 7CBTY06

Maximum towing weight* kg 600 ←
Maximum speed (no load) Km/h 8.5 ←
Maximum speed (load) Km/h 7.5 ←
Uphill gradeability Degrees 4 ←
Minimum turning radius mm 1480 1510
Overall length mm 1460 1505
Overall width mm 745 ←
Overall height mm 995 1195
Wheel base mm 950 ←
Tread mm 590 ←
Under clearance mm 65 ←
Overhang Front mm 195 240
Overhang rear mm 225 ←
Step height mm 140 135
Weight kg 205 220
Motor type DC permanent magnet ←
Motor output Kw/h 0.4/60 MIN ←
Voltage V 24 ←
Battery type Paste type EB100 ←
Battery Voltage V 12V×2 ←
AH/hour
Battery Capacity 100/5 ←
rate
Controller type FET chopper ←
Steering type Front wheel direct drive ←
Reduction gear countershaft
Main brake ←
internal expanding type
Main brake interlocking
Parking brake ←
lever type
Tire (front wheel) 2.50-4 4P ←
Tire (Rear wheel) 3.50-5 4P ←
Charger Type Separate type ←
Charger Input voltage/current AC100V/6V ←
Charger Output voltage/current DC24V/15A ←
*Includes weight of trailer

■ Options
Back lamp Hour meter
Back mirror Front bumper
Pneumatic-shaped Cusion tire Forward chime
Battery Slide-out Trolley Auto parking brake (Solenoid brake)

0-2
CE681.book Page 3 Friday, July 30, 2010 3:34 PM

NAME AND APPEARANCE OF MAIN COMPONENTS

7CBT06

Handle switch

Back mirror Switch panel

(Option)

Handle Brake lever

Seat
Accelerator
Rear body

Stop lamp Step

(Center)

Turn signal lamps

(Right and Left)

Rear tire

Towing hitch
Back lamp
(Option)

0-3
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Turn signal lamp

Turn signal lamp

Headlight

Front tire Bumper

(Option)

0-4
CE681.book Page 5 Friday, July 30, 2010 3:34 PM

7CBTY06

Back mirror
Handle switch (Option) Switch panel

Handle

Accelerator

Brake lever

Rear body

Stop lamp
(Center)

Turn signal lamps

(Right and Left) Mat
(Ops)

Towing hitch

Back lamp Rear tire

(Option)

0-5
CE681.book Page 6 Friday, July 30, 2010 3:34 PM

Turn signal lamp

(Right and Left)

Head light

Front tire

0-6
CE681.book Page 7 Friday, July 30, 2010 3:34 PM

FRAME NUMBER PUNCHING LOCATION

■ Frame Number
The Frame Number is located at the position
shown in the diagram at the left.
Example: 7CBT06:70002

Frame Number
The Frame Number is also punched on the
name plate.

Name plate

0-7
CE681.book Page 8 Friday, July 30, 2010 3:34 PM

DEFINITION OF TERMS
Adjustment Standard : Values for the permitted range when performing inspection
and adjustment.
Replacement Standard : Values for the standard for parts replacement.
Limit values : Maximum or minimum values that must not be exceeded
when performing inspection and adjustment.

Danger : An action where there is danger of possible death if a repair operation is

performed incorrectly.
Warning : An action where serious personal injury may occur if a repair operation is
performed incorrectly.
Notice : An action where personal injury may occur if a repair operation is per-
formed incorrectly.
Note : Provides advice on how to perform the repair

0-8
CE681.book Page 1 Friday, July 30, 2010 3:34 PM

1. STEERING, FRONT WHEEL

[1] CONSTRUCTION .....................................................................1-2

[2] DISASSEMBLY ........................................................................1-2
1. Remove the meter cover. ........................................................................ 1-2
2. Remove the meter panel surrounding parts ............................................ 1-2
3. Remove the inner cover: Up to Model #70105 (to 02.99)........................ 1-3
4. Remove the inner cover: From Model #70106 (from 03.99).................... 1-3
5. Remove the front cowl............................................................................. 1-4
6. Remove the steering shaft....................................................................... 1-4
7. Remove the front fork. ............................................................................. 1-5
8. Remove the front wheel hub.................................................................... 1-6

[3] INSPECTION ............................................................................1-7

1. Steering post ........................................................................................... 1-7
2. Wheel housing......................................................................................... 1-7
3. Front wheel hub....................................................................................... 1-7

[4] ASSEMBLY, ADJUSTMENT ...................................................1-8

1. Assemble the front wheel hub. ................................................................ 1-8
2. Assemble the front fork tire Assy............................................................. 1-9
3. Assemble the steering shaft. ................................................................... 1-9
4. Assemble the front cowl. ....................................................................... 1-10
5. Install the inner cowl cover. Models to #70105 (to 02.99) ..................... 1-11
6. lnstall the inner cover: From Model #70106 - (from 03.99).................... 1-11
7. lnstall the meter panel surrounding parts. ............................................. 1-12
8. Install the meter cover. .......................................................................... 1-12
9. Check .................................................................................................... 1-12

1-1
CE681.book Page 2 Friday, July 30, 2010 3:34 PM

[1] CONSTRUCTION
The steering shaft is supported by the pillow block inside the column cover, and the end of
the steering shaft is connected by a universal joint to the front fork of the front wheel housing.
The front fork is supported by the front wheel housing via a bearing so that the operators
steering force is transmitted to the front wheel tire. The front fork is set at a castor angle of
15° so only light steering power is needed for driving and excellent directional drive.
The front tire is fitted to the hub together with a divided rim, and the hub is secured to the
front fork at the shaft via a bearing.

[2] DISASSEMBLY

Warning: With the vehicle on a level surface, remove the battery plug before the
inspection or servicing of electrical parts. Take care to avoid electric shocks
when you disconnect the harness connector.

1. Remove the meter cover.

1) 2) 1) Remove the two screws from the

lower part in front of you.
2) Push the cover forward , then
release the catch at the front edge .
3) Turn the front part toward you
around the pivot of the front attach-
ment .
3) 4) 4) Remove the cover downward, then
remove it toward you.

2. Remove the meter panel surrounding parts.

1) Remove the neck cover .
2) Before you remove the brake lever
, first loosen the wire at the adjust-
ment nut on the brake body side.
3) Disconnect each harness connector.
4) Remove the meter panel .
5) Remove the U nut , remove the
accelerator lever , then pull off the
accelerator grip .
6) Remove the handle switch .

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CE681.book Page 3 Friday, July 30, 2010 3:34 PM

3. Remove the inner cover: Up to Model #70105 (to 02.99)

1) Remove the 3 screws from the outer side.

2) Insert your hand in the gap made by removal of the screws, then remove the lower
end from the groove.
3) Pull the lower part of the cover outward using the upper catch as the fulcrum,
then remove the 3 inserts on the column side.
4) Pull the cover straight down and remove it starting from the upper catch .

4. Remove the inner cover: From Model #70106 (from 03.99)

Remove the 4 screws from the inner side.

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CE681.book Page 4 Friday, July 30, 2010 3:34 PM

5. Remove the front cowl.

1) Remove the 4 bolts from the cowl bot-
tom, slide the cowl upward, then re-
move the front cowl . Disconnect
the harness connector for the head-
light and indicator light, etc.
2) Remove the grommet at the top of
the steering, then remove the brake
wire cable.
3) Loosen the adjustment nut from
the upper steering, then remove the
accelerator wire cable.
4) Cut the wiring tie around the steer-
ing upper, then remove the Wire har-
ness.

6-1. Remove the steering shaft. (to #70917) (to 04. 2004)
1) Remove the stop ring at the lower
From Model
end of the universal joint, then
#70106 - remove the set pin .
(from 03.99) 2) Turn the steering 90° to remove the
stop ring of the upper universal
joint from the groove, then pull out the
set pin .
3) Loosen the 4 upper and lower screws
from the pillow block, then remove
the steering shaft from the pillow
block.

Note: If the steering shaft is difficult to

remove, pull it out while lightly tap-
ping its base from below with a plas-
tic hammer.

4) Remove the pillow block from the col-

umn cover.
5) Loosen the 4 bolts at the bottom of
the column cover and remove the col-
umn cover.

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CE681.book Page 5 Friday, July 30, 2010 3:34 PM

6-2. Remove the steering shaft. (# from 70918) (from 05. 2004)
1) Remove the U nut from the bolt
at the lower end of the universal joint,
#70106~ then remove the bolt .
(’99.3~) 2) Turn the steering 90° to remove U nut
from bolt of the upper universal
joint, then remove the bolt .
3) Loosen the 4 upper and lower screws
from the pillow block, then remove
the steering shaft from the pillow
block.

Note: If the steering shaft is difficult to

remove, pull it out while lightly tap-
ping its base from below with a plas-
tic hammer.

4) Remove the pillow block from the col-

umn cover.
5) Loosen the 4 bolts at the bottom of
the column cover and remove the col-
#70918~ umn cover.
(’04.5~)

7. Remove the front fork.

1) Attach a sling to the step and use a
hoist or forklift to lift the front tire up
about 20cm, then set a wooden block
under the left and right side of the
frame for safety. Then remove the
snap ring .
2) Tap the top end of the front fork with a
plastic hammer to drop out the front
fork .
3) Remove the remaining 2 bearings ,
from the front wheel housing.

Note: When you remove the bearings,

take care not to damage the seals.

1-5
CE681.book Page 6 Friday, July 30, 2010 3:34 PM

8. Remove the front wheel hub

1) Remove the left and right nuts ,
then remove the front wheel hub
and tire assy , from the front
fork.
2) Remove the 3 hexagonal bolts ,
spring washers and nuts so
that you can remove the tire assy
from the front wheel hub .
3) Remove the distance collar and
washer , then tap the end of the
axle shaft with a plastic hammer to
remove the bearing at one end.
4) Tap the other end to remove the other
bearing.

Notice: The rim has divided construction and it is pressed together from both
sides of the tire , so if you remove the bolt carelessly from a pneumatic
tire, the expansion of the internal tube may cause the rim to fly off, which
can be extremely dangerous. Do not disassemble the rim except when
replacing the tire. Always deflate the tire before performing disassembly. Per-
form reassembly using the special tools.

1-6
CE681.book Page 7 Friday, July 30, 2010 3:34 PM

[3] INSPECTION

Notice: Wash each disassembled part in fresh cleaning oil, and completely wash off
dirt and dust before inspecting the part.

1. Steering post
1) Pillow block
Support the inner ring of the bearing with your hand while you turn the outer ring. If
you feel catching, hear abnormal noise or find the seal damaged, replace the bearing
with a new one. If the block is deformed or damaged, replace it with a new one.
2) Universal joint
Replace the universal joint with a new one if there is abnormal rattling in the yoke or
the boot is torn. Apply new grease through the yoke shaft hole. If the stop ring
becomes deformed during removal or installation, replace it with a new one.
3) Steering shaft
Replace the steering shaft with a new one if the set pin hole for universal joint installa-
tion is worn.

2. Wheel housing
1) Ball bearing
Support the inner ring of the bearing with your hand while you turn the outer ring. If
you feel catching, hear abnormal noise or find the seal damaged, replace the bearing
with a new one.

3. Front wheel hub

1) Ball bearing
Support the inner ring of the bearing with your hand while you turn the outer ring. If
you feel catching, hear abnormal noise or find the seal damaged, replace the bearing
with a new one.
2) Washer
Replace the washer with a new one if it is deformed or damaged.
3) Distance collar
Replace it with a new one if it is worn.
4) Axle shaft
Replace the axle shaft with a new one if the part in contact with the bearing is worn.
5) Front wheel hub
Replace the front wheel hub with a new one if the part in contact with the bearing is
worn.
6) Wheel
Replace the rim and tyre with a new one if it is deformed or cracked. Replace the tire
with a new one if the tire wear or damage to the side of the tire is marked.

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CE681.book Page 8 Friday, July 30, 2010 3:34 PM

[4] ASSEMBLY, ADJUSTMENT

Perform assembly in the reverse order to disassembly.

