Introduction 0-1

Introduction
Introduction
Table of Contents
Introduction........................................................................0-2
safety information..........................................................0-2
0-2 Introduction
Introduction
safety information
1. Repair work
Warning：
・ Workshop manuals are created for qualified
service technicians that have specialized
training. If vehicle maintenance is performed
by a person without the necessary
qualifications or that has not received the
appropriate training, damage may be caused
to the vehicle, or harm may come to the
service technician and people in the vicinity.
・ If vehicle maintenance is performed without
using the appropriate tools and devices,
damage may be caused to the vehicle, or
harm may come to the service technician and
people in the vicinity.
・ If vehicle maintenance is performed using a
procedure other than indicated in the
workshop manual, damage may be caused to
the vehicle, or harm may come to the service
technician and people in the vicinity.
Caution：
・ When replacing parts, make sure to use only
genuine parts, because the appropriate
maintenance and repair procedures are
essential to maintaining the safety of the
service technician and the safety and reliability
of the vehicle.
・ Make sure to read the workshop manual
thoroughly before performing any work
because it contains procedures and
information that must be followed when
performing vehicle maintenance and repairs.
・ When performing maintenance and repairs, be
sure to correctly use the special tools specially
designed for each purpose.
・ To ensure the safety of the service technician
and the safety and reliability of the vehicle, do
not perform procedures or use tools other than
those recommended in the workshop manual.
・ To ensure accidents do not occur during
maintenance and repair procedures, to prevent
damage to the vehicle due to inappropriate
procedures, and to ensure the safety and
reliability of the vehicle, the workshop manuals
indicate information that must be followed
particularly closely, using the terms "Warning",
"Caution", and "Supplement".

Jacking up
Legend
1. Clean and safe work clothes
2. Installation of chock blocks
3. Use of support stands after jacking up vehicle
Caution：
・ Prepare tools, instruments, and special tools in
advance.
・ Prepare the parts that require replacements
and parts that cannot be re-used in advance.
・ The service technician must wear a clean
service technician uniform, hat, and safety
footwear.
・ Make sure to use a seat cover, etc.
・ Disconnect the negative terminal of the battery
cable in advance.
・ Always remember to perform operations in a
safe manner.
・ Make sure to use chock blocks when the
vehicle is jacked up.
・ After jacking up, make sure to support the
specified position using a stand.
・ When lifting up the vehicle using a lift, make
sure to set the safety device.
Introduction 0-3
・ When performing a procedure with two or
more people, make sure to ensure each
other's safety before performing an action.
・ Do not leave the engine running for an
extended period of time or perform painting in
a poorly ventilated working environment.
・ Make sure to use the special tools if the
procedure requires them for the work.
・ Do not use tools such as a wrench that has
lost its edges, a hammer with frayed edges, or
a chipped chisel.
・ When performing work using a device such as
a grinder, crane, or welder, make sure that a
qualified technician performs the procedure
while paying sufficient attention to the handling
precautions.
・ When performing maintenance on the fuel
system, make sure to check that there is no
fuel leakage.
・ When handling volatile materials, take care
that they do not catch fire.
・ Make sure to wipe away any oil that sticks to
rubber parts, as it can cause deterioration.
・ Arrange removed parts in the correct order
and ensure they do not get mixed up with parts
that cannot be re-used.
0-4 Introduction

・ Perform sufficient cleaning and washing when Note：

performing assembly/installation.
・ Perform sufficient grease removal on areas
where applying liquid gasket, etc.
・ After completing the procedure, perform a final
check to confirm that the problem has been
solved.
・ Check that there is no fuel, oil, or engine
coolant leakage.
・ Disconnect battery cables before conducting
welding.
・ Disconnect all control cables before
conducting welding.
・ Turn all switches OFF before conducting
welding.
Caution：
・ Make sure the ground connection for the
welder is as close to the welding area as
possible.
・ When performing the welding operations of the
frame section, use the following welding rods.

