Contents

1 Drawings of removed units .........................................................................1

2 Dimensions of removed units.....................................................................1
3 Assembly procedure, necessary equipments, and schedule..................2
4 Necessary tools and equipments ...............................................................3
5 Assembly procedure....................................................................................4
A-1 Positioning bare machine...................................................................4
A-2 Installing tire and wheel assembly .....................................................5
A-3 Installing engine hood mirror..............................................................6
A-4 Installing front cover ...........................................................................7
A-5 Adjusting N2 gas of front and rear suspensions ................................8

Slinging procedure...........................................................................................9

Tail gate specification (If equipped) .............................................................15

Payload meter specification (If equipped) ...................................................27

1 Drawings of removed units

1. Tire and wheel assembly 4. Bare machine

2. Engine hood mirror

3. Front cover

Specifications of completed truck

Related items
Specifications
Weight (kg) Overall length (mm) Overall width (mm) Overall height (mm)

Self-propelled travel 30,350 11,025 3,450 3,700

(Weight of machine) (When empty)

2 Dimensions of removed units

No. Unit name Weight (kg) Overall length (mm) Overall width (mm) Overall height (mm)
1 Tire and wheel assembly 900 1,972 883 –
2 Engine hood mirror 1 500 200 200
3 Front cover 15 1,404 – 377
4 Bare machine 28,550 11,025 3,450 3,700

Drawings of bare machine on trailer

3,986
1,680

530

3,000 6,200 2,780 1,126

11,980

1
3 Assembly procedure, necessary equipments, and schedule

Day 1st day

Hour
1 2 3 4 5 6 7 8

Assembly unit

(1) Positioning chassis on stand (1) Installing tires

(2) Installing engine hood mirror
(3) Installing front bumper
Assembly manual No. A-1 A-2 to A-4
2 units
Crane (Hydraulic,
with operator)
245 kN {25 ton} 245 kN {25 ton}

Air compressor 3.7m3/min

(KOMATSU EC35Z5 or equivalent)

Generator For driving air compressor

Number of workers 3

Forklift
19.6 kN
{2 ton}

Meeting before work Removing wood blocks

Remarks Unloading Completion of assembly
Starting assembly

2
4 Necessary tools and equipments
(1) Necessary tools

No. Tool name Specifications Q'ty Remarks

1 Ring wrench 19 mm 1 For installing hood mirror and front cover
2 Socket 36 mm (Insertion angle: 25.4°) 1 For installing tire
3 Extension bar 25.4° × L160 mm 1 For installing tire
4 Impact wrench GT-S22M or equivalent 1 For installing tire
5 Torque wrench For measurement of 927 Nm {94.5 kgm} 1 For installing tire
6 Bar 1 For adjusting holes of tire
7 Paint spray can Clear 2 For touching up bolt head
(2) Necessary equipments
No. Equipment name Specifications Q'ty Remarks
1 Truck crane Min. 245 kN {25 ton} 2 For slinging bare machine
2 Forklift Min. 19.6 kN {2 ton} 1 For installing tire
3 Compressor Capacity: Min. 32 l 1 For impact wrench
4 Stepladder (Work stand) 4 steps (About 1.5 m) 1 For work
5 Steel plate t9 × 1,219 × 2,438 mm 1 For positioning bare machine
6 Wood block 400 × 400 × 900 mm 6 For positioning bare machine
(3) Necessary slings
No. Sling name Specifications Q'ty Remarks
1 Nylon sling For 147 kN {15 ton} × L4000 mm 4 For slinging bare machine
2 Tire sling L4000 mm, nominal chain size: ø6.3 mm 1 For slinging tire

1 2

Nominal chain size

ø6.3 mm
4 ,0
00

Using load: 147 kN Using load: 31.4 kN

4,000

{15 ton} {3.20 ton}

3
Assembly procedure No.
Positioning bare machine
A-1

1. Slinging bare machine

Nylon sling Nylon sling
For 147 kN {15 ton} × L4000 mm × 2 pieces For 147 kN {15 ton} × L4000 mm × 2 pieces

Steering lock bar

1. Set the steering lock bar securely.

2. Sling the bare machine with two 245 kN {25 ton} cranes.
Sling: Nylon sling (For 147 kN {15 ton}, L4000 mm × 4 pieces)
Front sling position: Lifting eye under bumper
Rear sling position: Body lock pin mounting part (Use body lock pin)

2. Positioning bare machine

1,200 Wood blocks

Steel plate
Position the bare machine as shown above.
(Secure the ground clearance shown above so that you can install the tire and wheel assembly.)
When positioning the bare machine on the ground, place a steel plate under the wood blocks so that the bare machine will
not sink and lean. (1219 × 2438 × 9t × 1 piece)

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Before starting the work, set the steering
Crane (245 kN {25 ton}) 2
lock bar securely.
Nylon sling 4
Steel plate (1219 × 2438 × t9) 1
Wood blocks (400 × 400 × 900) 6
Others

4
Assembly procedure No.
Installing tire and wheel assembly
A-2

1. Slinging tire and wheel assembly

How to sling tire and wheel assembly Image of mounting tire

Chain sling
(Endless × 2)

Weight of tire
900 kg

1. Set the sling to the tire and wheel assembly.

Sling: Chain sling (L4000 mm, nominal chain size: ø6.3 mm)
2. Sling the tire and wheel assembly with the 245 kN {25 ton} crane and mount it on the forklift.