1. Assemble the front wheel hub.

1) Insert the bearing into the front
wheel hub up to the flange on that
side. Take care to avoid damaging the
bearing seal or gauge when inserting
the bearing into the hub. Insert the
washer with the protruding side
inward.
2) Install the axle shaft from the hole
in the other side of the front wheel
hub up to the flange.
3) Install the bearing and washer
into the other hole of the front wheel
hub the same way as in 1) above,
then install the distance collar ,
and over the axle shaft from each
end.

Note: Take care not to knock the axle

shaft.

4) With 3 hexagonal bolts , spring

washer and nut , install to the
front wheel hub assy the wheel assy
that was assembled using the 3
hexagonal bolts , spring washer
and nut .
5) After you install the chamfered part of
the axle shaft of the front wheel assy
to the slit of the front fork ( on the
next page), install the plate washer
and spring washer to the axle shaft
screw, then tighten the nut .

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CE681.book Page 9 Friday, July 30, 2010 3:34 PM

2. Assemble the front fork tire Assy.

1) Install the bearing to the bearing
housing of the front wheel housing of
the main frame, taking care not to
damage the seal.
2) Insert the shaft of the front fork
from the previous page into the front
wheel housing from below, then
slowly lower the hoist supporting the
frame.

Note: Check that the bearing housing is

securely inserted into the front
wheel housing before you start the
next operation.

3) Tap the bearing in as far as the

flange of the bearing housing of the
front wheel housing upper part, then
insert the snap ring securely into the
groove of the front fork shaft.

3-1. Assemble the steering shaft. (to #70917) (to 04. 2004)
1) Install the bottom of the column cover
with the 4 bolts.
From Model
#70106 -
2) Temporarily install the pillow block to
(from 03.99) the column cover with the 4 bolts.
3) Insert the steering shaft into the
pillow block and universal joint.
4) Turn the steering 90°, insert the set
pin into the universal joint upper
part, then fit the stop ring into the
groove.
5) Insert the set pin into the universal
joint lower part, then fit the stop ring
into the groove.
6) Adjust and secure the steering shaft
angle so that it passes through the
center of the column cover.
7) Tighten the 4 upper and lower secur-
ing screws of the pillow block.

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CE681.book Page 10 Friday, July 30, 2010 3:34 PM

3-2. Assemble the steering shaft. (from #70918) (from 05. 2004)
1) Install the bottom of the column cover
with the 4 bolts,
#70106~ 2) Temporarily install the pillow block to
(’99.3~) the column cover with the 4 bolts.
3) Insert the steering shaft into the
pillow block and universal joint.
4) Turn the steering 90°, insert the set
pin into the universal joint upper
part, then tighten the U nut .
5) Insert the bolt into the universal
joint lower part, then tighten the U nut
.
6) Adjust and secure the steering shaft
angle so that it passes through the
center of the column cover.
7) Tighten the 4 upper and lower secur-
ing screws of the pillow block.

#70918~
(’04.5~)

4. Assemble the front cowl.

1) Secure the Wire harness with a wiring
tie .
2) Install and adjust the adjustment nut
to the accelerator wire cable.
3) Install the brake wire cable to the col-
umn cover with the grommet .
4) Connect the harness connector in the
front cowl for the headlight and indica-
tor light, etc.
5) Install the front cowl with the 4 bolts in
the cowl bottom.

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CE681.book Page 11 Friday, July 30, 2010 3:34 PM

5. Install the inner cowl cover. Models to #70105 (to 02.99)

1) Attach the inner cover from below to the cowl upper part.
2) Using the upper catch as the fulcrum, insert the lower part of the cover into the 3
slots on the column side.
3) Insert the bottom end into the groove.
4) Install the outer side with the 3 screws .

6. lnstall the inner cover: From Model #70106 - (from 03.99)

lnstall the 4 screws on the inner side.

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CE681.book Page 12 Friday, July 30, 2010 3:34 PM

7. lnstall the meter panel surrounding parts.

1) lnstall the handle switch .
2) Insert the accelerator grip , align
and insert the chamfer of the acceler-
ator lever , install the U nut ,
then adjust the accelerator wire.

Note: Check that the accelerator grip

moves smoothly. If it is stiff, loosen
the U nut until the grip moves
smoothly. For accelerator adjust-
ment, see 5. ACCELERATOR.

3) lnstall the meter panel .

4) Connect each harness connector.
5) lnstall the brake lever , and adjust
the brake using the adjustment nut on
the main body.

Note: For brake adjustment, see 3.

BRAKE, PARKING BRAKE (SOLE-
NOID BRAKE).

6) lnstall the neck cover .

8. Install the meter cover.

1) 2) 1) Insert the body upward from

below.
2) With the body front as the pivot,
turn the meter cover toward the
front.
3) Secure the front catch against the
front edge .
3) 4) 4) Install the lower part in front of you
with the two screws .

9. Check
1) Connect the battery plug and check the lamps.
2) Drive the vehicle and check the steering and brakes.

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CE681.book Page 1 Friday, July 30, 2010 3:34 PM

2. REAR AXLE

[1] CONSTRUCTION .....................................................................2-2

1. Reduction gear unit and differential unit .................................................. 2-2
2. Rear wheel .............................................................................................. 2-2
3. Weight ..................................................................................................... 2-2

[2] DISASSEMBLY ........................................................................2-2

1. Rear axle unit, drive motor removal......................................................... 2-2
2. Rear wheel, tire removal.......................................................................... 2-3
3. Drive motor removal ................................................................................ 2-3
4. Hub removal ............................................................................................ 2-3
5. Oil drain ................................................................................................... 2-4
6. Axle shaft removal ................................................................................... 2-4
7. Transmission case disassembly.............................................................. 2-5

[3] INSPECTION ............................................................................2-5

1. Rear wheel .............................................................................................. 2-5
2. Differential gear ....................................................................................... 2-5

[4] ASSEMBLY, ADJUSTMENT ...................................................2-6

1. Differential case assembly....................................................................... 2-6
2. Transmission case assembly .................................................................. 2-7
3. Axle shaft assembly................................................................................. 2-7
4. Hub installation ........................................................................................ 2-7
5. Motor installation ..................................................................................... 2-8
6. Rear axle unit installation ........................................................................ 2-8
7. Rear wheel installation ............................................................................ 2-8
8. Add oil...................................................................................................... 2-8
9. Check ...................................................................................................... 2-8

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CE681.book Page 2 Friday, July 30, 2010 3:34 PM

[1] CONSTRUCTION

1. Reduction gear unit and differential unit

The rear axle is a bolted unitary construction comprising a reduction gear unit connected
directly to the drive motor, and a differential with axle, enclosed in an aluminum die-cast
case. The motor revolutions are reduced to 10:72 from the drive helical gear to the idle
helical gear, then reduced further to 17:59 by the ring helical gear. Accordingly, the drive
force is transmitted to the axle via the differential gear unit at a total reduction ratio of
1:24.99.

2. Rear wheel
A divided rim is used, with the tire pressure-inserted into the rim and secured by 4 bolts.

3. Weight
The rear axle unit weighs about 20 - 30kg with the drive motor and wheel installed. Take
care to observe all safety precautions when removing and installing parts.

[2] DISASSEMBLY

Warning: Perform disassembly at a level location with the battery plug disconnected.
It is extremely dangerous if the motor should start by accident.

1. Rear axle unit, drive motor removal

1) Remove the battery from the vehicle.
2) Jack up the vehicle with the rear supported at 2 or more places, then remove the
brake wire from the brake lever on the body.
3) Disconnect the wiring connector on the drive motor side at the motor drive.
4) If the vehicle is equipped with a solenoid brake, also disconnect the solenoid brake
wiring connector.
5) Loosen the 2 nuts securing the axle, remove the front bolt securing the transmission,
then remove the nuts.

Notice: When you remove the front bolt securing the transmission, take care to not
drop the transmission.

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CE681.book Page 3 Friday, July 30, 2010 3:34 PM

2. Rear wheel, tire removal

By removing the 2 bolts on the left and right side from the 4 bolts securing the wheel, you can
remove the wheel set , and without disassembling it.

Warning: The rim has divided construction and it is installed from both sides of
the tire , so if you remove the bolt carelessly from a pneumatic tire,
the expansion of the internal tube may cause the rim to fly off, which
can be extremely dangerous. Do not disassemble the wheel except when
replacing the tire. Always deflate the tire before performing disassembly.
Perform reassembly using the special tools.

3. Drive motor removal

1) Remove the 4 hexagonal bolts securing the drive motor and the rear axle unit.
2) Lift up the motor body and remove it from the rear axle unit. Also remove the motor
coupling .

4. Hub removal
1) Use a chisel to remove the hub cap .
2) Remove the cotter pin and castle nut , then you can remove the hub .
3) Follow the same procedure to disassemble the other side.

Note: Brake repairs are explained in 3. BRAKE, PARKING BRAKE (SOLENOID BRAKE).

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CE681.book Page 4 Friday, July 30, 2010 3:34 PM

5. Oil drain
1) Place an oil drainage pan under the drain plug , remove the drain plug with a
spanner, then remove the oil inlet cap and fully drain the oil into the oil drainage
pan.
2) Tighten the drain plug securely with a spanner.

Tightening torque : 1372 - 1764N·cm (140 - 180kgf·cm)

Note: Do not forget to reinstall the oil inlet cap .

6. Axle shaft removal

1) Remove the housing pipe , and the stop ring , then pull out the bearing .
2) After you remove the snap ring , tapping the inner end of the axle shaft with a plas-
tic hammer will push out the oil seal and bearing , then you can remove the axle
shaft , .

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CE681.book Page 5 Friday, July 30, 2010 3:34 PM

7. Transmission case disassembly

Notice: The packing is not reusable. Before you begin disassembly, prepare new
packing.

1) Remove the 6 bolts securing the transmission case and separate them into 2 lots.
2) Remove each gear , and .
3) Remove the bolt so that you can remove the differential case . Remove the
spring pin , then remove each gear from inside the differential case.

[3] INSPECTION

Notice: Wash each disassembled part in fresh cleaning oil, and completely wash off
dirt and dust before inspecting the part. Remove bits of packing, etc. with a
scraper, taking care not to scratch the parts.

1. Rear wheel
Replace the rim and tyre with a new one if it is deformed or cracked. Replace the tire with
a new one if the tire wear or damage to the side of the tire is marked (worn to the tip of
the mark on the tire side for Unique tires).

2. Differential gear
1) Bearing
Check that there is no catching or abnormal noise when you turn the bearing by hand.
If there is any abnormality, replace the bearing with a new one.
2) Differential side gear
Insert the axle shaft and check whether the tooth contact is good, whether there is
wear or damage to the tooth, and whether there is excessive wear of the serration. If
there is too much damage or looseness, replace the gear with a new one.
3) Bevel pinion gear , differential shaft
Check for wear and seizing, and if there is too much looseness, replace the part with
a new one.
4) Ring helical gear
Check the tooth contact, wear and damage. If there is excessive wear or damage,
replace the gear with a new one.
5) Differential case
Check for wear on the face in contact with the differential side gear and bevel pinion
gear, and check the case for cracks and damage. If there is excessive wear, cracks or
damage, replace the case with a new one.
6) Idler helical gear
Check the tooth contact, wear and damage. If there is excessive wear or damage,
replace the gear with a new one.
7) Drive helical gear
Check the tooth contact, wear, damage, knock marks, and looseness with the cou-
pling for the motor. If there is excessive wear or damage, replace the gear with a
new one.

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CE681.book Page 6 Friday, July 30, 2010 3:34 PM

8) Axle shaft ,
Check for wear or damage to the spline and serration teeth, check the oil seal contact
surface and the contact surface of the bearing for wear. If there is excessive wear or
damage, replace the shaft with a new one.

Notice: Replace combination gears as a set.

[4] ASSEMBLY, ADJUSTMENT

1. Differential case assembly

1) Differential side gear
Install the 2 differential side gears into the differential case .
2) Bevel pinion gear
Install the 2 bevel pinion gears into the differential case .

