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DESCRIPTION
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ZX120-5_ZX330-5-201
ZH200-A-207
SUBJECT ZH200-5B-204
PROCEDURE FOR INSTALLING AND MODIFYING HEADLAMPS OF
ZX-5/ZH STANDARD MACHINE CABS

OUTLINE
This service bulletin contains the procedure for installing headlamps of ZX-5/ZH standard
machine cabs.

If customers want to have headlamps installed, install them in accordance with this service
bulletin.
*The parts list does not include the sealing compound “Super-X No. 8008 black (product code:
AX-123) made by Cemedine Co., Ltd.”
Prepare the sealing compound separately before starting installation.

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.

Machine Model(s): ZX120-5 to ZX330-5 and ZH200-A/-5B

DESCRIPTION

Refer to the following page(s).

DWN
CHKD
SA/GI: ZX-5 (all)-054, ZH200-031 WHITE APPD
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Table of Contents ZX120-5_ZX330-5-201
ZH200-A-207
ZH200-5B-204

1 Models affected Page 3

2 List of headlamp installation specifications Page 4

3 Parts list Page 5

4 Removing the interior parts Page 8

4-1. Removing the rear covers Page 8

4-2. Removing the pillar covers Page 9
4-3. Removing the roof covers Page 11

5 Installing the headlamps Page 13

5-1. Routing the harness in the cab Page 13

5-2. Installing the electrical equipment Page 16
5-2-1. Two-lamp specification (ZX5 (standard machine cab)) Page 16
5-2-2. Two-lamp specification (ZH) Page 18
5-2-3. Four-lamp specification Page 20
5-3. Installing the lamps Page 21
5-3-1. Two over-cab lamps Page 21
5-3-2. Four over-cab lamps Page 23
5-3-3. Two under-rain visor lamps Page 25
5-3-4. Four under-rain visor lamps Page 27

6 Assembling the interior parts Page 29

6-1. Installing the roof covers Page 29

6-2. Installing the pillar covers Page 31
6-3. Installing the rear covers Page 33

7 Inspection items Page 34

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1 Models affected ZX120-5_ZX330-5-201
ZH200-A-207
Representative models ZH200-5B-204
ZX120-5 / ZX160-5 / ZX180-5 / ZX200-5 / ZX240-5 /
ZX280-5 / ZX330-5 / ZH200-A / ZH200-5B

*For the latest information, use the menu for searching for models affected.
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2 List of headlamp installation specifications ZX120-5_ZX330-5-201
ZH200-A-207
There are four kinds of specifications: two over-cab lamps, four over-cab lamps, ZH200-5B-204
two under-rain visor lamps, and four under-rain visor lamps (Fig. 2.1 to Fig. 2.4).
The details in 5-2. “Installing the electrical equipment” and 5-3. “Installing the lamps” vary depending on the
specification. All other work is the same.

Two over-cab lamps

This service bulletin contains the procedures for the
specifications for two over-cab lamps.
For the parts used for the ZX5 (standard machine cab),
refer to Table 3.1 (page 5) and for the ZH, refer to Table
3.2 (page 6).

Fig. 2.1 Appearance of two over-cab lamps after

installation
Four over-cab lamps
Add the lamps, the harnesses used for the additional
lamps (electrical equipment), and other parts to the
parts for the specifications for two over-cab lamps.
For additional parts, refer to Table 3.3 (page 7).

Fig. 2.2 Appearance of four over-cab lamps after

installation
Two under-rain visor lamps
Add a bracket for hanging the lamps and clips for
routing the harnesses to the parts for the specifications
for two over-cab lamps.
For additional parts, refer to Table 3.4 (page 7).
*The rain visor should be ordered separately.

Fig. 2.3 Appearance of two under-rain visor lamps

after installation
Four under-rain visor lamps
Add the lamps, a bracket for hanging the lamps, clips for
routing the harnesses, harnesses used for the additional
lamps (electrical equipment), and other parts to the
parts for the specifications for two over-cab lamps.
For additional parts, refer to Table 3.5 (page 7).
*The rain visor should be ordered separately.