2. Installing tire and wheel assembly

Installed to front axle temporarily

3 824 - 1,030 Nm {84 - 105 kgm}

Target: 927 Nm {94.5 kgm}

Part No. Part name Q'ty State of parts

(1) 56B-30-11910 BOLT 42 Installed to front axle temporarily
(2) 01643-32460 WASHER 42 Installed to front axle temporarily

1. Remove the bolts and washers installed to the axle temporarily.

2. Install the tire to the axle with the forklift and then install the bolts and washers.
a Take care that the tire will not fall from the forklift.
When positioning the tire and wheel assembly, take care not to damage the tube for inflating the tire.
3. Tighten the tire mounting bolts with the impact wrench temporarily.
4. Lift up the front part of the bare machine with the 245 kN {25 ton} crane and remove the wood blocks.
Sling: Nylon sling (For 147 kN {15 tons}, L4000 mm × 2 pieces)
5. Tighten the tire mounting bolts to the specified torque with the torque wrench.
6. Touch up the bolt heads with paint spray (clear) (to prevent rusting).

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
1) When carrying the tire and wheel as-
36 mm socket 1 Crane (245 kN {25 ton}) 1
sembly, take care that it will not fall from
Impact wrench 1 Forklift (Min. 19.6 kN {2 ton}) 1
the forklift. (GT-S22M or equivalent)
Torque wrench Tire sling
2) When positioning the tire and wheel as- (927 Nm {94.5 kgm}) 1 1
sembly, take care not to damage the Extension bar 1
tube for inflating the tire.
Bar 1
Paint spray can 2
Others

5
Assembly procedure No.
Installing engine hood mirror
A-3

1. Installing engine hood mirror

Engine hood

Engine hood mirror 1

Mounted in cab

3
Installed to engine hood temporarily
2

Part No. Part name Q'ty State of parts

56B-54-11512 STAY 1
(1) Mounted in cab
23S-54-36270 MIRROR 1
(2) 01010-81225 BOLT 2 Installed to engine hood temporarily
(3) 01643-31232 WASHER 2 Installed to engine hood temporarily

1. Remove the bolts and washers installed to the engine hood temporarily.
2. Take the engine hood mirror out of the cab and install it to the engine hood.
3. Adjust the angle of the mirror.

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Ring wrench (19 mm) 1 Stepladder (Work stand) 1
Others

6
Assembly procedure No.
Installing front cover
A-4

1. Installing front cover

Sub Frame

Front cover 1
Fixed to top of
battery box cover

a Fixed to front center bumper.

Adjust front cover with this bracket so

3 that it will be flush with both bumpers.

2
4 Installed to front center bumper temporarily

Installed to front Part No. Part name Q'ty State of parts

cover temporarily (1) 56C-46-11533 COVER 1 Mounted in cab
(2) 01010-81220 BOLT 4 Installed to front center bumper temporarily
(3) 01643-31232 WASHER 4 Installed to front center bumper temporarily
(4) 09415-02512 CAP 4 Installed to front cover temporarily

1. Remove the bolts, washers, and caps installed to the

center bumper.
2. Take the front cover out of the cab and install it to the
center bumper.
3. Adjust front cover so that it will be flush with both FWD R/D
bumpers.
4. Install the front cover as shown at right (Take care not
to install it reversely).
5. After installing the front cover, move the engine hood Installed direction of front
up and down and check that it will not interfere with cover (section)
the front cover.

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Socket wrench (19 mm) 1
Others

7
Assembly procedure No.
Adjusting N2 gas of front and rear suspensions
A-5

1. Adjusting N2 gas of front and rear suspensions

Adjust the quantity of N2 gas (4 places).

F.SUS.CYL R.SUS.CYL

i Chassis side i Chassis side

Axle side o Axle side o

Dimension A Dimension B
When cylinder is retracted fully: MIN (32 ± 1 mm) When cylinder is retracted fully: MIN (26 ± 1 mm)
Specified quantity of filled oil: OIL 53 ± 3 mm Specified quantity of filled oil: OIL 66 ± 3 mm
When empty : EMPTY (153 ± 10 mm) When empty : EMPTY (96 ± 10 mm)
When cylinder is extracted fully: MAX (209 ± 1 mm) When cylinder is extracted fully: MAX (116 ± 1 mm)

a Judge the quantity of the filled N2 gas by dimensions A and B when the truck is empty.
a Stop the truck slowly without using the foot brake, and then measure the dimensions.

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
The suspension pressure is set a little
higher than the specification when the truck
is delivered. Accordingly, adjust it
according to the above procedure.
Others

8
 SLINGING PROCEDURE

Contents

1 Preparation for slinging ............................................................................10

2 How to install sling .................................................................................... 11
3 Precautions ................................................................................................12
4 Related specifications ............................................................................... 13

CAUTION
This section describes the procedure for slinging a completed
truck with 1 crane when it needs to be slung and carried in a har-
bor, etc.
For the ordinary work, sling the truck with 2 cranes described in
Assembly procedure No. A-1.

9
 Slinging procedure No.
for completed truck
Preparation (When slinging with 1 crane)
1

1. Preparation of sling and crane

Beam Length: Min. 12 m, Load capacity: Min. 343 kN {35 ton} (excluding weight of beam)
Crane Lifting capacity shall be total of 343 kN {35 ton} and weight of beam and sling. Lifting height shall be total of
7 m and necessary height of lifted chassis.
Nylon sling 4 × 147 kN{15-ton} slings (Apply pads to parts of truck (4 places) which interfere with chassis.)

2. Preparation of chassis
Check that the front grille is removed.
Set the steering lock bar securely.

Check that front

grille is removed.