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CE681.book Page 7 Friday, July 30, 2010 3:34 PM

3) Differential shaft
After passing the differential shaft through the bevel pinion gear hole so that the
differential shaft is not out of alignment with the top or bottom of the differential case
exterior or the spring pin hole, tap in the differential shaft with a plastic hammer. After
checking that the spring pin hole is still aligned, tap in the spring pin .
4) Ring helical gear
Fit the ring helical gear to the differential case, then tighten the 4 bolts .

2. Transmission case assembly

1) Install the drive helical shaft into the idle helical gear into which the differential
case and idle helical gear shaft are installed.
2) Install the new packing in between, then secure the case with the 6 bolts .

3. Axle shaft assembly

1) Insert the axle shaft into the housing pipe , , then secure the bearing with the
stop ring .
2) Install the oil seal , bearing and snap ring , then install the housing pipe , .
When you install the housing pipe , install the switch bracket .

Tightening torque : 1568 - 2058N·cm (160 - 210kgf·cm)

4. Hub installation

1) Install the hub into the axle shaft, then tighten the castle nut and secure it with
the clevis pin .

Notice: Use a new clevis pin.

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CE681.book Page 8 Friday, July 30, 2010 3:34 PM

2) Install the hub cap .

3) Follow the same procedure for installation on the other side.

5. Motor installation
1) Match the coupling direction.
2) Install the 4 bolts , .

6. Rear axle unit installation

1) Temporarily install the axle with the 2 nut plates.
2) Align the transmission with the position of the front bolt and secure the transmission.
3) Secure the 2 nuts.

7. Rear wheel installation

Install the wheel Assy into the hub, then install the 4 bolts with the spring washers.

8. Add oil
Slowly pour the specified oil into the oil port until the oil level comes up to around the mid-
dle of the oil gauge window.

Specified oil: Engine oil SAE#30 or equivalent

Specified oil quantity: 325 cc approx.

Notice: Keep the bike level while pouring in the oil and judge the appropriate quantity
by the oil gauge.

Note: Work in a well-lit location and use a hand mirror to make the work easier.

9. Check
Drive the bike and test the steering.

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CE681.book Page 1 Friday, July 30, 2010 3:34 PM

3. BRAKE, PARKING BRAKE (SOLENOID BRAKE)

[1] CONSTRUCTION .....................................................................3-2

1. Brake ....................................................................................................... 3-2
2. Parking brake .......................................................................................... 3-2
3. Solenoid brake (Option)........................................................................... 3-2

[2] DISASSEMBLY ........................................................................3-2

1. Brake cable Assy..................................................................................... 3-3
2. Brake removal ......................................................................................... 3-3
3. Solenoid brake (option) release and removal.......................................... 3-4

[3] INSPECTION ............................................................................3-4

1. Brake lever (stopper) ............................................................................... 3-4
2. Brake wire Assy....................................................................................... 3-4
3. Brake ....................................................................................................... 3-4
4. Pins.......................................................................................................... 3-5
5. Solenoid brake......................................................................................... 3-5

[4] ASSEMBLY, ADJUSTMENT ...................................................3-6

1. Brake installation ..................................................................................... 3-6
2. Brake cable Assy installation................................................................... 3-7
3. Solenoid brake installation....................................................................... 3-7
4. Check ...................................................................................................... 3-7

3-1
CE681.book Page 2 Friday, July 30, 2010 3:34 PM

[1] CONSTRUCTION

1. Brake
A reduction gear countershaft internal expanding type brake is used with a drum brake fit-
ted to a reduction gear countershaft, controlled by a brake lever with a wire cable passing
through it.

2. Parking brake
For the parking brake, a main brake interlocking lever type brake is adopted that locks the
brake with a stopper after the brake lever is gripped. Accordingly, the parking brake per-
formance is dependent on the main brake adjustment, so it is necessary that normal
operation of the main brake is always maintained.

3. Solenoid brake (Option)

A more powerful parking brake is available as the dry-type single plate solenoid brake
(option).

[2] DISASSEMBLY

Warning: Perform disassembly at a level location with the battery plug disconnected.
It is extremely dangerous if the motor should start by accident.

Adjustment nut
Clevis pin

3-2
CE681.book Page 3 Friday, July 30, 2010 3:34 PM

1. Brake cable assy

1) Loosen the brake cable adjustment
nut, then remove the clevis pin from
the brake cable’s brake body lever.
2) Remove the brake cable assy.
3) Remove the front cowl, then the brake
cable.

Note: Perform the operation in accordance

with the front cowl removal proce-
dure described earlier.

2. Brake removal

1) Remove the 4 cross-recessed hexagonal bolts .

Note: If you are unable to remove the brake case and brake cover because they
are fixed by packing , lightly tap the side of the cover with a plastic hammer to
release the packing.

2) Revolve the camshaft by operating the brake lever , then move aside the cam-
shaft groove and shoe.
3) When the shoe comes out of the camshaft groove, pull the shoe on one side toward
you to remove it.

Notice: The spring causes the shoe to fly out when you remove the shoe, so take
care.

3-3
CE681.book Page 4 Friday, July 30, 2010 3:34 PM

3. Solenoid brake (option) release and removal

1) Pull the release handle toward you
to release the solenoid brake.
2) Disconnect the wiring connector.
3) Remove the snap ring , the 3 bolts
and the solenoid brake.

Note: The solenoid brake is installed at the

rear edge of the drive motor.

[3] INSPECTION

Warning: Never wash the brake shoe in cleaning oil.

1. Brake lever (stopper)

Replace the brake lever with a new assy if there is deformation of the ratchet claw or
teeth, or if there is severe wear.

2. Brake wire assy

Install a new wire assy if there is any catching due to rust or corrosion, or if sliding is poor.
1) Inner cable
Install a new wire assy if the wire is cut or bent, or if the adjustment value is not
obtainable.
2) Outer cable
Install a new wire assy if the outer cable is crushed or damaged.

3. Brake
1) When you pull the brake lever toward
you with the brake lever pull value
return spring and the brake wire on
Approx. the body side disconnected and free,
7° if the freeplay is great before the
brake takes effect, check for brake
shoe wear first before you install a
new brake.

Brake action start position

: Approx. 7mm at the Ø6 pin position
: Body lever 7° approx.
Approx. Brake rated pull force
7mm : 196N (20kgf)
: Body lever 9° – 10° approx.

3-4
CE681.book Page 5 Friday, July 30, 2010 3:34 PM

87mm 2) Shoe Assy

Measure the outer diameter of the
shoe and install a new shoe if the
diameter is 86mm or less. Even if
wear is not advanced, install a new
shoe if the shoe is burned black or is
hard.
When you exchange the shoe,
replace the left and right side at the
same time.
Install new packing .

Standard value : 87mm

Exchange value : 86mm

4. Pins
Perform Assy replacement of pins that are badly worn or rusted.

5. Solenoid brake
Measure the gap at the gap measure-
Gap measurement ment location (circumference) and
location
replace the solenoid brake if the mea-
surement is at the exchange value or
above.

Standard value : 0.1 - 0.2mm

Exchange value : 0.6mm

Note: This solenoid brake does not have

adjustment function, so if the
exchange value is reached, install a
new solenoid brake.

3-5
CE681.book Page 6 Friday, July 30, 2010 3:34 PM

[4] ASSEMBLY, ADJUSTMENT

1. Brake installation
1) Temporarily install the left and right shoe and the spring , then hook the shoe on
the anchor pin .
2) Using the anchor pin as the fulcrum, expand the spring as you hook it onto the cam-
shaft , then turn the cam lever so that the shoe enters the camshaft groove.
3) When you install the brake Assy to the brake case , pull the lever and tighten
the cross-recessed hexagonal bolt while you center the drum and shoe .

Tightening torque : 343 - 539N·cm (35 - 55kgf·cm)

Bracket

Nut A
Grease
application area Nut B
Brake lever

3-6
CE681.book Page 7 Friday, July 30, 2010 3:34 PM

2. Brake cable assy installation

1) Pass the brake cable through the meter panel, then install it to the brake lever on the
handle side.
2) Pass the brake cable from inside the column to the bottom of the vehicle.

Note: Perform the operation in accordance with the front cowl installation procedure
described earlier.

3) Install the brake cable adjustment nut to the transmission bracket, then install the
brake cable assy.
4) Install the brake cable to the brake lever pin of the brake body using a clevis pin.
5) Pull the brake lever on the brake body by hand in the direction of the arrow until you
feel resistance.
6) Attach the wire at that position, lightly lock nut A and nut B for temporary installation.
7) To provide freeplay from that position, move nut A the width of one nut.
8) Move nut B likewise and lock it securely.
9) Make sure the lever is virtually parallel to the handle grip when the brake starts to take
affect when the lever is applied. When you grip the lever further and the stopper is
applied, make sure that the brake lever is not touching the grip even when you
squeeze the handle grip.
10) Operate the brake and apply lubrication grease to the exposed part of the brake cable
inner cable.

3. Solenoid brake installation

1) Set the solenoid brake, insert the key and secure it with a snap ring.

Note: Set the solenoid brake with the release lever at the release position

2) Secure the solenoid brake with the 3 bolts.

3) Connect the solenoid brake harness.

4. Check
1) After adjustment is completed, drive the vehicle and test the braking and parking.

3-7
CE681.book Page 8 Friday, July 30, 2010 3:34 PM
CE681.book Page 1 Friday, July 30, 2010 3:34 PM

4. DRIVE MOTOR

[1] DC MOTOR TYPE ....................................................................4-2

[2] DISASSEMBLY ........................................................................4-2
1. Motor disassembly................................................................................... 4-2

[3] INSPECTION ............................................................................4-3

1. Motor body insulation inspection ............................................................. 4-3
2. Armature coil insulation inspection .......................................................... 4-3
3. Commutator inspection............................................................................ 4-3
4. Brush holder insulation inspection........................................................... 4-3
5. Brush spring load inspection ................................................................... 4-4
6. Brush inspection ...................................................................................... 4-4
7. Bearing .................................................................................................... 4-4

[4] ASSEMBLY, ADJUSTMENT ...................................................4-5

1. Motor installation ..................................................................................... 4-5

4-1
CE681.book Page 2 Friday, July 30, 2010 3:34 PM

[1] DC MOTOR TYPE

This is a separately excited DC motor using permanent magnets.

[2] DISASSEMBLY

Note: For motor removal, see 2. REAR AXLE.

1. Motor disassembly
1) Move the cover to the motor center.
2) Apply matchmarks to the frame end and the yoke , and to the frame commuta-
tor end and the yoke .
3) Remove the 2 through bolts .
4) Remove the cover .
5) Grasp the brush spring with radio pliers and lift the brush up from the commu-
tator.
6) Remove the frame commutator end .
7) Pull out the yoke .

Notice: Pull the yoke out straight to avoid scratching the armature coil and separat-
ing the magnets.

8) Remove the 3 screws securing the bearing plate , then remove the armature
.

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CE681.book Page 3 Friday, July 30, 2010 3:34 PM

[3] INSPECTION
Clean each disassembled part with an air gun.

1. Motor body insulation inspection

Before disassembly and after reassembly, be sure to measure the insulation resistance
between the motor (body) and each terminal using a megger Tester (500V, 100MΩ).

Standard value : 0.1MΩ or more

Notice: Take care to avoid scratching the armature commutator.

2. Armature coil insulation inspection

Measure the insulation resistance between the shaft and the commutator using a megger
Tester (500V, 100MΩ).

Standard value : 0.1MΩ or more

3. Commutator inspection
Using vernier calipers, measure the
commutator outer diameter.

Standard value : Ø40mm

Limit : Ø35mm

4. Brush holder insulation inspection

Measure the insulation resistance
between the brush holder and the
holder, and between the + side brush
holder and the - side brush holder,
using a megger tester (500V, 100MΩ).
Megger

Standard value : 0.1MΩ or more

4-3
CE681.book Page 4 Friday, July 30, 2010 3:34 PM

5. Brush spring load inspection

Assemble the armature and brush, sus-
pend spring scales from the brush
spring, then measure the force applied
the instant the brush spring separates
Brush spring from the brush.

