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ZX-5-All-211
SUBJECT ZH200-204
ZX-5/ZH POLYCARBONATE ROOF (TRANSPARENT ROOF WINDOW)
MODIFICATION PROCEDURE

OUTLINE
This Service Bulletin provides you with a rework manual that explains how to rework the roof of
ZX-5/ZH to a polycarbonate roof. A polycarbonate roof gives you good upper range of vision even
when it is closed and at the same time, allows you to open and close it. Furthermore, the
polycarbonate roof has the same durability as the normal iron roof. Even if it is not used together
with head guard, in Japan, it is equivalent to the head guard defined in Article 153 of the Ordinance
on Industrial Safety and Health. However, this roof needs to be replaced every five years in order to
maintain durability. For details, refer to the cautionary remarks described below.
Refer to the instructions given from page 3.

＊ Thoroughly read the safety section in the service manual before starting the work to ensure safe operation.
Welding work, if any, should only be done by qualified welders.
＊ After replacing the main hydraulic equipment or engine or after post-assembling the aforementioned as an
option, be sure to change and register the post-assembled device serial number on Global e-Service (MMR,
HR, MME, G-Claim).

APPLICABLE MODELS / SERVICE BULLETIN NO. FOR EACH MODEL

Machine Model(s): ZX75 ∼ 870-5, ZH200-A/5B, ZX140W ∼ 220W-5
Machine Serial Nos.: ZX120 ∼ 870-5, ZH200-A/5B
ZX140 ∼ 220W-5, ZX75US ∼ 225US-5
Verify details of the target models on Global e-Service S/B (Service Bulletin).

STD. LABOR HOURS

3 Hours / one person

EXPENSES AND THE TIME TO BE CHARGED

Charge to the customer.

PARTS
Place an order for all necessary parts (Guard, bracket, etc.). Scrap the parts removed.

DESCRIPTION
Refer to the following page(s).

DWN
SA/GI: ZX-5(All)-103 CHKD
ZH200-057 APPD
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CONTENTS

1 Target models ………………………………………………………………………………… 3

2 Outline ……………………………………………………………………………………… 3

3 Cautionary remarks (Provide the cautionary remarks to the customer.) …………… 4

4 List of components …………………………………………………………………………… 4

5 Work procedure for cab interior …………………………………………………………… 5

5-1 Removal of inner parts ……………………………………………………………… 5

5-1-1 In the case of STD cab ………………………………………………………… 5

5-1-2 In the case of US cab …………………………………………………………… 9

5-2 Installation of roof (sunshade) …………………………………………………… 10

5-3 Installation of inner parts ………………………………………………………… 12

5-3-1 In the case of STD cab ………………………………………………………… 12

5-3-2 In the case of US cab …………………………………………………………… 16

6 Reassembly of roof (work procedure for cab exterior) ………………………………… 17

7 Inspection items ……………………………………………………………………………… 17

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1 Target models ZH200-204
<Leading models> (All models, beginning with the initial S/No., are applicable.)

STD cab-mounted models: ※ All ZX-5B, -5G, -5N and -5A machines are included.
ZX120-5 / ZX160-5 / ZX180-5 / ZX200-5 /
ZX240-5 / ZX270-5 / ZX330-5 /
ZX470-5 / ZX620-5 / ZX670-5 / ZX870-5 /
ZX140W-5 / ZX170W-5 / ZX190W-5 / ZX220W-5 /
ZH200-A / ZH200-5B

US cab-mounted models
ZX75US-5 / ZX85US-5 / ZX135US-5 / ZX225US-5 / ZX225USR-5

Verify details of the target serial numbers on Global e-Service S/B (Service Bulletin).

2 Outline
The polycarbonate roof (transparent roof window) is made from hard coated surface of polycarbonate
(PC), a resin.
Polycarbonate is a material that is used for arcade ceilings and bullet-proof glass.
This roof has the same durability as the normal iron roof. Even if it is not used together with head guard,
in Japan, it is equivalent to the head guard defined in Article 153 of the Ordinance on Industrial Safety
and Health.
Depending on the roof form, some parts might develop warps. However, this will not be problematic to the
open-close motion of the roof window and its performance.
Obtain the consent of the customer before you carry out the modification work.
Also provide the cautionary remarks described on the next page to the customer.
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3 Cautionary remarks (Provide the cautionary remarks ZH200-204
to the customer.)
1. To clean the roof, use a neutral detergent. Using an acidic/alkaline detergent can result in the
development of cracks. If cracks develop, replace.