Fig. 2.4 Appearance of four under-rain visor lamps

after installation
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3 Parts list ZX120-5_ZX330-5-201
ZH200-A-207
ZH200-5B-204

Table 3.1 Parts for the specifications for two over-cab lamps for the ZX5 (standard machine cab)
Page to be
Code Part No. Part Qty Remarks
referenced
00 4722649 Harness: Wire 1 13 Headlamp harness (in the cab)
01 4654945 Clip: Band 3 14
*1 02 4121859 Clip: Band 2 15 For routing the harness (in the cab)
03 4662758 Clip 1 15
04 4662718 Clip 14 29 For reinstalling the roof covers
05 2053073 Harness: Wire 1 16 Additional fuse box
*2 06 J460620 Screw: Sems 2 16 For installing the additional fuse box
07 4055312 Clip: Band 2 16 For routing the harness (additional fuse box)
08 4680516 Harness: Wire 1 17 Electrical equipment harness
09 4436534 Relay 1 17 Headlamp relay
10 4055312 Clip: Band 2 17
For routing the harness (electrical equipment)
11 4254600 Clip 1 17
12 YA00031006 Bracket 1 17
For installing the relay
13 J260816 Bolt: Sems 2 17
14 4274478 Lamp: Head 2 21 Headlamp
15 8104656 Bracket 2 21
For installing the headlamps
16 J271230 Bolt: Sems 2 21
17 4652915 Harness: Wire 1 22 Headlamp harness (outside the cab)
18 4259220 Clip: Band 6 22
19 4257159 Bracket 1 21
For routing the harness (outside the cab)
*3 20 J271025 Bolt: Sems 1 21
21 4654945 Clip: Band 1 22
*5 22 7054613 Bracket 1 21 Headlamp base bracket
*4 23 J781225 Bolt: Socket 2 21
For installing the headlamp base bracket
24 A590112 Washer: Plane 2 21
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ZX120-5_ZX330-5-201
ZH200-A-207
ZH200-5B-204
Table 3.2 Parts for the specifications for two over-cab lamps for the ZH
Page to be
Code Part No. Part Qty Remarks
referenced
00 4722649 Harness: Wire 1 13 Headlamp harness (in the cab)
01 4654945 Clip: Band 3 14
*1 02 4121859 Clip: Band 2 15 For routing the harness (in the cab)
03 4662758 Clip 1 15
04 4662718 Clip 14 29 For reinstalling the roof covers
08 4680516 Harness: Wire 1 18 Electrical equipment harness
09 4436534 Relay 1 18 Headlamp relay
10 4055312 Clip: Band 2 19
For routing the harness (electrical equipment)
11 4254600 Clip: Band 1 18
12 YA00031006 Bracket 1 18
For installing the relay
13 J260816 Bolt: Sems 2 18
14 4274478 Lamp: Head 2 21 Headlamp
15 8104656 Bracket 2 21
For installing the headlamps
16 J271230 Bolt: Sems 2 21
17 4652915 Harness: Wire 1 22 Headlamp harness (outside the cab)
18 4259220 Clip: Band 6 22
19 4257159 Bracket 1 21 For routing the harness (outside the cab)
*3 20 J271025 Bolt: Sems 1 21
21 4654945 Clip: Band 1 22 For routing the harness (outside the cab)
*5 22 7054613 Bracket 1 21 Headlamp base bracket
*4 23 J781225 Bolt: Socket 2 21
For installing the headlamp base bracket
24 A590112 Washer: Plane 2 21
25 YA40002177 Spacer 2 18 For installing the relay bracket
26 YA40002178 Cover 1 18 For the relay
27 J460616 Screw: Sems 1 18 For installing the relay cover