Standard value : 5.5N (560gf)

Limit : 2.6N (270gf)
Spring

6. Brush inspection
Using vernier calipers, measure the
height of the brush.

8
Exchange standard : 14mm
22 (Measurement
dimension)
14

30

7. Bearing
Install a new bearing if you find abnor-
mal noise or catching when you turn the
Bearing
bearing by hand.

4-4
CE681.book Page 5 Friday, July 30, 2010 3:34 PM

[4] ASSEMBLY, ADJUSTMENT

1. Motor installation

Screw Yoke AY Cover Brush

Bearing plate
Bearing
Ring snap
Rustproofing Rustproofing
application location application location

Bearing

End frame Commutator

Commutator
Armature end frame
Through bolt

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CE681.book Page 6 Friday, July 30, 2010 3:34 PM

Notice: Apply the MP Grease to the 2 locations specified in the armature shaft.
Tighten the screw and the through bolt to the following tightening
torque.

Screw : 196N·cm (20kgf·cm)

Through bolt : 588N·cm (60kgf·cm)

1) Insert the armature core , then install the bearing plate with 3 screws .
2) Insert the yoke .
3) Install the frame commutator end .
4) Grasp the brush spring with radio pliers and set the brush in contact against
the commutator.
5) Install the cover .
6) Install the 2 through bolts .
7) Check the matchmarks against the frame end and the yoke , and against the
frame commutator end and the yoke , then install the parts.
8) Move the cover to the exposed part of the motor.

4-6
CE681.book Page 1 Friday, July 30, 2010 3:34 PM

5A. ACCELERATOR (to 2006. 06)

[1] CONSTRUCTION .................................................................. 5A-2

[2] INSPECTION ......................................................................... 5A-2
1. Accelerator grip .....................................................................................5A-2
2. Accelerator wire Assy ............................................................................5A-2
3. Lever spring...........................................................................................5A-2
4. Potentiometer ........................................................................................5A-2
5. Limit switch ............................................................................................5A-3
6. Wrapping bushing..................................................................................5A-3
7. Stopper rubber.......................................................................................5A-3

[3] DISASSEMBLY ..................................................................... 5A-3

1. Accelerator disassembly........................................................................5A-3

[4] ASSEMBLY, ADJUSTMENT ................................................ 5A-4

1. Accelerator installation ..........................................................................5A-4

5A-1
CE681.book Page 2 Friday, July 30, 2010 3:34 PM

[1] CONSTRUCTION
The vehicle speed can be controlled no step speed change from stationary to maximum
speed depending on the extent the accelerator grip is turned. The accelerator grip is con-
nected to the accelerator wire via the shaft and lever. The accelerator wire passes through
the steering column to the accelerator and lever under the vehicle. Turning the accelerator
grip activates the accelerator link inside the accelerator, and reacting it with the movement by
the guide groove, the potentiometer lever moves to rotate the potentiometer shaft. The inbuilt
limit switch is for the driving chime option. The switch sends a cutoff signal in accordance
with the movement of the link. Accelerator return is controlled by the lever spring.

[2] INSPECTION

1. Accelerator grip
Replace it with a new one if deformation or wear is severe.

2. Accelerator wire Assy

Install a new wire Assy if there is any catching due to rust or corrosion, or if sliding is poor.
1) Inner cable
Install a new wire Assy if the wire is cut, or if the adjustment value is not obtainable.
2) Outer cable
Install a new wire Assy if the outer cable is crushed or damaged.

3. Lever spring
Install a new one if the spring is broken or damaged.

4. Potentiometer
Replace it with a new one if it catches when you turn it with your finger.
If the resistance value is wrong, adjust it. If there is an electrical fault, replace the potenti-
ometer with a new one

Notice: When replacing the potentiometer, take care to not make a mistake with the
color of the harness wiring.

Note: Use a screwdriver to adjust the potentiometer shaft end so that the resistance
between CN6 ⇔ CN6 is:
When accelerator is fully open: 4.8KΩ or more
When accelerator is fully closed: 100Ω or less.

5A-2
CE681.book Page 3 Friday, July 30, 2010 3:34 PM

5. Limit switch
Replace it with a new one if you hear no clear operating noise when you press it with your
finger.
Replace it with a new one if there is an electrical fault.

Notice: When replacing the limit switch, take care to not make a mistake with the
harness wiring color or the terminals.

Note: Continuity measurement between CN6 ⇔ CN6

Accelerator closed: ∞Ω
Accelerator open: 0Ω

6. Wrapping bushing
Replace it with a new one if there is severe deformation or wear.

7. Stopper rubber
Replace it with a new one if there is severe deformation or wear.

[3] DISASSEMBLY

1. Accelerator disassembly

5A-3
CE681.book Page 4 Friday, July 30, 2010 3:34 PM

1) Disconnect the harness connector, then loosen the accelerator wire adjustment nut
under the bike.
2) Remove the plate washer , clevis pin and accelerator wire.
3) Remove the screw to remove the cover .
4) Remove the 2 bolts to remove the accelerator from the bike body.
5) Loosen the bolt , remove the potentiometer lever and the nut , then remove
the bolt and the wrapping bearing .
6) Loosen the bolt and remove the bracket , then remove the potentiometer .
7) Remove the lever spring .
8) Remove the set screw , snap ring and accelerator lever then pull out the
accelerator ring .
9) Disconnect the harness terminal then remove the limit switch .

Note: For operations on the accelerator grip and accelerator wire, perform the operation in
accordance with the meter panel surroundings and front cowl removal procedure
described earlier.

[4] ASSEMBLY, ADJUSTMENT

1. Accelerator installation

1) Insert the accelerator link , then install the accelerator lever with the set screw
(apply the Loctite) and the snap ring .
2) Install the lever spring .
3) Install the potentiometer to the bracket . (Apply the Loctite)

5A-4
CE681.book Page 5 Friday, July 30, 2010 3:34 PM

4) Install the bracket . (Apply the Loctite)

5) Apply lubrication grease to the wrapping bearing , adjust the bolt so that the
bearing revolves smoothly, install it into the potentiometer and tighten it with the
bolt . (Apply the Loctite)
6) Tighten the potentiometer and the bolt while adjusting the resistance. (Apply
the Loctite)

Note: See the Inspection item on the previous page for the resistance adjustment value.

7) Perform adjustment and installation so that the limit switch cuts off when the accel-
erator link starts moving. Then install the terminals of the harness .
8) Install the accelerator to the vehicle body with the bolt .
9) Install the cover with the screw .
10) Pass the accelerator wire down the column, then half tighten the adjustment nut
under the vehicle body.
11) Insert the accelerator wire, then install the plate washer and the clevis pin .

Notice: Use a new clevis pin .

12) Adjust the adjustment nut on the handle side so that the outer cable is tight when the
accelerator is open and the inner cable is extended.

Note: For operations on the accelerator grip and accelerator wire, perform the operation in
accordance with the meter panel surroundings and front cowl installation procedure
described earlier.

5A-5
CE681.book Page 6 Friday, July 30, 2010 3:34 PM
CE681.book Page 1 Friday, July 30, 2010 3:34 PM

5B. ACCELERATOR (from 2006. 07)

[1] CONSTRUCTION .................................................................. 5B-2

[2] INSPECTION ......................................................................... 5B-2
1. Accelerator grip .....................................................................................5B-2
2. Lever spring...........................................................................................5B-2
3. Potentiometer ........................................................................................5B-2
4. Limit switch ............................................................................................5B-2
5. Bush ......................................................................................................5B-3
6. Stopper rubber.......................................................................................5B-3

[3] DISASSEMBLY ..................................................................... 5B-3

1. Accelerator disassembly........................................................................5B-3

[4] ASSEMBLY, ADJUSTMENT ................................................ 5B-4

1. Accelerator installation ..........................................................................5B-4

5B-1
CE681.book Page 2 Friday, July 30, 2010 3:34 PM

[1] CONSTRUCTION
The vehicle speed can be controlled with no step speed change from stationary to maximum
speed depending on the extent the accelerator grip is turned.
Turning the accelerator grip activates the accelerator link inside the accelerator, and reacting
it with the movement by the guide groove, the potentiometer lever moves to rotate the poten-
tiometer shaft.
The inbuilt limit switch is for the drive chime for option.
The switch sends a cutoff signal in accordance with the movement of the link.
Accelerator return is controlled by the lever spring.

[2] INSPECTION

1. Accelerator grip
Replace it with a new one if deformation or wear is severe.

2. Lever spring
Install a new one if the spring is broken or damaged.

3. Potentiometer
Replace it with a new one if it catches when you turn it with your finger.
If the resistance value is wrong, adjust it. If there is an electrical fault, replace the potenti-
ometer with a new one

Notice: When replacing the potentiometer, take care to not make a mistake with the
color of the harness wiring.

Note: Use a screwdriver to adjust the potentiometer shaft end so that the resistance
between CN15 ⇔ CN15 is:
When accelerator is fully open: 4.8KΩ or more
When accelerator is fully closed: 100Ω or less.

4. Limit switch
Replace it with a new one if you hear no clear operating noise when you press it with your
finger.
Replace it with a new one if there is an electrical fault.

Notice: When replacing the limit switch, take care to not make a mistake with the
harness wiring color or the terminals.

Note: Continuity measurement between CN15 ⇔ CN15

Accelerator closed: ∞Ω
Accelerator open: 0Ω

5B-2
CE681.book Page 3 Friday, July 30, 2010 3:34 PM

5. Bush
Replace it with a new one if there is severe deformation or wear.

6. Stopper rubber
Replace it with a new one if there is severe deformation or wear.

[3] DISASSEMBLY

1. Accelerator disassembly

1) Remove the Meter cover (refer to the 1-2)

2) Remove the Wire harness
3) Loosen the nut and remove the bolt and the bush from potentiometer lever
.
4) Loosen the bolt and remove the potentiometer from the bracket , then the
potentiometer lever can be removed.
5) Loosen the bolt and remove the limit switch from the bracket .
6) Loosen the bolt and remove the bracket .
7) Loosen the nut and remove washer , lever spring , accelerator link from
handle shaft.

Note: For operations on the accelerator grip and accelerator wire, perform the operation in
accordance with the meter panel surroundings and front cowl removal procedure
described earlier.

5B-3
CE681.book Page 4 Friday, July 30, 2010 3:34 PM

[4] ASSEMBLY, ADJUSTMENT

1. Accelerator installation

1) Insert the accelerator link into the handle shaft, and install the lever spring ,
washer , then tighten the nut with loctite.
2) Install the potentiometer to the bracket with loctite.
3) Install the bracket by bolt .
4) Apply the MP grease in the bush , the bush should be turned smoothly by adjusting
the bolt , then install it to the potentiometer and tighten the nut with loctite.
5) Tighten the bolt and potentiometer while adjusting the resistance with loctite.

Note: See the Inspection item on the previous page for the resistance adjustment value.

6) Perform adjustment and installation so that the limit switch cuts off when the accel-
erator link start moving, then install the wire harness .

Note: For operations on the accelerator grip and accelerator wire, perform the operation in
accordance with the meter panel surroundings and front cowl installation procedure
described earlier.