2. Do not bring an organic solvent close to the roof. Also, make sure that it has no contact with the roof.
This can result in the development of cracks. When you paint the machine, protect the roof with vinyl,
etc. so that it doesn’t come in contact with organic solvent. If cracks develop, replace.

3. In the event the roof is struck by a large impact, replace it even if it is not damaged.
Furthermore, to prevent quality drop due to natural material deterioration, replace the roof every five
years even if it is not externally scratched or damaged.

4 List of components
Components are not the same for all mounted cab types.

ZX-5/ZXW-5/ZH mounted with STD cab

Item No. Part Name Part No. Q’ty Remarks
00 Roof XB00000957 1 Polycarbonate roof
01 Roof XB00000964 1 Sunshade
02 Cover XB00000963 1 Right rail
03 Cover XB00000961 1 Left front rail
04 Cover XB00000962 1 Left rear rail
05 Clip 4662718 16 To be used to reinstall cab interior parts
06 Pin, lock 4022697 2 To be used to install roof (00)

ZX-5 mounted with US cab

Item No. Part Name Part No. Q’ty Remarks
00 Roof XB00000957 1 Polycarbonate roof
01 Roof XB00000964 1 Sunshade
02 Rail 4671640 1 Right rail
03 Rail 4663620 1 Left front rail
04 Rail 4671639 1 Left rear rail
05 Clip 4662718 20 To be used to reinstall cab interior parts
06 Pin, lock 4022697 2 To be used to install roof (00)
07 Screw, sems 4662252 1 To be used to install the rail
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5 Work procedure for cab interior ZH200-204
Remove the cab interior parts and install the roof (sunshade).
Then, reassemble the cab interior parts that were removed.

5-1 Removal of inner parts

This procedure varies by the type of cab (STD cab, US cab). Refer to the next page for each cab type.
In the case of STD cab: P.5 - P. 8
In the case of US cab: P. 9

5-1-1 In the case of STD cab

Unless there is a special mention, all parts are to be reused. Take this into consideration when you
remove them. Store properly so that they are not misplaced.
(a) Remove the rear cover (Figs. 5.1 and 5.2).
Remove each cap, screw, bolt, etc. Then, remove the right cover, left cover, top cover and tray
in the given order.
※ For details of work procedure, refer to the “Removal/installation of cab” section in the
Workshop Manual.
Remove the caps (screwed Remove the caps
type) (2 locations). (5 locations).
Top cover

Remove the
fuse cover.

Left cover

Right cover Tray

Details

Fig. 5.1 Rear cover at the cab interior rear (with the cap installed) (STD cab)
Top cover ※ Before removing the left
Remove the screws
cover, remove the connectors
(9 locations).
from the lighter and 12V
power socket.

Left cover

Remove the bolt.

Tray
Right cover
Remove the bolts and
washers (2 locations).

Fig. 5.2 Rear cover at the cab interior rear (with the cap removed) (STD cab)
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(b) Slide the guard pipe (Fig. 5.3).
ZH200-204
Right pillar cover

Guard pipe
Slide the guard pipe so
that you can remove the
right pillar cover.

Remove the screws

(2 locations).

Fig. 5.3 Guard pipe at the right side of cab interior (STD cab)

(c) Remove the glass holder-use bracket (Fig. 5.4).

Remove the screws

Remove the screws (2 locations).
(2 locations).

Bracket
Bracket

Remove the Remove the

screws screws
(2 locations). (2 locations).

Fig. 5.4 Pillar cover at the cab interior rear

(with the glass holder-use bracket attached) (STD cab)
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(d) Remove the pillar cover (Fig. 5.5).
ZH200-204
After removing the screws, clips and hook, remove the pillar cover.
Remove the screws (2 locations). Right pillar cover
※ In the same way, remove the
screws from the left pillar
cover side.
Remove the hook.

Left pillar cover

Details
Remove the screws (2 locations). Remove the clips (2 locations).