*1: If the cab-side headlamp harness has been installed (refer to Fig. 3.1 (page 7)), the parts numbered 00, 01, 02, 03, and 04
in the table are not required. In addition, the work shown on pages 9 to 15 and pages 29 to 32 is not required.
*2: If the additional fuse box has been installed (refer to Fig. 3.2 (page 7)), the parts numbered 05, 06, and 07 in the table are
not required. In addition, the work shown on page 16 is not required.
*3: When installing four over-cab lamps, the part numbered 20 in the table is not required.
*4: If the rain visor has been installed (refer to Fig. 3.3 (page 7)), the parts numbered 22, 23, and 24 in the table are not
required.
*5: The part numbered 22 in the table will be changed from 7054613 to YA40007399 in August 2014.
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ZX120-5_ZX330-5-201
ZH200-A-207
Table 3.3 Additional parts for the specifications for four over-cab lamps ZH200-5B-204
Page to be
Code Part No. Part Qty Remarks
referenced
28 4680510 Harness: Wire 1 20 Electrical equipment harness
29 4436534 Relay 1 20 Headlamp relay
30 4274478 Lamp: Head 2 23 Headlamp
31 8104656 Bracket 2 23
For installing the headlamps
32 J271230 Bolt: Sems 2 23
33 4259220 Clip: Band 3 24 For routing the harness (outside the cab)

Table 3.4 Additional parts for the specifications for two under-rain visor lamps
*The rain visor should be ordered separately.
Page to be
Code Part No. Part Qty Remarks
referenced
34 2053340 Bracket 1 25 Bracket for hanging the lamps
35 4259220 Clip: Band 1 25
For routing the harness (outside the cab)
36 4055312 Clip: Band 1 26

Table 3.5 Additional parts for the specifications for four under-rain visor lamps
*The rain visor should be ordered separately.
Page to be
Code Part No. Part Qty Remarks
referenced
28 4680510 Harness: Wire 1 20 Electrical equipment harness
29 4436534 Relay 1 20 Headlamp relay
30 4274478 Lamp: Head 2 27 Headlamp
31 8104656 Bracket 2 27
For installing the headlamps
32 J271230 Bolt: Sems 2 27
34 2053340 Bracket 1 27 Bracket for hanging the lamps
35 4259220 Clip: Band 1 27
For routing the harness (outside the cab)
36 4055312 Clip: Band 1 28

Cab-side
headlamp harness

Detail

Fig. 3.1 Cab with a cab-side headlamp harness

Additional fuse box Rain visor

Fig. 3.2 Cab with an additional fuse box Fig. 3.3 Cab with a rain visor
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4 Removing the interior parts ZX120-5_ZX330-5-201
ZH200-A-207
The removed parts will be used for reassembly later. Be careful not to lose or ZH200-5B-204
damage them.

4-1 Removing the rear covers

Remove the caps, screws, bolts, and other parts shown below. Then remove the right cover, left cover, upper
cover, and tray in this order (Fig. 4.1 and 4.2).
*For details on the work procedure, refer to the workshop manual “Removing and installing the cab.”

Remove the five caps.

Remove the two screw Upper cover
caps.

Remove the fuse

cover.

Left cover

Detail Right cover Tray

Fig. 4.1 Rear of the inside of the cab: Rear cover (before removing the caps)

Upper cover *Before removing the left cover,

disengage the connectors of the
lighter and 12-V power socket.
Remove the
nine screws.

Left cover

右
Remove the bolt.

Tray
Right cover Remove the two bolts
and washers.

Fig. 4.2 Rear of the inside of the cab: Rear cover (after removing the caps)
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4-2
スク Removing the pillar covers
ZX120-5_ZX330-5-201
*If the cab-side headlamp harness has been installed (refer to Fig. 3.1 (page 7)), ZH200-A-207
this work is not required. ZH200-5B-204

(a) Move the guard pipes out of the way (Fig. 4.3).
Right pillar cover

Guard pipes

Move the guard pipes

so that the right pillar
cover can be removed.

Remove the two caps

and bolts.

Fig. 4.3 Right side of the inside of the cab: Guard pipe

(b) Remove the glass holder brackets (Fig. 4.4).

Remove the two

Remove the two screws.
screws.

Bracket Bracket

Remove the two Remove the two

screws. screws.

Fig. 4.4 Rear of the inside of the cab: Pillar cover (with the glass holder
brackets installed)
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(c) Remove the pillar covers (Fig. 4.5).
Remove the screws, clips, and hook. Then, remove the pillar covers. ZX120-5_ZX330-5-201
ZH200-A-207
ZH200-5B-204

Remove the hook.

Right pillar cover

Left pillar cover

Remove the two screws.