Detail of part A

12 m beam
Load capacity: 343 kN {35 t} (excluding weight of beam)

Nylon sling Nylon sling

For 147 kN {15 ton} × L4000 mm × 2 pieces For 147 kN {15 ton} × L4000 mm × 2 pieces

Steering lock bar

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Before starting the work, set the steering
Crane 1
lock bar securely.
Nylon sling 4
Check that the front grille is removed. Beam (Min. 12 m long) 1
Others

10
 Slinging procedure No.
for completed truck
How to install sling (When slinging with 1 crane)
2

1. Installing points of sling

Install the sling to the following 4 points. Apply
pads to the parts of chassis which interfere
with the sling to protect the chassis. Install nylon sling to pins.
1. Towing hooks at the bottom of the front
side
Install the sling to the 2 circled points in the
figure at right.
2. Body lock pin
Install the sling to pins B shown in the fol- Detail of part B
lowing figure.

Slinging points

Apply pads to
protect chassis. Detail of part A

5,560
11,025

Center of gravity

12 m beam
Load capacity: 343 kN {35 t} (excluding weight of beam)

Nylon sling Nylon sling

B
A

For center of gravity, length of chassis,

and weight, see related specifications. Apply pads to protect chassis.

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Apply pads to the front grille mounting parts
Crane 1
and rear parts of the body to protect the
chassis. Nylon sling 4
Beam (Min. 12 m long) 1
Others

11
 Slinging procedure No.
for completed truck
Slinging (When slinging with 1 crane)
3

1. Precautions for slinging

1. Install the sling for the front side so
that it will be in front of the vertical line
to prevent it from interfering with the
engine hood.
2. Sling the chassis horizontally.
For the center of gravity of each mod- Sling
el, see the related specifications.

Install sling so that it will

be in front of vertical line.

G. L.

5,560
11,025

Center of gravity

12 m beam
Load capacity: 343 kN {35 t} (excluding weight of beam)

Nylon sling Nylon sling

B
A

For center of gravity, length of chassis,

and weight, see related specifications. Apply pads to protect chassis.

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Apply pads to the front grille mounting parts
Crane 1
and rear parts of the body to protect the
chassis. Nylon sling 4
Beam (Min. 12 m long) 1
Others

12
 Slinging procedure No.
for completed truck
Related specifications (Reference)
4

1. Specifications
The specifications necessary for slinging the completed truck are shown below.

HM400-1
Total weight of empty truck 30,350 kg
Overall length 11,025 mm
Overall width 3,450 mm
Overall height 3,700 mm
Distance from front end of Approx.
chassis to center of gravity 5,560 mm

CAUTION
The above are the standard data. Note that the total weight,
dimensions, center of gravity, etc. may change, depending on the
installed options and attachments.

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
When installing an option or an attachment,
change the above data accordingly.
Others

13
 TAIL GATE SPECIFICATION (IF EQUIPPED)

Contents

1 Drawings of removed units.......................................................................16

2 Dimensions of removed units...................................................................16
3 Assembly procedure, necessary equipments, and schedule................17
4 Necessary tools and equipments.............................................................18
5 Assembly procedure .................................................................................19
A-1 Assembling tail gate.........................................................................19
A-2 Positioning tail gate bracket .............................................................20
A-3 Welding tail gate bracket..................................................................21
A-4 Touching up tail gate........................................................................22
A-5 Installing tail gate .............................................................................23
A-6 Installing engine hood mirror............................................................24
A-7 Installing front cover.........................................................................25

15
1 Drawings of removed units

1. Tire and wheel assembly 4. Bare machine

2. Engine hood mirror

5. Tail gate and cable

3. Front cover

Specifications of completed truck

Related items
Specifications
Weight (kg) Overall length (mm) Overall width (mm) Overall height (mm)

Self-propelled travel 30,350 11,025 3,450 3,700

(Weight of machine) (When empty)

2 Dimensions of removed units

No. Unit name Weight (kg) Overall length (mm) Overall width (mm) Overall height (mm)
1 Tire and wheel assembly 900 1,972 883 –
2 Engine hood mirror 1 500 200 200
3 Front cover 15 1,404 – 377
4 Bare machine 29,233 11,025 3,450 3,700
5 Tail gate and cable 683 3,854 – –

Drawings of bare machine on trailer

3,986
1,680

530

3,000 6,200 2,780 1,126

11,980

16
3 Assembly procedure, necessary equipments, and schedule

Day 1st day

Hour
1 2 3 4 5 6 7 8

Assembly unit

(1) Positioning chassis on stand (1) Installing engine hood mirror

(2) Installing tail gate (2) Installing front bumper

Assembly manual No. A-1 to A-4 A-5 and A-6

2 units
Crane (Hydraulic,
with operator)
245 kN {25 ton} 245 kN {25 ton}

Air compressor Min. 3.7m3/min

Welding machine Rated current: Min. 250 A

Number of worker 3

Forklift
19.6 kN
{2 ton}

Meeting before work Completion of assembly

Remarks Unloading
Starting assembly

17
4 Necessary tools and equipments
(1) Necessary tools

No. Tool name Specifications Q'ty Remarks

1 Ring wrench 19 mm 1
2 Socket 36 mm (Insertion angle: 25.4°) 1
3 Extension bar 25.4° × L160 mm 1
4 Impact wrench GT-S22M or equivalent 1
5 Torque wrench 927 Nm {94.5 kgm}, 177 Nm {18 kgm} 1
6 Bar 1
7 Paint spray can Clear 2
(2) Necessary equipments
No. Equipment name Specifications Q'ty Remarks
1 Truck crane Min. 245 kN {25 ton} 2
2 Forklift Min. 19.6 kN {2 ton} 1
3 Compressor Min. 3.7 m3/min 1 For impact wrench
4 Welding machine Min. 250 A 1 For welding bracket
5 Stepladder (Work stand) 4 steps (About 1.5 m) 1 For work
6 Steel plate t9 × 1,219 × 2,438 mm 1
7 Wood block 400 × 400 × 900 mm 6
(3) Necessary slings
No. Sling name Specifications Q'ty Remarks
1 Nylon sling For 147 kN {15 ton} × L4000 mm 4 For slinging bare machine
2 Tire sling L4000 mm, nominal chain size: ø6.3 mm 1 For slinging tire