5B-4
CE681.book Page 1 Friday, July 30, 2010 3:34 PM

6A. DRIVE CONTROLLER

(9803-0103)
CURTIS 1203A-218

[1] INTRODUCTION ................................................................... 6A-2

[2] FEATURES............................................................................ 6A-2
[3] CONTROL DETAILS............................................................. 6A-2
[4] REPLACEMENT.................................................................... 6A-2
1. Removal ................................................................................................6A-3
2. Installation .............................................................................................6A-3

[5] TROUBLESHOOTING .......................................................... 6A-3

1. Outline ...................................................................................................6A-3
2. Wiring faults...........................................................................................6A-3
3. Preparation before inspection................................................................6A-3
4. Troubleshooting method........................................................................6A-4
5. Notices...................................................................................................6A-4
6. Troubleshooting.....................................................................................6A-5
(1) Vehicle does not run.......................................................................6A-5
(2) Unable to match speed to accelerator, or no power output............6A-8

6A-1
CE681.book Page 2 Friday, July 30, 2010 3:34 PM

[1] INTRODUCTION
The 7CBT06 performs speed adjustment during driving using a high frequency pulse ampli-
tude modulation power-FET DC motor speed controller 1203A-218 to control the drive motor.

[2] FEATURES

1. A continuously variable drive and regenerative brake control circuit using a power-MOS-
FET design provide excellent low-speed high torque, high frequency (quiet) driving with
high efficiency and smooth low speed performance.

2. The double lamp auto extinguishing function provides smooth deceleration/acceleration

transition when the throttle switches from forward to reverse or from reverse to forward.

3. In the case of potentiometer malfunction, abnormal overheating or uncontrolled accelera-

tor operation, the controller stops and the controller current still usable at that time is also
reduced.

[3] CONTROL DETAILS

1. The speed is adjusted in accordance with the position of the 5KΩ potentiometer.

2. Switching between forward and reverse uses an A contact switch. Forward travel occurs
when it is open between P1 ⇔ , and reverse travel occurs when it is closed.

3. If you switch between forward or reverse when the accelerator is engaged, deceleration
occurs gradually, then acceleration occurs in the switched direction after a momentary
stop.

4. The bike does not move even if the key switch is turned on when the accelerator is
engaged (uncontrolled accelerator operation prohibition). With the key switch still ON,
return the accelerator, then turn the accelerator again to start moving.

5. If the base with the control FET installed exceeds a temperature of 90°C, output is
reduced until the temperature drops to 75°C or less. (Abnormal overheating protection)

6. If the resistance (P1 ⇔ ) of the potentiometer circuit built into the accelerator greatly
exceeds 5KΩ (about 9Ω or more), driving is stopped (potentiometer malfunction detec-
tion).

[4] REPLACEMENT

Warning: Perform disassembly at a level location with the battery plug disconnected.
Otherwise an electric shock, breakdown or fire could occur.

6A-2
CE681.book Page 3 Friday, July 30, 2010 3:34 PM

1. Removal
1) Remove connectors P1 and P2, and the ten 250 Faston terminals M1, M2, B+ and B-.
2) Use a Phillips screwdriver to remove the 2 installation screws.
3) Pull the drive controller toward you to remove it.

2. Installation
1) From a position slightly in front, push the drive controller to its installation position.
2) Install the 2 installation screws with a Phillips screwdriver.
3) Install connectors P1 and P2, and the ten 250 Faston terminals M1, M2, B+ and B-.
(See the Wiring Diagram below.)

Wiring Diagram

Leave the inside open.

Thick black
Thin black

Thick red
Thin red

Black
Red

Notice: Repeated removal and installation of the 250 Faston terminal causes loose-
ness and may cause poor contact. Do not remove or install them unless nec-
essary.
If a terminal is clearly loose, stop using it and replace it with a new one.

[5] TROUBLESHOOTING

1. Outline
Troubleshooting involves establishing the fault location using a tester, etc. with the circuit
diagram as a basic tool.
It is important that you can accurately read the circuit diagram, check the location of the
connectors and terminals, and make the necessary measurements. The troubleshooting
procedure in this manual takes it for granted that you can use testers and meggers cor-
rectly and can accurately read a circuit diagram.

2. Wiring faults
When troubleshooting involves wiring faults, it may involve connector pin loss, harness
disconnection or poor terminal contact, so perform wiring inspection in accordance with
circuit diagram.

3. Preparation before inspection

When inspection involves running the bike, raise the bike rear up on stands before start-
ing inspection.

6A-3
CE681.book Page 4 Friday, July 30, 2010 3:34 PM

4. Troubleshooting method
The following two methods can be used when using a tester to find the circuit malfunction
location.
Defective part 1) Voltage measurement method
Connect the power to the circuit, then
measure the voltage in order between
- N1, - N1, and - N1, and
check whether each function part and
wire operates correctly or not.

2) Resistance measurement method

Disconnect the power to the circuit,
then check the resistance between
- , - , and - , and check
Defective part whether each function part and wire
operates correctly or not.

5. Notices
1) When a malfunction occurs, first perform a tester check of the fuses, check for broken
wires, loose terminals, broken connector wires or poor contact.
2) Before you install a new part, disconnect the battery plug.
3) When you measure a terminal voltage with the motor running or you touch electrical
parts with the power on, take care to keep the tester probe and tools away from parts
other than the target terminal. When you apply the tester probe to hidden terminals
such as those hidden at the back of parts, turn the power off first, secure alligator
clips, etc. then turn the power on again and make your measurement.

6A-4
CE681.book Page 5 Friday, July 30, 2010 3:34 PM

6. Troubleshooting
(1) Vehicle does not run
Inspection 1:
Battery capacity gauge operation check Battery maintenance, inspection

Inspection 2:
Replace faulty part, battery related fault
Check each component

Inspection 3:
Magnetic brake open inspection (Go to Inspection 5 if not fitted.)

Inspection 4: Driver (PMC) faulty

Magnetic brake (MB) wiring inspection
Magnetic brake (MB) faulty
Inspection 5:
Replace faulty part
Forward/reverse switch operation check

Inspection 6:
Accelerator (VRA) faulty
Accelerator (VRA) resistance measurement

Inspection 7: Drive motor (DM) Drive motor adjustment, exchange

Rear axle faulty, drive (PMC) faulty

OK NO
Inspection 1: Battery capacity gauge operation check
Turn the key switch on and check that the battery capacity gauge lights up.
1) Dose not operate → Check for a wiring fault.
Dose not operate → Inspection 2.
2) Operates, but LED is left of center,
or 2 left LED are flashing. → Check battery charge level, elec-
trolyte specific gravity, etc.
3) Operates, and half the LED or more are lit up → Inspection 3
Inspection 2: Check each component
1) Battery plug inspection
Disconnect the battery plug, press each terminal by hand and check them for move-
ment.
OK (smooth movement) → 2)
No (terminal moves poorly) → Disconnect the battery plug, then
remove the cause of the poor
movement.

6A-5
CE681.book Page 6 Friday, July 30, 2010 3:34 PM

2) Battery terminal inspection

Remove the battery terminal cover, and check the terminals for external appearance
and looseness.
OK (tight fit, no corrosion) → 3)
NO (loose, corrosion) → Tighten loose terminal
Replace the corroded battery
3) F1, F2 Fuse Inspection
Visually inspect the Fuse F1, F2.
OK (no cut off). → 4)
NO (cut off) → Replace F1, F2.
4) Key switch inspection
Disconnect the battery plug.

Measurement terminal P1 ⇔ B+

Tester range Ω

OK (as below) → Inspection 3

Key switch turned ON → 0Ω
Key switch turned OFF → ∞Ω
NO (other than above) → Check for fault in the key switch
body or wiring.
Inspection 3: Magnet brake inspection (Go to inspection 5 if not fitted.)
Raise the rear tire, turn the key switch to ON, turn the accelerator lightly and check for the
clicking sound of the magnetic brake releasing.
OK (sound occurs) → Inspection 5
NO (no sound) → Inspection 4
Inspection 4: Magnet brake wiring check
Raise the rear tire, turn the key switch to ON and turn the accelerator lightly.

Measurement terminal P2 ⇔ P2

Tester range DC V

OK (as below) → Magnet brake fault or wiring fault

(break)
DC24V - DC20V
NO (other than above) → P2 ⇔ CN8 wiring faulty (short) or
Driver (PMC) faulty

6A-6
CE681.book Page 7 Friday, July 30, 2010 3:34 PM

Inspection 5: Forward/reverse switch operation check

Disconnect the battery plug.

Measurement terminal P1 ⇔ P1

Tester range Ω

OK (as below) → Inspection 6

Switch set to Forward: ∞Ω
Switch set to Reverse: 0Ω
NO (other than the above) → Check for fault in forward/reverse
switch body and wiring.
Inspection 6: Accelerator (VRA) resistance measurement
Disconnect the battery plug and measure the VRA resistance.

1. P1 ⇔ P1
Measurement terminal 2. P1 ⇔ P1
3. P1 ⇔ P1

Tester range Ω

OK (as in table below) → Inspection 7

1. As accelerator is turned, resistance changes from 0Ω to 5KΩ.

2. Resistance is 5KΩ in any accelerator position (constant resistance).
3. As accelerator is returned, resistance changes from 5KΩ to 0Ω.
NO (other than the above table) → Check for accelerator (VRA) fault
or wiring fault.
Accelerator wire inspection
Inspection 7: Drive motor (DM) inspection
1) Disconnect the battery plug, disconnect the 4 wires to the DM, then measure the
resistance.

Measurement terminal M1 ⇔ M2

Tester range DC V

OK (0Ω for all 4 wires) → 2)

NO (other than the above) → Brush is raised up, armature coil,
field coil break
2) Remove the motor from the rear axle, reconnect the wiring, connect the battery plug,
turn the key switch ON, turn the accelerator and check the motor operation.
OK (motor turns) → Rear axle faulty
NO (motor does not turn) → Driver (PMC) faulty

6A-7
CE681.book Page 8 Friday, July 30, 2010 3:34 PM

(2) Unable to match speed to accelerator, or no power output

Inspection 8: Remove cause of protection
Driver (PMC) protection circuit operation check circuit operation

Inspection 2:
Faulty part replacement, battery fault
Check each component

Inspection 3:
Magnet brake inspection (Go to Inspection 7 if not fitted.)

Inspection 4: Driver (PMC) faulty

Magnet brake (MB) wiring check
Magnet brake (MB) faulty
Inspection 6:
Accelerator (VRA) faulty
Accelerator (VRA) resistance measurement

Driver (PMC) faulty

OK NO
Inspection 8: Driver (PMC) protection circuit operation check
Stop the vehicle for about 10 minutes to cool the Driver (controller) before starting driving
again.
OK (problem does not disappear) → Inspection 2
NO (problem disappears) → Take overloading into consider-
ation during use.
For other problems involving potentiometer malfunction and uncontrolled accelerator
detection circuit operation, see Inspection 6: Accelerator (VRA) resistance measurement.

* For the details of Inspection 2, 3, 4 and 7, see the same items for (1) vehicle does not run

6A-8
CE681.book Page 1 Friday, July 30, 2010 3:34 PM

6B. DRIVE CONTROLLER

(0104- )
CURTIS 1225-2702

[1] INTRODUCTION ................................................................... 6B-2

[2] FEATURES............................................................................ 6B-2
[3] CONTROL DETAILS............................................................. 6B-2
[4] REPLACEMENT.................................................................... 6B-2
1. Removal ................................................................................................6B-3
2. Installation .............................................................................................6B-3

[5] TROUBLESHOOTING .......................................................... 6B-4

1. Outline ...................................................................................................6B-4
2. Wiring faults...........................................................................................6B-4
3. Preparation before inspection................................................................6B-4
4. Troubleshooting method........................................................................6B-4
5. Notices...................................................................................................6B-5
6. Troubleshooting.....................................................................................6B-5
(1) Vehicle does not run.......................................................................6B-5
(2) Unable to match speed to accelerator, or no power output............6B-9

6B-1
CE681.book Page 2 Friday, July 30, 2010 3:34 PM

[1] INTRODUCTION
The 7CBTY06 performs speed adjustment during driving using a high frequency pulse ampli-
tude modulation full bridge power-FET DC motor speed controller 1225-2702 to control the
drive motor.

[2] FEATURES

1. A continuously variable drive and regenerative brake are provided excellent low-speed
high torque, high frequency (quiet) driving with high efficiency and smooth low speed per-
formance from a full bridge power MOSFET control circuit.