Fig. 5.5 Pillar cover at the cab interior rear (STD cab)

Remove the screws (4 locations). ※ Remove in the same way

※ The speaker grill and speaker as for the opposite side.
(e) Remove the speaker (Fig. 5.6). are tightened jointly.
Remove the screw, speaker grill
and speaker in the given order
(2 locations, left and right).
Speaker
※ Disconnect the connector
at the back of the speaker.

Speaker grill

Fig. 5.6 Speaker at the cab interior rear top (STD cab)

(f) Remove the room lamp (Fig. 5.7). Room lamp body
※ Disconnect the connector
Remove in the order of lamp at the back of the lamp.
cover, screw and room lamp. 䖪
To remove the lamp cover, drive 䖪
the small slot driver into the four
grooves at ☆ shown in Fig. 5.5. Lamp cover
Exert equal strength for all four
䖪
locations and remove gradually.
Remove the screws 䖪
(Turning one screw at a time (2 locations).
might damage the latch of the
lamp cover.) Fig. 5.7 Room lamp at the center of cab interior roof
(STD cab)
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(g) Remove the roof cover (Fig. 5.8).
After removing the roof cover clip and junction switch, remove the roof cover.
It is necessary to deform the roof cover (rear) slightly during the removal work,
so work carefully to avoid damaging, etc. it.
※ The roof cover clip cannot be reused. Discard.

Junction switch (wiper-use

contact switch)
※ Disconnect the connector
at the back of the switch.
Roof cover (rear)
※ It is necessary to deform the roof
cover slightly during the removal
Roof cover work, so work carefully to
Remove the screw
(center) avoiding damaging, etc. it.
(2 locations).

Details

Roof cover
(left front)

Roof cover
(front end)
Roof cover (right front)

Remove the clips (16 locations).

※ As the roof cover clip is a “screw rivet,” turn
only the inner pin up to 45° with a driver if it
Lock release state needs to be removed. Once the tip of the
Locked state inner-side pin comes out, the lock is released
Protrusion and you will be able to remove the entire clip.
Inserted
Before insertion (locked state)
(lock release state) How to use a “screw rivet”
・To lock, insert into the hole and push the protrusion.
・To unlock, turn the inner pin.

Fig. 5.8 Cab interior ceiling (STD cab)

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5-1-2 In the case of US cab ZH200-204
Unless there is a special mention, all parts are to be reused. Take this
into consideration when you remove them. Store properly so that they are not misplaced.

(a) Remove the roof cover (Fig. 5.9).

After removing the roof cover clip and junction switch, remove the roof cover.
It is necessary to deform the roof cover (rear) slightly during the removal work,
so work carefully to avoid damaging, etc. it.
※ The roof cover clip cannot be reused. Discard.
Junction switch (wiper-use
contact switch) Position ○ as shown in the photograph
※ Disconnect the connector at right comes in contact with the
at the back of the switch. protrusion inside the cab (rail) and is
prone to damage. Wind protection tape,
etc. around it.
Roof cover (rear)
※ It is necessary to deform the roof
Remove the screw cover slightly during the removal
(2 locations). work, so work carefully to
avoiding damaging, etc. it. Roof cover (rear) removal
process
Details

Roof cover
(left front)

Roof cover
(front end)
Roof cover (right front)

Remove the clips (20 locations).

Lock release state
Locked state
Protrusion
Before insertion
(lock release state)
※ As the roof cover clip is a “screw rivet,” turn
only the inner pin up to 45° with a driver if it
needs to be removed. Once the tip of the
inner-side pin comes out, the lock is released
and you will be able to remove the entire clip.
Inserted
(locked state)
How to use a “screw rivet”
・To lock, insert into the hole and push the protrusion.
・To unlock, turn the inner pin.

Fig. 5.9 Cab interior ceiling (US cab)

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5-2 Installation of roof (sunshade) ZH200-204
(a) Remove the bracket and rail (Fig. 5.10).
Unless there is a special mention, all parts are to be reused.
Take this into consideration when you remove them. Store
properly so that they are not misplaced.
Remove the screws that are used to fix the bracket at the cab interior ceiling
and left and right rails (14 screws for STD cab and 12 screws for US cab).
Remove the bracket and left and right rails.
※ Discard the removed rails. They will be replaced with new rails.
(The bracket and screws will be reused. Store properly so that they are not
misplaced.)