Remove the two clips.

Remove the two screws.

*Remove the screws on
the left pillar as well.

Detail

Fig. 4.5 Rear of the inside of the cab: Pillar cover

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4-3
スク
左ピ Removing the roof covers
ZX120-5_ZX330-5-201
*If the cab-side headlamp harness has been installed (refer to Fig. 3.1 (page 7)), ZH200-A-207
this work is not required. ZH200-5B-204

(a) Remove the speakers (Fig. 4.6).

Remove the screws, speaker grilles, and speakers in this order (two sections).
Speaker
*Disengage the connector
*Remove the parts on the opposite side as well.
on the back of the speaker.

Speaker
grille

Remove the four screws.

*The speaker grille and speaker
are tightened to each other.

Fig. 4.6 Upper section of the rear of the inside of the cab: Speaker

(b) Remove the room lamp (Fig. 4.7).

Remove the lamp cover, screws, and room lamp body in this order.
When removing the lamp cover, insert a small flathead driver into the grooves located in the four areas
shown in Fig. 4.7 (marked with the asterisks) and evenly pry these four places to gradually remove the
cover.
(Prying only one place may damage the lamp cover hooks.)

*
*

Lamp cover
※
*
Remove the two
screws. *
Fig. 4.7 Center of the roof inside the cab: Room lamp
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(c) Remove the roof covers (Fig. 4.8).
Remove the roof cover clips (refer to Fig. 4.9) and then remove the roof covers. ZX120-5_ZX330-5-201
When removing the roof cover (rear), the cover needs to be slightly bent. ZH200-A-207
Be careful not to damage it. ZH200-5B-204
*When assembling the covers again, use new roof cover clips ((04) 4662718, 14 pieces).

Roof cover (front)

Remove three of
the 14 clips.

Remove three of
the 14 clips.
Remove two of the
14 clips.

Remove three of
the 14 clips.

Remove two of
the 14 clips.

Remove one of Roof cover (rear)

the 14 clips.

Fig. 4.8 Roof inside the cab

Pop-up head

When locked
When inserted

Unlocked
Locked
Screw rivets are used for the roof cover clips. When
removing them, use a screwdriver to only turn the inside
pin by 45 degrees. If the tip of the inside pin springs out,
the clip is unlocked. The clip can then be removed.
*Screw rivet:
- Inserting a rivet into a hole and pressing the pop-up
head locks the rivet.
- Turn the inside pin to unlock the rivet to remove it.

Fig. 4.9 Structure of roof cover clips

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5 Installing the headlamps ZX120-5_ZX330-5-201
ZH200-A-207
5-1 Routing the harness in the cab ZH200-5B-204
*If the cab-side headlamp harness has been installed (refer to Fig. 3.1 (page 7)), this work is not required.

(a) Remove the grommet from the upper right corner in the front of the cab (Fig. 5.1).

Remove the grommet installed in the upper

right of the front of the cab.
*Sealing compound has been applied, so use
a cutter or other tool to remove it.

Fig. 5.1 Outside of the cab: Upper right corner of the front (before removing the grommet)

(b) Put the cab-side headlamp harness through the hole opened in Step (a) (Fig. 5.2).

5
Put the cab-side headlamp harness ((00) 4722649) through the hole
opened by removing the grommet.
Fit the grommet that came with the cab-side headlamp harness into the
hole. Apply sealing compound (Super-X No. 8008, black (or equivalent))
around the grommet (separately prepare the sealing compound).
Super-X No. 8008 black (product code:
AX-123) made by Cemedine Co., Ltd.
(00) 4722649, one piece *Curing time: Approximately 60 minutes
(Harness: Wire) (at 20°C)

Section to which Super-X

should be applied

Detail
Fig. 5.2 Outside of the cab: Upper right corner of the front (after installing the harness)
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(c) Route the cab-side headlamp harness in the cab (Fig. 5.3 to Fig. 5.6).
ZX120-5_ZX330-5-201
ZH200-A-207
ZH200-5B-204

(01) 4654945, one of the three clips

(Clip: Band)
* Fix the cab-side headlamp harness ((00)
4722649) to the upper side of the rail bracket.