2. A full bridge power MOSFET control circuit provides smooth deceleration/acceleration

transition when the throttle switch from forward to reverse or reverse to forward.

3. A full bridge power MOSFET control circuit provides long life in accordance with omission
of the contact point in the regenerative brake current circuit.

4. In the case of potentiometer malfunction, abnormal overheating or uncontrolled accelera-

tor operation, the controller stops and controller current still usable at that time is also
reduced.

[3] CONTROL DETAILS

1. The speed is adjusted in accordance with the position of the 5KΩ potentiometer.

2. Switching between forward and reverse uses a C contact switch, and there is no nutural
position.
Electrify to P1 : Forward Electrify to P1 : Reverse

3. If you switch between forward or reverse when the accelerator is engaged, deceleration
occurs gradually, then acceleration occurs in the switched direction after a momentary
stop.

4. The bike does not move even if the key switch is turned on when the accelerator is
engaged (uncontrolled accelerator operation prohibition). With the key switch still ON,
return the accelerator, then turn the accelerator again to start moving.

5. Output should be controlled if the controller inside temperature exceed 90°C, and output
should be stopped if the temperature exceed 105°C (Abnormal overheating protection).

6. Travel output should be stopped, if the resistance exceed 7.5KΩ in the potentiometer cir-
cuit of acceleration (potentiometer malfunction detection).

[4] REPLACEMENT

Warning: Perform disassembly at a level location with the battery plug disconnected.
Otherwise an electric shock, breakdown or fire could occur.

6B-2
CE681.book Page 3 Friday, July 30, 2010 3:34 PM

1. Removal
1) Disconnect 2pin connector for cooling fan.
2) Remove the bolt .
3) Remove the cooling fan bracket .
4) Disconnect 16pins connector P1 and M1, M2, B+, B- connectors.
5) Remove 4 screws .

2. Installation
1) Install the Drive controller by 4 screws .
2) Connect the 16 pins connector P1 and M1, M2, B+, B-.
3) Insert the edge of cooling fan bracket to the notch of the base plate, then tighten the
bolt .
4) Connect the 2 pins connector for cooling fan.

P1

Notice: Repeated removal and installation of the 250 Faston terminal causes loose-
ness and may cause poor contact. Do not remove or install them unless nec-
essary.
If a terminal is clearly loose, stop using it and replace it with a new one.

6B-3
CE681.book Page 4 Friday, July 30, 2010 3:34 PM

[5] TROUBLESHOOTING
1. Outline
Troubleshooting involves establishing the fault location using a tester, etc. with the circuit
diagram as a basic tool.
It is important that you can accurately read the circuit diagram, check the location of the
connectors and terminals, and make the necessary measurements. The troubleshooting
procedure in this manual takes it for granted that you can use testers and meggers cor-
rectly and can accurately read a circuit diagram.

2. Wiring faults
When troubleshooting involves wiring faults, it may involve connector pin loss, harness
disconnection or poor terminal contact, so perform wiring inspection in accordance with
circuit diagram.

3. Preparation before inspection

When inspection involves running the bike, raise the bike rear up on stands before start-
ing inspection.

4. Troubleshooting method
The following two methods can be used when using a tester to find the circuit malfunction
location.
Defective part 1) Voltage measurement method
Connect the power to the circuit, then
measure the voltage in order between
- N1, - N1 and - N1, and
check whether each function part and
wire operates correctly or not.

2) Resistance continuity measurement

method
Disconnect the power to the circuit,
then check the continuity in order
Defective part between - , - , and -
, and check whether each function
part and wire operates correctly or
not.

6B-4
CE681.book Page 5 Friday, July 30, 2010 3:34 PM

5. Notices
1) When a malfunction occurs, first perform a tester check of the fuses, check for broken
wires, loose terminals, broken connector wires or poor contact.
2) Before you install a new part, disconnect the battery chuck.
3) When you measure a terminal voltage with the motor running or you touch electrical
parts with the power on, take care to keep the tester probe and tools away from parts
other than the target terminal. When you apply the tester probe to hidden terminals
such as those hidden at the back of parts, turn the power off first, secure alligator
clips, etc. then turn the power on again and make your measurement.

6. Troubleshooting
(1) Vehicle does not run
Inspection 1:
Battery capacity gauge operation check Battery maintenance, inspection

Inspection 2:
Replace faulty part, battery related fault
Check each component

Inspection 3:
Magnetic brake open inspection (Go to Inspection 5 if not fitted.)

Inspection 4: Driver (PMC) faulty

Magnetic brake (MB) wiring inspection
Magnetic brake (MB) faulty

Inspection 5: Resistance of Dummy Resistance of Dummy faulty

Inspection 6:
Replace faulty part
Forward/reverse switch operation check

Inspection 7:
Accelerator (VRA) faulty
Accelerator (VRA) resistance measurement

Inspection 8: Drive motor (DM) Drive motor adjustment, exchange

Rear axle faulty, driver (PMC) faulty

OK NO
Inspection 1: Battery capacity gauge operation check
Turn the key switch on and check that the battery capacity gauge lights up.
1) Dose not operate → Check for a wiring fault.
Dose not operate → Inspection 2.
2) Operates, but LED is left of center,
or 2 left LED are flashing. → Check battery charge level, elec-
trolyte specific gravity, etc.
3) Operates, and half the LED or more are lit up → Inspection 3

6B-5
CE681.book Page 6 Friday, July 30, 2010 3:34 PM

Inspection 2: Check each component

1) Battery plug inspection
Disconnect the battery plug, press each terminal by hand and check them for move-
ment.
OK (smooth movement) → 2)
No (terminal moves poorly) → Disconnect the battery plug, then
remove the cause of the poor
movement.
2) Battery terminal inspection
Remove the battery terminal cover, and check the terminals for external appearance
and looseness.
OK (tight fit, no corrosion) → 3)
NO (loose, corrosion) → Tighten loose terminal
Replace the corroded battery
3) F1, F2 Fuse inspection
Visually inspect the Fuse F1, F2.
OK (no cut off) → 4)
NO (cut off) → Replace F1, F2.
4) Key switch inspection
Disconnect the battery plug.

P1 ⇔ B+
Measurement terminal
P1 ⇔ B+

Tester range Ω

OK (as below) → Inspection 3

Key switch turned ON → 0Ω
Key switch turned OFF → ∞Ω
NO (other than above) → Check for fault in the key switch
body or wiring.
Inspection 3: Magnet brake open inspection (Go to inspection 5 if not fitted.)
Raise the rear tire, turn the key switch to ON, turn the accelerator lightly and check for the
clicking sound of the magnetic brake releasing.
OK (sound occurs) → Inspection 5
NO (no sound) → Inspection 4

6B-6
CE681.book Page 7 Friday, July 30, 2010 3:34 PM

Inspection 4: Magnet brake wiring check

Raise the rear tire, turn the key switch to ON and turn the accelerator lightly.

Measurement terminal P1 (-) ⇔ P1 (+)

Tester range DC V

OK (as below) → Magnet brake fault or wiring fault

(break)
DC24V - DC20V
NO (other than above) → P1 ⇔ CN8 wiring faulty (short) or
driver (PMC) faulty
Inspection 5: Resistance of Dummy
Disconnect the battery plug.
Remove the resistance of dummy with connector (CN8), and measure both end of resis-
tance.

Measurement terminal CN8 ⇔ CN8

Tester range Ω

OK (as below) → Inspection 6

150Ω~300Ω (constant 200Ω)
NO (other than the above) → Check the resistance and wire
harness fault.
Inspection 6: Forward/reverse switch operation check
Raise the rear tire, turn the key switch to ON.

forward : P1 ⇔ B-
Measurement terminal
reverse : P1 ⇔ B-

Tester range DC V

OK (as below) → Inspection 7

Turn to forward forward: Battery voltage (24V)
reverse: 0V
Turn to reverse forward: 0V
reverse: battery voltage (24V)
NO (other than the above) → Check for fault in forward/reverse
switch body and wiring.

6B-7
CE681.book Page 8 Friday, July 30, 2010 3:34 PM

Inspection 7: Accelerator (VRA) resistance measurement

Disconnect the battery plug and measure the VRA resistance.

1. P1 ⇔ P1
Measurement terminal 2. P1 ⇔ P1
3. P1 ⇔ P1

Tester range Ω

OK (as in table below) → Inspection 8

1. As accelerator is turned, resistance changes from 0Ω to 5KΩ.

2. Resistance is 5KΩ regardless of accelerator position.
3. As accelerator is returned, resistance changes from 5KΩ to 0Ω.
NO (other than the above table) → Check for accelerator (VRA) fault
or wiring fault.
Accelerator wire inspection
Inspection 8: Drive motor (DM) inspection
1) Disconnect the battery plug, disconnect the 4 wires to the DM, then measure the con-
tinuity.

Measurement terminal M1 ⇔ M2

Tester range DC V

OK (0Ω for all 4 wires) → 2)

NO (other than the above) → Brush is raised up, armature coil,
field coil break
2) Remove the motor from the rear axle, reconnect the wiring, connect the battery plug,
turn the key switch ON, turn the accelerator and check the motor operation.
OK (motor turns) → Rear axle faulty
NO (motor does not turn) → Driver (PMC) faulty

6B-8
CE681.book Page 9 Friday, July 30, 2010 3:34 PM

(2) Unable to match speed to accelerator, or no power output

Cooling fan and Wire

Inspection 9: Cooling fan
Harness fault

Inspection 10: Remove cause of protection

Driver (PMC) protection circuit operation check circuit operation

Inspection 2:
Faulty part replacement, battery fault
Check each component

Inspection 3:
Magnet brake open inspection (Go to Inspection 5 if not fitted.)

Inspection 4: Driver (PMC) fault

Magnet brake (MB) wiring check
Magnetic brake (MB) fault
Inspection 5: Resistance of Dummy Resistance of Dummy fault

Inspection 7:
Accelerator (VRA) fault
Accelerator (VRA) resistance measurement

Driver (PMC) fault

OK NO
Inspection 9: Cooling fan
Raise the rear tire, turn the key switch to ON, and turn the accelerator lightly and check
the cooling fan function.
Note: Take care turning tire during inspection.
OK (turning the cooling fan) → Inspection 10
NO (does not turn the cooling fan) → Cooling fan and wire harness
fault.
Inspection 10: Driver (PMC) protection circuit operation check
Stop the vehicle for about 10 minutes to cool the driver before starting driving again.
OK (problem does not disappear) → Inspection 2
NO (problem disappears) → Take overloading into consider-
ation during use.
For other problems involving potentiometer malfunction and uncontrolled accelerator
detection circuit operation, see Inspection 7: Accelerator (VRA) resistance measurement.

* For the details of Inspection 2, 3, 4, 5 and 7, see the same items for (1) vehicle does not
run.

6B-9
CE681.book Page 10 Friday, July 30, 2010 3:34 PM
CE681.book Page 1 Friday, July 30, 2010 3:34 PM

7. CHARGER

GS-YUASA (STD)
[1] GENERAL OPERATION OUTLINE .........................................7-3
[2] OPERATION.............................................................................7-3
[3] INPUT VOLTAGE ADJUSTMENT ...........................................7-3
[4] PARTS......................................................................................7-4
[5] TROUBLESHOOTING .............................................................7-5

LESIP (OPT)
[1] General.....................................................................................7-8
[2] Wiring diagram and function ...............................................7-10
[3] Condition or ENVIRONMENT ...............................................7-10
[4] Wiring method.......................................................................7-11
[5] Operation ...............................................................................7-12
[6] Periodic maintenance and troubleshooting .......................7-14

7-1
CE681.book Page 2 Friday, July 30, 2010 3:34 PM

APPLICABLE CHARGER LIST

: OPT
APPLICABLE APPLICABLE VEHICLE
Maker MODEL BATTERY MODEL Remarks
(AH/5HR) 7CBT06 7CBTY06
GS-YUASA ZLC24-15A 100 - - 100V/200V
LESIP K33-148C024-212 100 OPT, 100V
LESIP K33-148C024-213 100 OPT, 200V

7-2
CE681.book Page 3 Friday, July 30, 2010 3:34 PM

GS-YUASA (STD)
[1] GENERAL OPERATION OUTLINE
During initial charging the battery terminal voltage is low, so the flow of charging current is
high. However, as charging proceeds and the battery voltage gradually increases, the current
decreases. When the terminal voltage for each cell reaches 2.4V, about 80% of charging is
completed, regardless of the discharge amount. Accordingly, when charging a 100% dis-
charged battery and a 60% discharged battery, the time to reach this 2.4V differs, this time
difference becoming the difference between the respective charging times. If charging then
continues until the charge voltage reaches 29V (this value at 20°; auto temperature compen-
sation to produce 30.3V at 0°, 27.7V at 40°), the internal timer starts operating. When the
timer starts operating, the charging lamp flashes. If charging occurs in an already sufficiently
charged state, when the charge reaches 29V within 15 minutes of starting charging, charging
is completed in 15 minutes. When the timer set time of 3 hours (in the case of normal charg-
ing) has elapsed, charging stops automatically.