Bracket

Before removal
(right side of the cab) Rail
Rail

Front Rear

After removal
(right side of the cab)

Front Rear

※Remove in the same way as for the opposite side.

Fig. 5.10 Rail at the cab interior ceiling

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(b) Install the rails, roof (sunshade) and bracket (Fig. 5.11). ZH200-204
Install rail (02) to the right side of the cab interior ceiling,
rail (03) to the left front and rail (04) to the left rear. To
install, use the screws that were used to install the old rails.
(In the case of US cab, add one screw (07).)
Insert roof (sunshade) (01) into the groove at the rail top.
After installing each rail to the cab, install the bracket to the
rail with screws.

(02)
(01) XB00000964 ∼ 1 In the case of STD cab: XB00000963 ∼ 1
(Roof (sunshade) In the case of US cab: 4671640 ∼ 1
※ Common to STD cab (Rail [right])
and US cab

Bracket
Using screws, install the rail and
bracket (13 locations).
(03)
In the case of STD cab: XB00000961 ∼ 1 Reuse the screws that were used to
In the case of US cab: 4663620 ∼ 1 install the old rails.
(Rail [left front]) ※ In the case of US cab, add one
sems screw (07) 4662252 ∼ 1.
(04)
In the case of STD cab: XB00000962 ∼ 1 ※ The basic structure of the STD cab and
In the case of US cab: 4671639 ∼ 1 US cab is the same although the rail
(Rail [left rear]) and bracket forms are different.

Fig. 5.11 Structure of the area surrounding the roof (sunshade)

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5-3 Installation of inner parts ZH200-204
Reassemble the inner parts by performing the procedure (pages 5 to 9)
described in “5-1. Installation of inner parts” in the reverse order.
This procedure varies by the type of cab (STD cab, US cab). Refer to the next page for each cab type.
In the case of STD cab: P. 12 - P. 16
In the case of US cab: P. 17

5-3-1 In the case of STD cab

(a) Install the roof cover (Fig. 5.12).

Use roof cover clips (05) to fix the roof cover. After connecting the connector at
the back of the junction switch, fix the junction switch using screws, working
from top of the roof cover (front end). When you install the roof cover (rear), it is
necessary to deform it slightly, so work carefully to avoid damaging, etc. it.
※ Use new clips for roof cover.
Junction switch (wiper-use Roof cover (rear)
contact switch) ※ It is necessary to deform
※ Properly wire the the roof cover slightly
connector at the back during the installation work,
of the switch. so work carefully to
Roof cover avoiding damaging, etc. it.
(center)

Install the screw

(2 locations).

Details

Roof cover
(left front)

Roof cover
(front end)
Roof cover (right front)

(05) 4662718 ∼ 16
(Clip)
Protrusion ※ Before inserting the clip, confirm that the lock
Inserted of the clip is released. Once the clip is inserted,
Before insertion push in the protrusion to lock the clip.
(locked state)
(lock release state)
How to use a “screw rivet”
・To lock, insert into the hole and push the protrusion.
・To unlock, turn the inner pin.

Fig. 5.12 Cab interior ceiling (STD cab)

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Room lamp
(b) Install the room lamp (Fig. 5.13). ※ Properly wire the connector
After connecting the connector at the back of the lamp.
to the back of the room lamp,
use screws to install the room
lamp and lamp cover. Lamp cover

Install the screws

(2 locations).

Fig. 5.13 Room lamp at the center of cab interior

(STD cab)

Remove the screws (4 locations). ※ Install in the same way

(c) Install the speaker (Fig. 5.14). ※ The speaker grill and speaker as for the opposite side.
are tightened jointly
After connecting the
connector to the back of the
speaker, install the speaker, Speaker
※ Properly wire the
speaker grill and screw in the connector at the back
given order (2 locations, left of the speaker.
and right).
Speaker grill

Fig. 5.14 Speaker at the cab interior rear top (STD cab)

(d) Install the pillar covers (Fig. 5.15).

Use screws, clips and hook to fix the pillar covers.
Install the screws (2 locations).
※ In the same way, install the Right pillar cover
screws to the left pillar
cover side,
Remove the hook.

Left pillar cover

Details Install the screws (2 locations). Install the clips (2 locations).

Fig. 5.15 Pillar cover at the cab interior rear (STD cab)
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(e) Install the glass holder-use bracket (Fig. 5.16)
ZH200-204

Install the screws

Install the screws (2 locations).
(2 locations).