1 2

Nominal chain size

ø6.3 mm
4 ,0
00

Using load: 147 kN Using load: 31.4 kN

4,000

{15 ton} {3.20 ton}

18
Assembly procedure No.
Assembling tail gate
A-1

1. Assembling tail gate

Assemble the side gate and tail gate.
Sling the gate with the crane and install it.
Sling: Nylon sling (For 147 kN {15 ton}, L4000 mm × 2 pieces)

4
5

9
7 1
6
8
3

Part No. Part name Q'ty State of parts

(1) 56B-83-14131 GATE ASS'Y 1 Loose-supply item
(2) 56B-83-14111 GATE L.H. 1 Loose-supply item
(3) 56B-83-14121 GATE R.H. 1 Loose-supply item
(4) 01010-82460 BOLT 16 Installed to (2) and (3) temporarily
(5) 20Y-09-11150 SPACER 16 Installed to (2) and (3) temporarily
(6) 56B-83-14170 CUSHION 2 Installed to (1) temporarily
(7) 424-54-14230 SPACER 4 Installed to (1) temporarily
(8) 01024-81225 BOLT 4 Installed to (1) temporarily
(9) 56B-83-14290 SHIM 8 Installed to (1) temporarily

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
36 mm socket 1 Crane (245 kN {25 ton}) 1
19 mm socket 1 Forklift (Min. 19.6 kN {2 ton}) 1
Impact wrench (GT-S22M or equivalent) 1
Torque wrench (927 Nm {94.5 kgm}) 1
Others

19
Assembly procedure No.
Positioning tail gate bracket
A-2

1. Setting clearance of tail gate

Clearance:
Target: 32
A 27 - 36
Sling the tail gate assembly by points A, B, and C shown

2 - 11
below and put it on the body so that the clearance shown
in the figure will be secured.
Z

A
Body

X
B To be fitted

Clearance:
Target: 32
A 27 - 36

2 - 11
to body.
View Z
Procedure for adjusting clearance Clearance A:
2 - 11 mm
t=12 t=9 t=6
1 2 3

a Select one from plates (1), (2), and (3) so that clearance A will be closest to
6 mm (Allowable clearance: 2 - 11 mm) and weld it to the indicated position.
View X Perform this work on both sides.
Part No. Part name Q'ty State of parts
(1) 56B-83-14430 PLATE 1 Loose-supply item
(2) 56B-83-14420 PLATE 1 Loose-supply item
(3) 56B-83-14410 PLATE 2 Loose-supply item
2. Installing bracket temporarily
a Install the bracket temporarily by tack welding under the
condition of 1. (on both sides). Reduce the clearance be-
tween the body and bracket to 2 mm or less.
Body

Part No. Part name Q'ty State of parts

(1) 56B-83-14240 BRACKET 2 Loose-supply item

1 79.2 kg

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Crane (245 kN {25 ton}) 1
Forklift (Min. 19.6 kN {2 ton}) 1
Welding machine 1
Others

20
Assembly procedure No.
Welding tail gate bracket
A-3

1. Disassembling tail gate

Lower the tail gate assembly from the body.
2. Welding bracket
Welding procedure
1. Cover around the parts to be welded (tires etc.) with protective material.
2. Remove paint, water, oil, and dust from the parts to be welded and areas around them (about 30 mm).
3. Check that the clearance between bracket (1) and body is 2 mm or less.
4. Weld the tail gate (2 pieces on both sides).
Arc welding
Welding rod: JIS Z3212, D5016, ø4 mm
Welding current: 130 - 160 A
Drying of welding rod: 2 hours at 150 - 200°C
5. After finishing welding, remove the spatters and finish the joints of the beads with a grinder.
6. Checking welded parts for defect
Check the welded parts for crack, undercut, overlap, spatter, and insufficient welding leg length (a negative welding leg
length is rejected).
7. Touch up the welded parts with natural yellow paint (KES 57.041.4).
Part No. Part name Q'ty State of parts
(1) 56B-83-14240 BRACKET 2 Loose-supply item

CONNECT WELDING
BEAD SMOOTHLY.

20
1 Q (4 PLACES)

2 PLACES
6
EXCEPT ∗ MARKED LENGTH

Q ∗ (600) 6
2 PLACES

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Paint spray 2 Crane (245 kN {25 ton}) 1
Forklift (Min. 19.6 kN {2 ton}) 1
Welding machine 1
Others

21
Assembly procedure No.
Touching up tail gate
A-4

1. Painting tail gate

Paint the bare areas of the body and tail gate assembly.

Necessary paint

Undercoat paint Topcoat paint

RETAN GP primer: 4 kg SR3000 natural yellow: 16 kg
RETAN GP hardener: 0.8 kg SR3000 hardener: 15 kg
RETAN GP thinner: 4 l Urethane thinner 205: 17 l

1. Paint each welded part and scratch with the specified paint.
2. Mix the base and hardener of the paint well at the ratio of "5 : 1, thinning rate: 10 – 30%" before using.
3. If there is a scratch on the chassis, touch up it with the above paint.