Rail

Fig. 5.3 Inside the cab: Right front section of the roof

Rail

(01) 4654945, two of the three clips

(Clip: Band)
*Fix the cab-side headlamp harness ((00)
4722649) to the upper side of the rail bracket.

Fig. 5.4 Inside the cab: Section above the right window
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ZX120-5_ZX330-5-201
ZH200-A-207
ZH200-5B-204

Frame (cab)

(02) 4121859, one of the two clips

(Clip: Band)
* Fix the cab-side headlamp
harness ((00) 4722649) to the
underside of the frame.

Fig. 5.5 Inside the cab: Right corner above the rear window

Frame (cab)

(02) 4121859, one of the two clips

(Clip: Band)
* Fix the cab-side headlamp (03) 4662758,
harness ((00) 4722649) to the one piece
underside of the frame. (Clip)

* Be careful to route the harness so that it

does not hinder pillar cover installation.

Fig. 5.6 Inside the cab: Left corner above the rear window
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5-2 Installing the electrical equipment
ZX120-5_ZX330-5-201
5-2-1. Two-lamp specification (ZX5 (standard machine cab)) ZH200-A-207
(a) Install the additional fuse box (Fig. 5.7). ZH200-5B-204
* If the additional fuse box has been installed (refer to Fig. 3.2 (page 7)),
this work is not required.

Connect the fuse box to the cab

(05)2053073, one piece
harness connectors.
(Harness: Wire) *Additional fuse box
* The cab harness has two
(06) J460620, two pieces
connectors, connect both.
(Screw: Sems)

Detail

(07) 4055312, two pieces

(Clip: Band)

Arrow view A
Fig. 5.7 Inside the rear cover of the ZX5 (standard machine cab): Fuse box
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(b) Install the relay (Fig. 5.8 and Fig. 5.9).
Install the harness, bracket, and relay. ZX120-5_ZX330-5-201
ZH200-A-207
ZH200-5B-204
Holes for installing the
relay bracket

Fig. 5.8 Inside the rear cover of the ZX5 (standard machine cab) (before installing the relay)

Connect the relay to the white connector of the

cab-side headlamp harness ((00) 4722649).

(08) 4680516, one piece

(Harness: Wire)

(09) 4436534, one piece (10) 4055312,

(Relay) two pieces
(Clip: Band)
(12) YA00031006, one piece
(Bracket)
(13) J260816, two pieces
Connect the relay to the
(Bolt: Sems)
connector labeled [CAB LAMP
FRONT] of the additional fuse
box ((05) 2053073).
* Do not remove the caps of
connectors that are not used.

(11) 4254600, one piece

(Clip)

Fig. 5.9 Inside the rear cover of the ZX5 (standard machine cab) (after installing the relay)
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5-2-2. Two-lamp specification (ZH)
(a) Install the relay (Fig. 5.10 to Fig. 5.12).
ZX120-5_ZX330-5-201
Install the harness, bracket, and relay. ZH200-A-207
ZH200-5B-204
Holes for installing the relay
bracket (spacer)

Fig. 5.10 Inside the rear box of the ZH (before installing the relay)

(25) YA40002177, two pieces

(Spacer)
* Tighten the spacers to the controller bracket
with the bolts for fixing the controller.

(09) 4436534, one piece

(Relay)

(12) YA00031006, one piece

(Bracket)
(13) J260816, two pieces
(Bolt: Sems)

(26) YA40002178, one piece (08) 4680516, one piece

(Cover) (Harness: Wire)
(11) 4254600, one piece
(27) J460616, one piece
(Clip)
(Screw: Sems)

Fig. 5.11 Section in the rear box of the ZH (after installing the relay)
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ZX120-5_ZX330-5-201
ZH200-A-207
ZH200-5B-204

Connect the relay to the white connector

of the cab-side headlamp harness ((00)
4722649).

(10) 4055312, two pieces

(Clip: Band)

Connect the relay to the

connector labeled [CAB LAMP
FRONT] of the cab harness.