Bracket Bracket

Install the Install the

screws screws
(2 locations). (2 locations).

Fig. 5.16 Pillar cover at the cab interior rear

(with the glass holder-use bracket attached) (STD cab)

(f) Install the guard pipe (Fig. 5.17)

Right pillar cover

Guard pipe

Install the screws

Retighten the screw as (2 locations).
moving the guard pipe
loosens it (2 locations).

Fig. 5.17 Guard pipe at the right side of cab interior (STD cab)
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(g) Install the rear cover (Figs. 5.18 and 5.19). ZH200-204
Install the tray, top cover, right cover and left cover in the given
order.
Install each bolt, screw, cap, etc.
※ For details of work procedure, refer to the “Removal/installation
of cab” section in the Workshop Manual.

Top cover
Install the screws ※ Before installing the left cover,
(9 locations). properly wire the connectors of
the lighter and 12V power socket.

Left cover

Install the bolt.

Tray
Right cover
Install the bolts and
washers (2 locations).

Fig. 5.18. Rear cover at the cab interior rear (with the cap removed) (STD cab)

Install the caps

(screwed type) Remove the caps (5 locations).
(2 locations). Top cover

Install the fuse cover.

Left cover

Right cover Tray

Details

Fig. 5.19. Rear cover at the cab interior rear (with the cap installed) (STD cab)
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5-3-2 In the case of US cab ZH200-204
(a) Install the roof cover (Fig. 5.20).
Use roof cover clips (05) to fix the roof cover. After connecting the
connector at the back of the junction switch, fix the junction switch
using screws, working from top of the roof cover (front end).
When you install the roof cover (rear), it is necessary to deform it
slightly, so work carefully to avoid damaging, etc. it.
※ Use new clips for roof cover.

Junction switch Position ○ as shown in the

(wiper-use contact switch)
※ Properly wire the connector
at the back of the switch.
photograph at right comes in
contact with the protrusion inside
the cab (rail) and is prone to
damage. Wind protection tape, etc.
around it.

Roof cover (rear)

※ It is necessary to deform
the roof cover slightly
Install the screw during the installation work,
(2 locations). so work carefully to Roof cover (rear)
avoiding damaging, etc. it. installation process
Details

Roof cover
(left front)

Roof cover
(front end)
Roof cover (right front)

(05) 4662718 ∼ 20
(Clip)
Protrusion ※ Before inserting the clip, confirm that the lock
Inserted of the clip is released. Once the clip is inserted,
Before insertion push in the protrusion to lock the clip.
(lock release state) (locked state)
How to use a “screw rivet”
・To lock, insert into the hole and push the protrusion.
・To unlock, turn the inner pin.

Fig. 5.20 Cab interior ceiling (US cab)

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6 Reassembly of roof (work procedure for cab exterior) ZH200-204
(a) Remove the iron plate roof.
Remove the lock pin that fastens the gas spring to the iron plate roof. Remove the gas spring
from the roof. In addition, remove the bolt to remove the iron plate roof from the cab.
※ Discard the lock pin and iron plate roof as they are no longer used. However, the bolts will
be reused. Store properly so that they are not misplaced.

(b) Install the polycarbonate roof (Fig. 6.1).

Install polycarbonate roof (00) to the cab by performing step (a) in the reverse order. To install,
use new lock pins (07) and bolts that were used to install the iron plate roof.

(07) 4022697 ∼ 1/2

(Pin, lock)

(00) XB00000957 ∼ 1 Gas spring

(Roof) [polycarbonate]

(07) 4022697 ∼ 1/2

(Pin, lock)

Install the roof with bolts

(4 locations)
※ Tightening torque: 10N・m
Gas spring

※ The illustration shows the structure of

the area surrounding the polycarbonate
roof. The same structure applies to all
iron plate roofs with the exception of
roof (00).

Fig. 6.1 Structure of the area surrounding the polycarbonate roof

7 Inspection items
・Check to make sure that the parts are properly installed.
・Check to make sure that there are no abnormalities to the open-close mechanism of the roof.
・Check to make sure that the roof (sunshade) slides properly.
・Check to make sure that the wiper works properly.
・(In the case of STD cab) Check to make sure that the speaker and room lamp work properly.