Recommended welding rod

・JISZ3211E4916/AWSA5, 1E7016
・JISZ3211E4316/AWSA5, 1E7016
or equivalent
(KOBELCO LB52, LB47, or equivalent)
2. Replacement parts and parts number Lock connector
Caution：
・ Whenever disassembly is performed, make
sure to replace the packing, oil seals, O-rings,
crimping lock nuts, bending lock plates, cotter
pins, etc., with new ones.
・ Make sure to check the supply system and
part numbers in the parts catalog as part
numbers indicated in this manual may differ
from the supply system and are subject to
change.
3. Connector handling
Note：
・ Disconnection of the connectors
Caution：
・ Many connectors have a lock to ensure secure
connections. Legend
・ The two types of locks generally used are 1. Lock
those that open by lifting the release area of 2. Release area
the lock, and those that open by pressing the
release area. Caution：
・ Before disconnecting the connector, determine ・ To remove the connector, firmly hold the male
in advance the connector lock type. and female sections of the connector and pull
them apart carefully after releasing the lock.
・ When removing the waterproof connector,
remove any dust or moisture adhering to the
connector by blowing air over it, etc.
If dust or moisture enters the connector,
remove it before connecting the connector. As
for moisture, dry well to prevent rust.
 Introduction 0-5

・ Do not pull the harness when disconnecting
the connector, as this may cause the wiring to
come out or disconnect.
Handling the connectors
・ If you use a fuse with high capacity, the fuse
will not perform its function when excess
current flows through it.
・ This may cause parts, wiring, etc. to burn, and
can result in a vehicle fire.

Handling the fuse

Note：
・ Connecting connectors
Caution：
Caution：
・ Even for electric parts that are installed outside
・ Securely hold the female side and male side of
the cab and are waterproofed, try as much as
the connector, and align the female side and
possible to avoid exposing them directly to
male side of the connector correctly.
high pressure water when washing the vehicle
・ Firmly push them together until both sides click (cover them with plastic sheets, etc.).
into place.
・ Handle electronic parts with sufficient care,
Connecting connectors and do not damage the parts by dropping or
throwing them.

Handling the electronic components

4. Electrical parts handling

Warning：
・ If the fuse blows out, make sure to replace it
with a non-defective fuse of the same capacity
after identifying the cause of the blowout.
0-6 Introduction
Caution： Harness routing
・ When installing electronic parts, take care to
ensure the harness does not get stuck and do
not forcibly push the harness in.

Pinching the harness

Legend
1. Clip
2. Protection tube

Caution：
Caution：
・ For wiring between the engine and chassis,
・ Make sure that all connections are clean and
give the wiring sufficient slack to prevent wear
secure.
and damage caused by vibration.
・ Use grommets or tubes to prevent damage to
harnesses that may come in contact with the Engine and transmission wiring
sharp edges or surfaces of other parts.

Protecting the harness

Caution：
・ When wiring a harness by diverting it around
other parts, give the harness a sufficient
amount of slack, and use a protection tube and
clip to ensure it does not contact surrounding
parts.

Caution：
・ When securing additional wires along existing
harnesses, install band clips on the protective
7.
materials (corrugated tubes, vinyl chloride
tubes, rigid tubes, protectors, etc.) installed on
the existing harnesses.
Repairing the harness
Introduction 0-7
while taking care to prevent the connector pins
from coming in contact with the packaging.
Cab overtilting
Caution：
・ When overtilting with the cab tilt stay pin
removed, use rag, etc. to protect the cab so
that it does not get damaged.
・ When performing overtilting, the maximum
tilting angle for the cab is 50 degrees. Make
sure not to tilt it more than this because the
torsion bar supporting the cab may break.
・ Be extremely careful when performing
overtilting, as the cab and surrounding parts
may interfere with each other.

Legend
1. Existing harness (With protective material)
2. Additional harness
3. Band clip for securing harnesses
4. Area where securing with band clips is prohibited

5. Commercial electronic products

Caution：
・ If commercial electronic products such as
lights, audio systems, or wireless devices are
installed to the vehicle, turn the power of the
devices OFF in advance.
・ Otherwise, remove the commercial electronic
products before inspection or maintenance.
6. Failure by electrostatic discharge
Caution：
・ Because a high voltage applied to electronic
components due to electrostatic discharge
may result in malfunctions, touch a known
good ground before inspecting or replacing
related parts.
・ Do not directly touch the connector pins of
related parts or rub them with parts or covers,
etc.
・ If replacing electronic components, connect
the parts to a known good ground while still in
their packaged state and then remove them