[2] OPERATION
Check that the AC input switch is OFF, connect the charger DC plug to the battery plug, then
when the AC input switch is turned ON after the AC plug is connected to the AC power outlet,
the PWB lights up the LED and charging starts. AC current is transformed to a lower voltage
by the transformer so that charging is performed by the DC current rectified at the PWB.
When the charging voltage reaches 29V (value at 20°; auto temperature compensation to
produce 30.3V at 0°, 27.7V at 40°), the PWB timer function starts operating and automatically
stops charging when the set time of 3 hours has elapsed (for standard charging).

[3] INPUT VOLTAGE ADJUSTMENT

In order to perform appropriate charging, it is necessary to fix the secondary side (DC side) of
the transformer. However, normal source voltage may vary depending on the region and
installation location, and this variation causes variation in the battery charging voltage, result-
ing in overcharging or undercharging. In order to provide fixed secondary voltage despite
such variations, setting the L/H switch at the rear of the body adjusts the voltage to the appro-
priate voltage.

Select the appropriate voltage position in accordance with the standard in the table below.

L H

100V 95 ~ 102V 103 ~ 110V

200V 190 ~ 205V 206 ~ 220V

The measured voltage is the voltage for the time of day that the charger is normally used. If
charging is done at night, measure the source voltage at night.

7-3
CE681.book Page 4 Friday, July 30, 2010 3:34 PM

[4] PARTS

NF1: Circuit breaker

250V 15A
NF2: Circuit breaker
36V 25A Auto reset (built-in)
SW1: Power switch
125V 15A/250V 10A
SW2: 100/200 switch
125V 6A/250V 3A
SW3: L/H switch
125V 6A/250V 3A
T1: Transformer
24V 15A B Type Dedicated design (built-in)
TS1: Thermostat
145°C (built into Transformer)
PWB: Control board
Main rectifier/control circuit
TH: Temperature sensor
Silicon diode

7-4
CE681.book Page 5 Friday, July 30, 2010 3:34 PM

[5] TROUBLESHOOTING
OK NG
(1) Charging start failure

lnspection 1 :
Start charging using correct procedure
Check charging start procedure

Inspection 2:
Reset input voltage switch
Input voltage switch check

Inspection 3: Battery inspection Battery maintenance, inspection

Inspection 4: Check each component Repair or replace damaged parts

Malfunction inside charger

(2) Charging completion failure

Inspection 3: Battery inspection Battery maintenance, inspection

lnspection 5: L/H switch check Reset L/H switch

Malfunction inside charger

(3) Overcharging

Inspection 5: L/H switch check Reset L/H switch

Inspection 6: Charging time check Malfunction inside charger

7-5
CE681.book Page 6 Friday, July 30, 2010 3:34 PM

Inspection 1: Check charging start procedure

If the AC input switch is turned ON before the DC plug is inserted, the internal protection
circuit mechanism operates and charging does not start. First turn the switch OFF, then
wait 5 seconds before turning the switch ON.

Inspection 2: Input voltage switch check

If you apply 200V with the input voltage set at 100V, the charging completion display
lights up and charging does not occur. Reset the input voltage switch to the correct posi-
tion.

Inspection 3: Battery inspection

If you try to charge an overdischarged battery, the internal protection circuit is activated to
prevent charging. Undercharging may also occur due to reduced battery capacity. Check
the battery fluid level and specific gravity, etc. and if anything is abnormal, perform main-
tenance or replace the battery.

Inspection 4: Check each component

Charging may not occur due to activation of the internal protection circuit by a plug short-
circuit or abnormal overheating of the transformer, a broken wire or poor contact, etc.
Repair or replace damaged parts, and cool the main body.

Inspection 5: L/H switch check

If the L/H switch setting is incorrect, overcharging or undercharging will occur. Set the L/H
switch in accordance with the table in [3] INPUT VOLTAGE ADJUSTMENT.

Inspection 6: Charging time check

If normal timer operation is not possible due to a malfunction inside the charger, the total
timer is activated. It automatically stops charging 18 hours after initial charging.

7-6
CE681.book Page 7 Friday, July 30, 2010 3:34 PM

Application Battery charger for cycle service

Charger Specifications
Model ZLC24-15A
Item Unit Standard Remarks
Rectifier type – Single phase full-wave
Cooling method – Natural cooling
Rating – Continuous
Type

Timer cutoff after voltage detection

Charging method – (Voltage detected within 15 mins → With total timer
stops for 15 mins)
No. phases Ø Single phase
Frequency Hz 50/60
• With switch to
change
Voltage V 100V/200V • Required to
AC

change the AC
plug
Voltage variation 100V L95 ~ 102V H103 ~ 110V
L/H selection switch
range 200V L190 ~ 205V H206 ~ 220V
Current A 100V 6A or 200V 3A At rated output
Rating V 24
Current A 15
Initial charging
DC

A 15 On L side, 100/200V
current
at ambient temp.
Final charging
A 5 20°C
current
On L side, 100/200V
Normal charging
Charging conditions About 6.5 - 8 hrs at ambient temp.
time
20°C
Steel core and coil
°C less 85 or less B type insulation
of transformer
Temp. rise

Rectifier °C less 90 or less Silicon

Switching device °C less (knob) 20/35 Metal/other
Case surface °C less 35 or less
Insulation
MΩ 3 or more 500 megger
resistance
Dielectric strength V/min AC-E, AC-DC1500/1: DC-E500/1
Panel: Pale silver
Paint color –
Cover: black
Panel:
Name plate – Polyester film label
Polycarbonate film
Application Electrical appliance and material
Other

–
standard control law
Usage ambient
°C 0 - 40
temp.
Storage battery
– Connector
connection method
Weight kg About 7.9

7-7
CE681.book Page 8 Friday, July 30, 2010 3:34 PM

LESIP (OPT)
[1] General
• This charger is a charger for Industrial vehicle.

1. Features
• The unit’s microcomputer circuitry continuously regulates the recharging so as to be
optimal for the battery.
• Operation is easy.

2. Parts name and its function

1) Charger

Control panel
Cover

Charger body

Ventilation holes

Input fuse
2) Construction
Input fuse
Transformer

Control board

Input plug Input cable

Output plug
Output cable

Output fuse

Note: Input plug can be used 100V specification only.

7-8
CE681.book Page 9 Friday, July 30, 2010 3:34 PM

3) Detail of charger control

Inspection lamp

Automatic mode switch

and indicator lamp

Charge level
Equalizing switch and indicator lamps
indicator lamp

Operation stop switch

Test lamp

• Automatic mode switch Push the switch, which will cause the automatic cycle
and indicator lamp: will start.
The indicator lamp lights up during automatic charge.
• Equalizing switch and Push the switch, which will cause the equalized
indicator lamp: charge cycle will start.
The indicator lamp lights up during equalizing charge.
• Operation stop switch: Push the switch, which stops charge.
• Charge level indicator lamps: The lamp stepwise lights up according to a charge
state.
* The lamp holds lighting after reaching at the setting
time of a timer.
• Inspection lamp: The lamp lights up in the case of malfunction.
• Test lamp: The lamp lights up in the case of timer test.

7-9
CE681.book Page 10 Friday, July 30, 2010 3:34 PM

[2] Wiring diagram and function

AC100V

F1 : Input fuse
F2 : Output fuse
TR : Transformer
SF : Charging controller

AC200V

F1 : Input fuse
F2 : Output fuse
TR : Transformer
SF : Charging controller

[3] Condition of Environment

Temp. for storing unit -20 ~ 70°C
Temp. for operating unit -10 ~ 40°C
30 ~ 95%
Note: 30% is a level approachable
Humidity range
only as long as condensation
dose not form.

7-10
CE681.book Page 11 Friday, July 30, 2010 3:34 PM

[4] Wiring method

• 100V specification: The AC plug is equipped, and connect it with the AC outlet for
100V.
• 200V specification: Set the Barker (MCB) for AC200V single phase on the input side
of the charger.
• Be certain to ground the unit by the earth cable.
• Selection and switching of the input tap: The switching of the transformer tap depends
on the voltage of the AC power supply.
• The tap is changed by remove the cover of unit and changing the connection location
of the electrical line connected to the transformer.
• Connect the line to the appropriate tap following the instruction for tap switching on
the label.
• It causes the accident and damage when connected the tap with wrong place.
• All tap (connected and un-connected) should be isolated.

• Table for applicable voltage of the tap

AC100V
Input voltage Tap selection Remark
AC 96 ~ 100V 100V
Connected from
AC 101 ~ 105V 105V
factory
AC 106 ~ 110V 110V

AC200V
Input voltage Tap selection Remark
AC 191 ~ 200V 200V
Connected from
AC 201 ~ 210V 210V
factory
AC 211 ~ 220V 220V

• Detail of tap change

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CE681.book Page 12 Friday, July 30, 2010 3:34 PM

[5] Operation
• The vehicle set to near charger and the key switch turn to OFF.
• Check the battery fluid before staring the battery charge.
• Check the battery whether the voltage and capacity are adapted with charger specifi-
cation or not.
• Connect the output plug to the battery plug, then turn ON the AC input.

• The “AUTO” and “EQUAL” indicators will illuminate at the same time.
Then, start the charging if you push the switch (Automatic charging or Equalized
charging).

Light up at the same time

Automatic switch
Equalized switch

Stop switch

• Ordinarily, choose the automatic charge cycle to perform each time. Then perform the
equalizing charge once a week.

● Automatic charging procedure

• Push the AUTO switch, which will cause that switch’s lamp to illuminate.
And the automatic cycle charging will start.

Illuminates

Push

• The indicator lamp lights up from E to F indicator lamp as charge progresses.

• When the charge has been completed, the charge level indicator lamps from E to F
will illuminate, and the other indicators will turn to off.

Illuminates all

7-12
CE681.book Page 13 Friday, July 30, 2010 3:34 PM

• When charging is completed, turn off the AC input and disconnect the battery plug.
• If needs to stop the charging intermediately, push the stop switch.

Lit at the same time

When the automatic charge cycle is terminated, all of charge level indicator lamps will
turn off, and both AUTO and EQUAL switch’s lamps are turn on at the same time.
After checking the indicator lamp, AC input turn to OFF and disconnect battery pulg.

● Equalizing charge procedure

• Push the EQUAL switch, and the switch’s lamp with illuminate, and the equalized
charge cycle will start.

Illuminates

Push

• The indicator lamp lights up from E to F lamp as charge progresses.

• When the charge has been completed, the charge level indicator lamps from E to F
will illuminate.
And other indicator lamp will turn off.

Illuminates

• When charging is completed, turn off the AC input, and disconnect the battery plug.
• If needs to stop the charging intermediately, push the stop switch.
When the equalizing charge cycle is terminated, all of the charge level indicator will
turn off, and indicator lamp within the AUTO and EQUAL will illuminate at the same
time.
After checking the indicator lamp, AC input turn to OFF and disconnect battery pulg.