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Others

22
Assembly procedure No.
Installing tail gate
A-5

1. Installing tail gate assembly

Part No. Part name Q'ty State of parts
(1) 287-70-13330 CAP 2 Installed to tail gate assembly
(2) 01011-82410 BOLT 4 Installed to tail gate assembly
(3) 01643-32460 WASHER 4 Installed to tail gate assembly

Apply G2-LI to
both places.

Body

1
3
2
(1) Install the gate to the body.
Sling: Nylon sling
1. Install the tail gate assembly to the body.
(For 147 kN {15 ton}, L4000 mm × 3 pieces)
2. Check the clearance shown in A-2, 1, View Z.

(2) nstall the wires to the frame and gate.

1. Install the wire to the gate.
2. Install the wire to the body.

Part No. Part name Q'ty State of parts

Body
(1) 56B-83-14160 WIRE ASS'Y 2 Loose-supply item
(2) 565-81-27820 PIN 2
(3) 281-70-15290 PLATE 2
Installed temporarily
(4) 01010-81430 BOLT 4
(5) 01643-31445 WASHER 4
(6) 01013-83615 BOLT 2 Loose-supply item
(7) 01643-33690 WASHER 4 Loose-supply item
1 (8) 04050-16065 COTTER PIN 2 Loose-supply item
2
3 (9) 01590-33638 NUT 2 Loose-supply item
8 5
9 Tightening torque of (4) and (6): 157 - 196 Nm {16 - 20 kgm}
7
7 4 Target: 177 Nm {18 kgm}
6
Rear frame
a Perform (1) and (2) for both sides similarly.

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
36 mm socket 1 Crane (245 kN {25 ton}) 1
55 mm socket 1 Forklift (Min. 19.6 kN {2 ton}) 1
55 mm ring wrench 1
Impact wrench (GT-S22M or 1
equivalent)
Torque wrench (177 Nm {18 kgm}) 1
G2-LI grease Little
Others

23
Assembly procedure No.
Installing engine hood mirror
A-6

1. Installing engine hood mirror

Engine hood

Engine hood mirror 1

Mounted in cab

3
Installed to engine hood temporarily
2

Part No. Part name Q'ty State of parts

56B-54-11512 STAY 1
(1) Mounted in cab
23S-54-36270 MIRROR 1
(2) 01010-81225 BOLT 2 Installed to engine hood temporarily
(3) 01643-31232 WASHER 2 Installed to engine hood temporarily

1. Remove the bolts and washers installed to the engine hood temporarily.
2. Take the engine hood mirror out of the cab and install it to the engine hood.
3. Adjust the angle of the mirror.

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Ring wrench (19 mm) 1 Stepladder (Work stand) 1
Others

24
Assembly procedure No.
Installing front cover
A-7

1. Installing front cover

Sub Frame

Front cover 1
Fixed to top of
battery box cover

a Fixed to front center bumper.

Adjust front cover with this bracket so

3 that it will be flush with both bumpers.

2
4 Installed to front center bumper temporarily

Installed to front Part No. Part name Q'ty State of parts

cover temporarily (1) 56C-46-11533 COVER 1 Mounted in cab
(2) 01010-81220 BOLT 4 Installed to front center bumper temporarily
(3) 01643-31232 WASHER 4 Installed to front center bumper temporarily
(4) 09415-02512 CAP 4 Installed to front cover temporarily

1. Remove the bolts, washers, and caps installed to the cen-

ter bumper.
2. Take the front cover out of the cab and install it to the cen-
ter bumper.
3. Adjust front cover so that it will be flush with both FWD R/D
bumpers.
4. Install the front cover as shown at right (Take care not to
install it reversely).
5. After installing the front cover, move the engine hood up Installed direction of front
and down and check that it will not interfere with the front cover (section)
cover.

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Socket wrench (19 mm) 1
Others

25
PAYLOAD METER SPECIFICATION (IF EQUIPPED)

Contents

Assembly procedure......................................................................................28
B-1 Installation of payload meter external indicator lamps .....................28

Detail of components divided for delivery................................................... 29

M41-00-000.................................................................................................. 29
M41-01-010.................................................................................................. 30
M41-02-010.................................................................................................. 31
M41-05-010.................................................................................................. 32
M41-05-020.................................................................................................. 33
M41-05-030.................................................................................................. 34
M41-05-040.................................................................................................. 36
M41-05-041.................................................................................................. 37
M41-05-050.................................................................................................. 38
M41-05-060.................................................................................................. 39
M41-09-010.................................................................................................. 40

27
Assembly procedure No.
Installation of payload meter external indicator lamps
B-1

1. Installation of payload meter external indicator lamps

Detail of connection of wiring harness

Connect the following connectors of the cab wiring harness to the corresponding lamps.
After connecting indicator lamp connectors, bind and fix the wiring harness with bands (5).
(The wiring harness is bound when delivered. If it is not loosened, it does not need to be bound again.)
Ground GRER RLER
(To be connected to ARER ALER
Install so that lamps female of lamp)
1 will be seen from rear. RRER GLER

Z
2
Power supply
3 (To be connected
RR AR GR GL AL RL
to male of lamp)
View Y (View from front)

Y FWD

Cab
PMER
Check installation
of ground wire. Fix with clips
installed temporarily
(04434-00810).
View Z (View from above)