Fig. 5.12 Inside the rear box of the ZH (after installing the relay)
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5-2-3. Four-lamp specification
- Add a harness and relay to the parts for the two-lamp specifications
ZX120-5_ZX330-5-201
(Fig. 5.13). ZH200-A-207
Install the harness, bracket, and relay. ZH200-5B-204
(When only two lamps are used, this work is not required.)

*The work for the ZH is same.

*Additional part: Connect the relay to the

(29) 4436534, one piece black connector of the
(Relay) cab-side headlamp harness
((00) 4722649).

Connect the relay to the

connector labeled [CAB LAMP
FRONT +2] of the additional fuse
box ((05) 2053073).
* Do not remove the caps of
connectors that are not used.

*Additional part:
(28) 4680510, one piece
(Harness: Wire)

Fig. 5.13 Inside the rear box of the ZH5 (standard machine cab) (when installing four lamps)
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5-3 Installing the lamps
ZX120-5_ZX330-5-201
5-3-1. Two over-cab lamps ZH200-A-207
(a) Fix the lamps (Fig. 5.14). ZH200-5B-204

(14) 4274478, two pieces

(Lamp: Head)
(15) 8104656, two pieces
(Bracket)
(16) J271230, two pieces
(Bolt: Sems)

(22) 7054613, one piece

(Bracket)
* This part is not required
if the rain visor has
already been installed.

(23) J781225, two pieces * Pay attention to the positions at which

(Bolt: Socket)
(24) A590112, two pieces
(Washer: Plane)
* These parts are not required if the rain
visor has already been installed.
the lamps are installed.
Use the leftmost hole and the fourth
hole from the right.

Fig. 5.14 Appearance of two over-cab lamps after installation

(b) Route the harness (Fig. 5.15 and Fig. 5.16).

(20) J271025, one piece

(Bolt: Sems)

(19) 4257159, one piece

(Bracket)

Fig. 5.15 Outside of the cab: Upper right in front (when installing two over-cab lamps)
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ZX120-5_ZX330-5-201
ZH200-A-207
Connect the harness to the connector of
the lamp ((14) 4274478) and bind the joint
ZH200-5B-204
with a clip ((18) 4259220). (17) 4652915, one piece
(Harness, Wire)
* Install the harness so
that it does not come
into contact with any
sharp edges.
(18) 4259220, two of the
six clips
(Clip: Band) B
A
Detail A (two sections)

(18) 4259220, three of

the six clips

A
(Clip: Band)

(21) 4654945, one

piece
(Clip: Band)

Connect the harness to the

connector of the cab-side
headlamp harness ((00) 4722649).

(18) 4259220, one

of the six clips
(Clip: Band)
Detail B

Fig. 5.16 Back of the lamps (when installing two over-cab lamps)
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5-3-2. Four over-cab lamps
Add or change the work of the specifications for two over-cab lamps to that ZX120-5_ZX330-5-201
listed below (Fig. 5.17 to Fig. 5.19). ZH200-A-207
- Add two lamps. ZH200-5B-204
- Change the method for installing the connector bracket.
- Change the harness routing.
- Add clips used for routing the harness.
The work for sections without a special note is the same as that for two over-cab lamps.
*Additional parts:
(30) 4274478, two pieces
(Lamp: Head)
(31) 8104656, two pieces,
(Bracket)
(32) J271230, two pieces
(Bolt: Sems)

* Pay attention to the positions at which the lamps are installed.

Use the leftmost hole, the third hole from the left, the fourth
hole from the right, and rightmost hole.

Fig. 5.17 Appearance of four over-cab lamps after installation

* Put the connector bracket ((19) 4257159)

between the lamp bracket ((32) 8104656) and
the headlamp base bracket ((22) 7054613).
The bolt ((20) J271025) is not used.

(55)

Detail

Fig. 5.18 Outside of the cab: Upper right in front (when installing four over-cab lamps)
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ZX120-5_ZX330-5-201
ZH200-A-207
ZH200-5B-204

Connect the harness to the

connectors of the lamps ((14) and
(30) 4274478) and bind the joints
with clips ((18) and (33) 4259220).