● Changing the charge mode

• Perform to stop the charging in case of change the charging mode while charging,

7-13
CE681.book Page 14 Friday, July 30, 2010 3:34 PM

[6] Periodic maintenance and troubleshooting

● Periodic maintenance
• At the regular interval of once a month, check the charger unit, and if tears or worn-
out parts are found in the cable, or if the battery plug has developed cracks, replace
them with new parts.
• Clean the charger outer case every 3 month.

● Settlement of trouble
• If the check light illuminates, turn off the AC input, and disconnect the battery plug.

Lit

• Check the Fuse both input and output in the charger.

Remove the cover

Fuse (input) Fuse (output)

15A (100V spec.)

rating AC 250V 10A (200V spec.)
rating DC 125V 30A

• AC input should not ON till the cause of problem is cleared.

● Caution
• The Charger is categorized with Industrial waste, so it is needed to ask a certified
scrap/disposal service company, if the charger is scrapped.

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CE681.book Page 1 Friday, July 30, 2010 3:34 PM

8. MAINTENANCE STANDARDS TABLE

[1] MAINTENANCE STANDARDS TABLE (MECHANICAL) .......8-2

[2] MAINTENANCE STANDARDS TABLE (ELECTRICAL).........8-2
[3] PERIODIC INSPECTION..........................................................8-4

8-1
CE681.book Page 2 Friday, July 30, 2010 3:34 PM

[1] MAINTENANCE STANDARDS TABLE (MECHANICAL)

Steering
Lock to lock 100°
Front axle and wheel
Front axle type Semi-floating
Front fork caster angle 15°
Front tire size 2.50-4
Rim size 1.75DT × 4
Wheel tightening torque N·cm 3030
Rear axle and wheel
Reduction ratio 1/24.99
Drive helical gear Teeth 10
Idle helical gear Teeth 72
Idle pinion gear Teeth 17
Ring helical gear Teeth 59
Differential drain bolt tightening torque N·cm 1372-1764
Rear axle housing pipe tightening torque N·cm 1568-2058
Drive motor: Screw N·cm 196
Drive motor: Through bolt N·cm 588
Type Engine oil SAE#30
Oil
Quantity 325cc
Rear axle type Semi-floating fixed type
Rear tire size 3.50-5
Rim size 3.00SP × 5
Wheel tightening torque N·cm 3430
Brake
Brake lining thickness Limit 86mm (diameter)
Standard 7°
Initial response position
Limit 9 - 10°

[2] MAINTENANCE STANDARDS TABLE (ELECTRICAL)

Battery
Capacity 100AH/5HR
Voltage 12V × 2 24V
Charging completion specific gravity 1.280 (20°C)
Discharged specific gravity 1.150 (20°C)
Weight 33Kg × 2 66Kg
Insulation resistance 1Ω or more

8-2
CE681.book Page 3 Friday, July 30, 2010 3:34 PM

Drive controller
Rated voltage DC24V
Operational voltage range DC18 - 30V
30A (1 hour)
Rated current
45A (2 minutes)
Current limit 90A (15 seconds)
Regenerative brake current limit 45A
Motor minimum internal resistance 0.08Ω
Operational temperature range -10 ~ 45°C
Voltage drop standard 0.25V@20A
Operational frequency 15KHz
Accelerator
Potentiometer resistance 0 ~ 5KΩ
Insulation resistance 3MΩ or more (500 megger)
Limit switch life 500,000 times
Driver motor
Rated voltage DC23V
Rated output 400W
Rated time 60 minutes
Rated rpm 3250 rpm
Insulation resistance 3MΩ or more
Weight 5Kg
Standard Ø40mm
Commutator outer diameter
Limit Ø35mm
Standard 5.5N
Brush spring force
Limit 2.6N
Exchange
Brush length 14mm
standard
Wiring
F1: Main fuse 24V 75A (9803-1004), 80A (1005- )
F2: Control system fuse 24V 5A
Lamp type
HL: Front lamp DC24V12W
DC24V6W (9803-1004)
WL: Indicator lamp
DC24V 0.5W (1005- )
DC24V6W (9803-1004)
SL: Brake lamp
DC24V0.5W (1005- )
BL: Backup lamp (Option) DC24V12W
Warning indicators
H: Horn DC24V60mA
BB: Backup alarm DC24V15mA
CH: Forward alarm (Option) DC24V150mA

8-3
CE681.book Page 4 Friday, July 30, 2010 3:34 PM

[3] PERIODIC INSPECTION

Periodic Inspection

Pre-inspection
12 Monthly
3 Monthly
6 Monthly
Monthly
Weekly
Steering handle operation condition and looseness
Front wheel attachment nut looseness check,
tightening
Universal joint, looseness check, tightening
Brake lever freeplay, return, grip clearance
adjustment
Brake efficiency
Brake drum & lining gap adjustment
Mechanical & Chassis

Brake lining wear check

Brake drum wear check
Accelerator lever operation check
Brake adjustment nut looseness check, tightening
Tire air pressure (pneumatic only)
Tire external damage
Tire wear
Hub nut, bolt looseness check, tightening
Rear axle installation check, tightening
Rear axle unit oil leak
Rear axle unit * * 100 hrs
Drive motor noise check
Drive motor brush replacement 2000 hrs
Chassis overall noise check
Forward/reverse switch operating condition
Key switch operation
Lamp operation
Horn operation
Battery capacity meter operation
Electrical

Check for looseness of each wiring connection

Battery connector, charging connector installation
bolt looseness
Battery connector, charging connector damage
Charging operation of charger
Battery electrolyte level
Battery specific gravity measurement (densimeter)
Battery terminal installation condition
* Change the oil after 3 months or 100 operation hours, whichever occurs first, then the oil
should be replaced every one year.

8-4
CE681.book Page 1 Friday, July 30, 2010 3:34 PM

9. MAINTENANCE STANDARDS TABLE

Wiring diagram Production date: 2006/7~2009/11 .....................9-2

Wiring diagram Production date: 2006/7~2009/11 .....................9-3
Wiring diagram Production date: 2009/12~2010/4 .....................9-4
Wiring diagram Production date: 2009/12~2010/4 .....................9-5
Wiring diagram Production date: 2010/5~ ..................................9-6
Wiring diagram Production date: 2010/5~ ..................................9-7

9-1
 symbol name Qty

9-2
RY1 OPS relay 1
D1 Diode 1
OPS SW OPS switch 1
LO OPS lamp 1
BT Battery 12V 2
F1 Fuse (75A) 1
F2 Fuse (5A) 1
DM Drive motor 1
Driver for
PMC 1
Motor
H Horn 1
CE681.book Page 2 Friday, July 30, 2010 3:34 PM

Turn signal
WL** 4
lamps
SL Stop lamp 1
Dummy
R1 1
resistance
Battery
BF capacity 1
indicator
HL Head light 1
Accelerator
CH SW 1
switch
VR Potentiometer 1
BB Back buzzer 1
HSW Handle switch 1
Turn signal
FRY 1
relay
Stop lamp
SL SW 1
switch
SW KY Key switch 1
Battery for
BTM voltage 1
memory
Battery
BTC 1
connector
Auxiliary
AC100V/
Charger 200V (can be 1
changed)
Wiring diagram Production date: 2006/7~2009/11

OPT
HM Hour meter 1
BL Backup lamp 1
Alarm for
CH 1
forward
symbol color symbol color symbol color symbol color Alarm for
Dotted lines are shown the OPT items (total 6) RY2 1
W white P pink RG red/green YL yellow/blue forward relay
R red V violet RW red/white LW blue/white D2 Diode 1
O orange Gy gray RB red/black LR blue/red Auto parking
MB 1
brake
Y yellow Br brown LY blue/yellow LB blue/black
G green L blue RY red/yellow WB white/black
light
B black Lg BY black/yellow BW black/white
green
 alarm
CE681.book Page 3 Friday, July 30, 2010 3:34 PM

Wiring diagram Production date: 2006/7~2009/11

corrugate

Look the number from

Dotted line are shown the OPT (total 6)
terminal side

View from this way

Wire
Harness

9-3
 symbol name Qty

9-4
RY1 OPS relay 1
D1 Diode 1
OPS SW OPS switch 1
LO OPS lamp 1
BT Battery 12V 2
F1 Fuse (75A) 1
F2 Fuse (5A) 1
DM Drive motor 1
Driver for
PMC 1
Motor
BB Back buzzer 1
CE681.book Page 4 Friday, July 30, 2010 3:34 PM

H Horn 1
Turn signal
WL** 4
lamps
SL Stop lamp 1
Dummy
R1 1
resistance
Battery
BF capacity 1
indicator
HL Head light 1
VR Potentiometer 1
HSW Handle switch 1
Turn signal
FRY 1
relay
Stop lamp
SL SW 1
switch
SW KY Key switch 1
Battery for
BTM voltage 1
memory
Battery
BTC 1
connector
Auxiliary
AC100V/
Charger 200V (can be 1
changed)
OPT
HM Hour meter 1
Wiring diagram Production date: 2009/12~2010/4

BL Backup lamp 1
Alarm for
CH 1
forward
Auto parking
MB 1
brake
symbol color symbol color symbol color symbol color
Dotted lines are shown the OPT items (total 6)
W white P pink RG red/green YL yellow/blue
R red V violet RW red/white LW blue/white
O orange Gy gray RB red/black LR blue/red
Y yellow Br brown LY blue/yellow LB blue/black
G green L blue RY red/yellow WB white/black
light
B black Lg BY black/yellow BW black/white
green
 CE681.book Page 5 Friday, July 30, 2010 3:34 PM

Wiring diagram Production date: 2009/12~2010/4

corrugate

Look the number from

Dotted line are shown the OPT (total 5)
terminal side

View from this way

Wire
Harness

9-5
 symbol name Qty

9-6
RY1 OPS relay 1
D1 Diode 1
OPS SW OPS switch 1
LO OPS lamp 1
BT Battery 12V 2
F1 Fuse (80A) 1
F2 Fuse (5A) 1
DM Drive motor 1
Driver for
PMC 1
Motor
BB Back buzzer 1
CE681.book Page 6 Friday, July 30, 2010 3:34 PM

H Horn 1
Turn signal
WL** 4
lamps
SL Stop lamp 1
Dummy
R1 1
resistance
Battery
BF capacity 1
indicator
HL Head light 1
Accelerator
CH SW 1
switch
VR Potentiometer 1
HSW Handle switch 1
Turn signal
FRY 1
relay
Stop lamp
SL SW 1
switch
SW KY Key switch 1
Battery
BTC1 1
connector
Wiring diagram Production date: 2010/5~

Battery
BTC2 connector for 1
charger
Auxiliary
AC100V/
Charger 200V (can be 1
changed)
OPT
for exclusive
Charger 1
AC100V
for exclusive
Charger 1
AC200V
symbol color symbol color symbol color symbol color HM Hour meter 1
W white P pink RG red/green YL yellow/blue
Dotted lines are shown the OPT items (total 6) BL Backup lamp 1
R red V violet RW red/white LW blue/white Alarm for
CH 1
forward
O orange Gy gray RB red/black LR blue/red Note: OPS SW Seat switch for 7CBT06 Auto parking
Y yellow Br brown LY blue/yellow LB blue/black MB 1
brake
G green L blue RY red/yellow WB white/black
Mat switch for 7CBTY06
: OPT for export vehicle (2 times)
light
B black Lg BY black/yellow BW black/white
green
 CE681.book Page 7 Friday, July 30, 2010 3:34 PM

Wiring diagram Production date: 2010/5~

corrugate corrugate

Look the number from

terminal side Dotted lines are shown the OPT items (total 5)
View from this way
Wire Note: OPS SW Seat switch for 7CBT06
Harness
Mat switch for 7CBTY06

9-7
CE681.book Page 8 Friday, July 30, 2010 3:34 PM
CE681.book Page 1 Friday, July 30, 2010 3:34 PM

Published by

1st Printing: Aug. 2010

Pub. No. CE681

Printed in JAPAN