FWD Part No. Part name Q'ty State of parts

Indicator lamp
(1) –
assembly
2 Mounted on cab

(2) 01010-81235 BOLT 8 Temporarily installed to cab

(3) 175-54-34170 WASHER 8 Temporarily installed to cab
(4)
(5) 08034-20519 BAND 2 –

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Install the indicator lamp assembly so that
Socket wrench (19 mm) 1
its green lamp will be on the chassis center
side. (Take care not to install it in reverse.) Socket wrench (17 mm)
Others

28
Detail of components divided for delivery M41-00-000
Model Name

HM400-1 Correspondence table of codes and

specifications
No. Code No. Classification Section Specification Sales code Remarks
01 010 Parts common to all specifications All specifications
02
M41-01 Whole truck
03
04
05 010 Parts common to all specifications All specifications
06 Tire and wheel
M41-02
07 assembly

08
09
10
M41-03
11
12
13
14
M41-04
15
16
17 010 Parts common to all specifications All specifications
18 020 Parts added to wide tire specification SHW– All tire wheels wider than standard
19 030 Transportation style for Russia 7HC992004 For Russia
20 M41-05 Exterior parts 040 Tail gate specification 4HCTG22–A Tail gate specification
21 050 Yellow rotary lamp 6HA36
22 060 Payload meter external indicator lamp 7HC993010A
23
24
25
M41-06
26
27
28
29
M41-07
30
31
32
33
M41-08
34
35
36 010 Tool kit All specifications On-truck tools mounted for Japanese
specification and tool kit specification
37
38 Tools and other
M41-09
items
39
40

Legend Specification When changing a component

M41-01-010 01? is common to all specifications. because of a trouble, etc., notify us.
020- is component added to only For how to read the list or another
Model name (HM400-1) Section this specification. question, call us.

29
Detail of components divided for delivery M41-01-010
Model Name Object
Standard
HM400-1 Whole truck All options
Component
Remarks
No. Specification Part No. Part name Type Q'ty
01 STD–M 56B-00-10000 WHOLE TRUCK A 1 01. Remove 2 tires.

03 STD–W 56B-00-11000 WHOLE TRUCK A 1 03. Deliver without removing tires.

05 Wide tire 56B-00-12000 WHOLE TRUCK A 1 05. Remove 6 tires.

06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21 (Note 1) Install the parts (bolts, washers, nuts,
retaining plates, pins, etc.), which have
22 been used to install the parts packed
separately, to the normal positions.
23 (Note 2) Install or weld the component parts
specified in the delivery instruction
24 sheet to the normal positions, unless
they are ordered to be packed
25 separately.
If where to install a part is not clear, ask
Legend: A --- Assembly item, L --- Lot item, B --- Bulk item us.

01 03

05

30
Detail of components divided for delivery M41-02-010
Model Name Object

HM400-1 Tire and wheel Standard

assembly All options
Component
Remarks
No. Specification Part No. Part name Type Q'ty
01 STD–M 56B-00-20000 WHEEL ASSEMBLY A 2 01. Put 2 front tires on dump body when delivering.

03 STD–W 56B-00-21000 0 03. Deliver without removing tires.

05 Wide tire 56B-00-22000 WHEEL ASSEMBLY A 6 05. Remove 6 tires and put 2 front tires on dump
body when delivering.
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21 (Note 1) Install the parts (bolts, washers, nuts,
retaining plates, pins, etc.), which have
22 been used to install the parts packed
separately, to the normal positions.
23 (Note 2) Install or weld the component parts
specified in the delivery instruction
24 sheet to the normal positions, unless
they are ordered to be packed
25 separately.
If where to install a part is not clear, ask
Legend: A --- Assembly item, L --- Lot item, B --- Bulk item us.

01

03

31
Detail of components divided for delivery M41-05-010
Model Name Object

HM400-1 Exterior parts Standard

(Common) All options
Component
Remarks
No. Specification Part No. Part name Type Q'ty
01 All specifications 56B-00-50000 ENGINE HOOD MIRROR A 1 01. Mounted in cab.
56B-54-11512 STAY L 1
23S-54-36270 MIRROR L 1

05 All specifications 56B-00-51000 FRONT COVER A 1

(Excluding specification for Russia) 56C-46-11533 GUARD L 1

08
09
10
11
12
13
14
15
16
17
18
19
20
21 (Note 1) Install the parts (bolts, washers, nuts,
retaining plates, pins, etc.), which have
22 been used to install the parts packed
separately, to the normal positions.
23 (Note 2) Install or weld the component parts
specified in the delivery instruction
24 sheet to the normal positions, unless
they are ordered to be packed
25 separately.
If where to install a part is not clear, ask
Legend: A --- Assembly item, L --- Lot item, B --- Bulk item us.

01

05

Fix to top of battery box.

32
Detail of components divided for delivery M41-05-020
Model Name Object

HM400-1 Exterior parts Wide tire

(Wide tire)
Component
Remarks
No. Specification Part No. Part name Type Q'ty
01 Wide tire 56B-00-55000 RIGHT AND LEFT A 1 01. Mount 2 guards for right and left together in cab.
OVER-FENDER GUARDS
56B-54-11970 GUARD L.H. L 1
56B-54-11980 GUARD R.H. L 1

06 Wide tire 56B-54-55100 RIGHT AND LEFT A 1 06. Assemble with plate by 1 set of bolt and nut
MUDGUARDS
and mount on chassis.
56B-54-12414 GUARD L.H. L 1
56B-54-12382 PLATE L 2
56B-54-12441 GUARD R.H. L 1

12
13
14
15
16 For wide tire specification, pack and mount parts
shown at left separately in cab.
17
18
19
20
21 (Note 1) Install the parts (bolts, washers, nuts,
retaining plates, pins, etc.), which have
22 been used to install the parts packed
separately, to the normal positions.
23 (Note 2) Install or weld the component parts
specified in the delivery instruction
24 sheet to the normal positions, unless
they are ordered to be packed
25 separately.
If where to install a part is not clear, ask
Legend: A --- Assembly item, L --- Lot item, B --- Bulk item us.