A
A

Detail A (four sections)

A
A *Additional parts:
(33) 4259220, three pieces
(Clip: Band)

Fig. 5.19 Back of the lamps (when installing four over-cab lamps)
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5-3-3. Two under-rain visor lamps
Add or change the work of the specifications for two over-cab lamps to that ZX120-5_ZX330-5-201
listed below (Fig. 5.20 to Fig. 5.22). ZH200-A-207
- Install the lamps under the rain visor. ZH200-5B-204
- Change the harness routing.
- Add clips used for routing the harness.
The work for sections without a special note is the same as that for two over-cab lamps.
*These instructions assume that the rain visor has already been installed. (For how to install the rain visor, refer
to the relevant service bulletin.)

Rain visor

* Installation position
change:
(14) 4274478, two pieces
(Lamp: Head)
(15) 8104656, two pieces
(Bracket)
(16) J271230, two pieces
(Bolt: Sems)

Fig. 5.20 Appearance of two under-rain visor lamps after installation

Tighten the bracket for hanging the lamps ((34)

2053340) to the rain visor with the bolts used for
fixing the rain visor (two places).

*Additional part: * Installation

(34) 2053340, position change:
one piece (18) 4259220, three
(Bracket) of the six clips
(Clip: Band)

*Additional part:
(35) 4259220, one
piece
Connect the harness to the two connectors (Clip: Band)
of the two lamps ((14) 4274478).

Fig. 5.21 Back of the lamps (when installing two under-rain visor lamps)
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ZX120-5_ZX330-5-201
ZH200-A-207
ZH200-5B-204

*Additional part:
(36) 4055312, one
piece
(Clip: Band)

* Installation
position change:
(18) 4259220, two
of the six clips
(Clip: Band)

Fig. 5.22 Outside of the cab: Upper right front corner

(when installing two under-rain visor lamps)
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5-3-4. Four under-rain visor lamps
Add or change the work of the specifications for two over-cab lamps to that ZX120-5_ZX330-5-201
listed below (Fig. 5.23 to Fig. 5.25). ZH200-A-207
- Add two lamps. ZH200-5B-204
- Install the lamps under the rain visor.
- Change the harness routing.
- Add clips used for routing the harness.
The work for sections without a special note is the same as that for two over-cab lamps.
* These instructions assume that the rain visor has already been installed. (For how to install the rain visor, refer
to the relevant service bulletin.)

*Additional parts: Rain visor

(30) 4274478, two
pieces
(Lamp: Head)
(31) 8104656, two
pieces,
(Bracket)
(32) J271230, two
pieces
(Bolt: Sems)
* Installation position
change:
(14) 4274478, two pieces
(Lamp: Head)
(15) 8104656, two pieces
(Bracket)
(16) J271230, two pieces
(Bolt: Sems)

Fig. 5.23 Appearance of four under-rain visor lamps after installation

Tighten the bracket for hanging the lamps ((34)

2053340) to the rain visor with the bolts used for
fixing the rain visor (two places).

*Additional part: * Installation position

(34) 2053340, change:
one piece (18) 4259220, three
(Bracket) of the six clips
(Clip: Band)

*Additional part:
(35) 4259220, one piece
(Clip: Band)
Connect the harness to the four
connectors of the four lamps
((14) and (30) 4274478).

Fig. 5.24 Back of the lamps (when installing four under-rain visor lamps)
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ZX120-5_ZX330-5-201
ZH200-A-207
ZH200-5B-204

*Additional part:
(36) 4055312, one
piece
(Clip: Band)

* Installation position
change:
(18) 4259220, two of
the six clips
(Clip: Band)

Fig. 5.25 Outside of the cab: Upper right front corner (when installing four under-rain visor lamps)
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6 Assembling the interior parts ZX120-5_ZX330-5-201
ZH200-A-207
Assemble the interior parts removed in Step 4. “Removing the interior parts” in ZH200-5B-204
the reverse order of removal.

6-1 Installing the roof covers

(a) Install the roof covers (Fig. 6.1).
Fix the roof covers to the cab with the clips ((04) 4662718).
For instructions on how to use the clips, refer to Fig. 6.2.
*Use new clips ((04) 4662718) to fix the roof covers.

Roof cover (front) * If the roof covers have not been

removed, the clips ((04) 4662718)
are not required.