01 06

33
Detail of components divided for delivery M41-05-030
Model Name Object

HM400-1 Transportation style 7HC992004

for Russia
Component
Remarks
No. Specification Part No. Part name Type Q'ty
01 For Russia 56B-00-57000 FLOOR MAT A 1 Mounted on chassis
02 56B-54-15773 MAT L 1
03 56B-54-15783 MAT L 1
04 56B-54-15792 MAT L 1
05
06 For Russia 56B-00-57100 FIRE EXTINGUISHER A 1 Mounted on chassis
07 09495-00000 EXTINGUISHER L 1
08
09 For Russia 56B-00-57200 MIRROR ASSEMBLY A 2 Mount 2 assemblies for right and left on chassis.
10
11 For Russia 56B-00-57300 WIPER ASSEMBLY A 2 Mount 2 assemblies for front and rear on chassis.
12
13 For Russia 56B-00-57350 CAB REAR GUARD Mounted on chassis
14 56B-54-18312 GUARD, CAB
15
16 For Russia 56B-00-55000 RIGHT AND LEFT A 1
OVER-FENDER GUARDS
17 56B-54-11970 GUARD L.H. L 1
18 56B-54-11980 GUARD R.H. L 1
19
20 For Russia SUPRA ACE ΙΙ A 1 Mount paint and welding rods for field welding on chassis.
NATURAL YELLOW
21 S THINNER #100 A 1 (Note 1) Install the parts (bolts, washers, nuts,
retaining plates, pins, etc.), which have
22 SHINKO LB-524 mm A 1 been used to install the parts packed
separately, to the normal positions.
23 (Note 2) Install or weld the component parts
specified in the delivery instruction
24 sheet to the normal positions, unless
they are ordered to be packed
25 separately.
If where to install a part is not clear, ask
Legend: A --- Assembly item, L --- Lot item, B --- Bulk item us.

Fix these parts to mirror

temporarily and pack
them separately.

Fender handrail 11
01 06
(Note: Do not pack this separately.)

09

To be packed separately.

16

To be fixed to
cab temporarily.

To be packed separately.

13

34
Detail of components divided for delivery M41-05-030
Model Name Object

HM400-1 Transportation style 7HC992004

for Russia
Component
Remarks
No. Specification Part No. Part name Type Q'ty
01 For Russia 56B-00-57400 LAMP ASSEMBLY A 4 Mount right and left headlamps, side lamps, and
brake lamp assembly together.
02
03
04 For Russia 56B-00-57500 CURTAIN A 2 Mount radiator curtain on chassis.
05 56C-84-11890 CURTAIN L 1 Mount engine hood curtain on chassis.
06 56C-84-11870 CURTAIN L 1
07 56C-84-11810 CURTAIN L 1
08
09
10 For Russia 56B-00-57600 HYDRAULIC HEATER A 1
ADAPTER ASSEMBLY
11 Bind wiring harnesses and fix them to muffler.
12
13 For Russia 56B-54-55100 RIGHT AND LEFT A 1 13. Assemble with plate by 1 set of bolt and nut
MUDGUARDS
and mount on chassis.
14 56B-54-12413 GUARD L.H. L 1
15 56B-54-12382 PLATE L 2
16 56B-54-12441 GUARD R.H. L 1
17
18 For Russia 56B-00-57700 PROTECTOR A 1 Mount on chassis
19 56C-74-11150 BODY, PROTECTOR L 1
20
21 (Note 1) Install the parts (bolts, washers, nuts,
retaining plates, pins, etc.), which have
22 been used to install the parts packed
separately, to the normal positions.
23 (Note 2) Install or weld the component parts
specified in the delivery instruction
24 sheet to the normal positions, unless
they are ordered to be packed
25 separately.
If where to install a part is not clear, ask
Legend: A --- Assembly item, L --- Lot item, B --- Bulk item us.

Remove both
right and left ones.

Remove both
right and left ones.

04
Headlamp 01

13 10

Brake lamp Note that all the parts to be mounted on the chassis (including
the ones other than the above) must be packed specially.

35
Detail of components divided for delivery M41-05-040
Model Name Object

HM400-1 Tail gate 4HCTG22-A

specification
Component
Remarks
No. Specification Part No. Part name Type Q'ty
01 Tail gate specification X250416760 TAIL GATE 9 1
02 56B-83-14131 GATE, REAR ASS’Y A 1
03 56B-83-14111 GATE, L.H. ASS’Y A 1
04 56B-83-14121 GATE, R.H. ASS’Y A 1
05 56B-83-14160 WIRE ASS’Y L 2
06 565-81-27820 PIN L 2
07 281-70-15290 PLATE B 4
08 01010-81430 BOLT B 4
09 01643-31445 WASHER B 4
10 56B-83-14240 BRACKET L 2
11 56B-83-14180 PLATE L 2
12 424-54-14230 SPACER B 4
13 56B-83-14170 CUSHION L 2
14 56B-83-14290 SHIM B 8
15 01024-81225 BOLT B 4
16 01010-82460 BOLT B 16
17 20Y-09-11150 SPACER L 16
18 287-70-13330 CAP L 2
19 01011-82410 BOLT B 4
20 01643-32460 WASHER B 4
21 01013-83615 BOLT L 2 (Note 1) Install the parts (bolts, washers, nuts,
retaining plates, pins, etc.), which have
22 01643-33690 WASHER B 4 been used to install the parts packed
separately, to the normal positions.
23 04050-16065 PIN, COTTER B 2 (Note 2) Install or weld the component parts
specified in the delivery instruction
24 01590-33638 NUT L 2 sheet to the normal positions, unless
they are ordered to be packed
25 separately.
If where to install a part is not clear, ask
Legend: A --- Assembly item, L --- Lot item, B --- Bulk item us.