(04) 4662718, three

of the 14 clips
(Clip)

(04) 4662718, three

of the 14 clips
(Clip)
(04) 4662718, two of
the 14 clips
(04) 4662718, three (Clip)
of the 14 clips
(Clip)

(04) 4662718, two of

the 14 clips
(Clip)

(04) 4662718, one of

the 14 clips Roof cover (rear)
(Clip)

Fig. 6.1 Roof inside the cab

Pop-up head
Before inserting a clip,
make sure that the clip is
Unlocked
Locked unlocked. Insert the clip
and press the pop-up head
to lock it (Fig. 6.2).

Fig. 6.2 Structure of roof cover clips

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(b) Install the room lamp (Fig. 6.3).
Install the room lamp body with the screws and then install the lamp cover. ZX120-5_ZX330-5-201
ZH200-A-207
ZH200-5B-204

Lamp cover

Install the two screws.

Fig. 6.3 Center of the roof inside the cab: Room lamp

(c) Install the speakers (Fig. 6.4).

Connect the connector on the back of the speaker. Then install the speakers, speaker grilles, and screws
(two places).
Speaker
*Be sure to properly connect the
connector on the back of the * Install the speaker on the opposite
speaker. side as well.

Speaker
grille

Install the four screws.

* Tighten the speaker grille to the
speaker.

Fig. 6.4 Upper rear section of the inside of the cab: Speaker
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6-2 Installing the pillar covers
ZX120-5_ZX330-5-201
(a) Install the pillar covers (Fig. 6.5). ZH200-A-207
Install the pillar covers and then install the screws, clips, and hook. ZH200-5B-204

Install the two screws.

* Install the screws to the left
pillar cover as well.

Install the hook.

Right pillar cover

Left pillar cover

Install the two clips.

Install the two

screws.

Fig. 6.5 Rear of the inside of the cab: Pillar cover

(b) Install the glass holder brackets (Fig. 6.6).

When storing the lower front glass, adjust the brackets so that the glass is tightly secured.

Install the two screws.

Install the two screws.

Bracket
Bracket

Install the two screws. Install the two screws.

Fig. 6.6 Rear of the inside of the cab: Pillar cover (with the glass holder brackets installed)
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(c) Install the guard pipes (Fig. 6.7).
ZX120-5_ZX330-5-201
ZH200-A-207
ZH200-5B-204

Right pillar cover

Guard pipes

Tighten the two bolts as the Install the two caps and bolts.
bolts became loose when the
guard pipes were moved out
of the way.

Fig. 6.7 Right side of the inside of the cab: Guard pipe
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6-3 Installing the rear covers
ZX120-5_ZX330-5-201
Install the tray, upper cover, right cover, and left cover in this order. ZH200-A-207
Then install the bolts, screws, and caps (Fig. 6.8 and Fig. 6.9). ZH200-5B-204
*For the detailed work procedure, refer to the workshop manual “Removing and
installing the cab.”
Upper cover * Before installing the left cover, be sure
to properly connect the connectors of
the lighter and 12-V power socket.
Install the nine screws.

Left cover

Install the bolt.

Tray
Right cover Install the two bolts
and washers.

Fig. 6.8 Rear of the inside of the cab: Rear cover (before installing the caps)

Install the five caps.

Install the two screw caps. Upper cover

Install the fuse cover.

Left cover

Detail Right cover Tray

Fig. 6.9 Rear of the inside of the cab: Rear cover (after installing the caps)
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7 Inspection items ZX120-5_ZX330-5-201
ZH200-A-207
• When the working lamp switch (refer to Fig. 7.1) of the switch box is ZH200-5B-204
set to “2,” the headlamps must turn on.

• When the working lamp switch (refer to Fig. 7.1) of the switch box is set to “OFF” or “1,” the
headlamps must not turn on.

• Water must not be able to get in from the place where Super-X was applied (refer to Fig. 5.2 on page
13).

* If any of the following specifications are installed, the front may interfere with the
headlamp(s) and rain visor. Be sure to inform the customers of this issue.

• Four headlamps are installed

• A rain visor is installed
• A front other than the standard bucket is installed

Work lamp switch

Fig 7.1 Switch box