16

17

03 04

16 18
02
18 20
17 14 19

11
06 07 08 09 10 12 23
24
13 22
21

05
15
a Install 16 - 20 to both gates temporarily.

36
Detail of components divided for delivery M41-05-041
Model Name Object

HM400-1 Tail gate 4HCTG22-A

specification
Component
Remarks
No. Specification Part No. Part name Type Q'ty
01 Tail gate specification X250416760 TAIL GATE 9 1
02 56B-83-14410 PLATE (t = 6 mm) L 2
03 56B-83-14420 PLATE (t = 9 mm) L 1
04 56B-83-14430 PLATE (t = 12 mm) L 1
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21 (Note 1) Install the parts (bolts, washers, nuts,
retaining plates, pins, etc.), which have
22 been used to install the parts packed
separately, to the normal positions.
23 (Note 2) Install or weld the component parts
specified in the delivery instruction
24 sheet to the normal positions, unless
they are ordered to be packed
25 separately.
If where to install a part is not clear, ask
Legend: A --- Assembly item, L --- Lot item, B --- Bulk item us.

01

02

03

37
Detail of components divided for delivery M41-05-050
Model Name Object

HM400-1 Yellow rotary lamp 6HA36

Component
Remarks
No. Specification Part No. Part name Type Q'ty
01 Tail gate specification 56B-00-59000 ROTARY LAMP A 1 Mount on chassis
ASSEMBLY
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21 (Note 1) Install the parts (bolts, washers, nuts,
retaining plates, pins, etc.), which have
22 been used to install the parts packed
separately, to the normal positions.
23 (Note 2) Install or weld the component parts
specified in the delivery instruction
24 sheet to the normal positions, unless
they are ordered to be packed
25 separately.
If where to install a part is not clear, ask
Legend: A --- Assembly item, L --- Lot item, B --- Bulk item us.

01 Rotary lamp assembly

(Mounted on chassis)

Remove wiring harness

A
and fix lamp to cab.

Cab

Fix to cab temporarily.

Pack separately up to ground wire.

Detail of A

38
Detail of components divided for delivery M41-05-060
Model Name Object

HM400-1 Payload meter external 7HC993010A

indicator lamp
Component
Remarks
No. Specification Part No. Part name Type Q'ty
01 Payload meter 56B-00-60000 Indicator lamp assembly A 2 Mount on chassis
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21 (Note 1) Install the parts (bolts, washers, nuts,
retaining plates, pins, etc.), which have
22 been used to install the parts packed
separately, to the normal positions.
23 (Note 2) Install or weld the component parts
specified in the delivery instruction
24 sheet to the normal positions, unless
they are ordered to be packed
25 separately.
If where to install a part is not clear, ask
Legend: A --- Assembly item, L --- Lot item, B --- Bulk item us.

Bind wiring harness and fix it to seat bracket.

01 External indicator lamp assembly

(Mounted on cab)

Install seat bracket to cab.

Tighten lamp mounting bolts lightly.

39
Detail of components divided for delivery M41-09-010
Model Name Object

HM400-1 On-truck tools Tool kit

Component
Remarks
No. Specification Part No. Part name Type Q'ty
01 STD–M 56B-00-90000 ON-TRUCK TOOLS B 1
Tool kit (1) 07950-90403 CARTRIDGE B 1 01. Mount on-truck tools on truck.
(Only standard model for Japan and tool kit option)
(2) 07951-31400 NOZZLE L 1
(3) 07952-70004 PUMP ASSEMBLY B 1
(4) 09000-30006 WRENCH SET B 1
(5) 09014-10200 WRENCH B 1
(6) 09019-08035 WRENCH B 1
(7) 09020-10284 SOCKET WRENCH S L 1
(8) 09023-00380 HANDLE B 1
(9) 09033-00190 SCREW DRIVER B 1
(10) 09036-00150 PLIERS B 1
(11) 09039-00150 HAMMER B 1
(12) 09054-00009 GAUGE B 1
(13) 09055-10390 BAR B 1
(14) 09056-05513 TOOL BAG B 1
(15) 09288-30011 HOSE L 1
(16) 09289-10000 GAUGE B 1
(17) 6215-21-5610 NIPPLE L 1
(18) 07280-03423 CLAMP B 1 23. Do not attach on-truck tools on truck for
overseas tool-kit-less specification.
(19) 07286-02680 HOSE L 1
(20) 6218-81-9980 SOCKET L 1 (Note 1) Install the parts (bolts, washers, nuts,
retaining plates, pins, etc.), which have
been used to install the parts packed
separately, to the normal positions.
23 STD–W (Tool-kit-less) 56B-00-91000 ON-TRUCK-TOOL-LESS 0 (Note 2) Install or weld the component parts
specified in the delivery instruction
sheet to the normal positions, unless
they are ordered to be packed
separately.
If where to install a part is not clear, ask
Legend: A --- Assembly item, L --- Lot item, B --- Bulk item us.

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

17 18 19 20

40 GEN00029-00