Assembly process No.

Painting
0950

Painting

Welded parts of exhaust pipe

(Heat-resistant silver paint) Welded parts body

Welded part of
body mount

Paint (Sent from factory for trucks in Japan)

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

Heat-resistant silver paint : Spray can

Black gray paint : Spray can

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
Cup gun set (W87-20R2S) 1
Brush 1
Paint sander (914B) 1
Paint sand paper (#80) 100
Paint sand paper (#180) 10

Other remarks

146
Assembly process No. Touchup
0960

Touchup

* The paint may be removed from the parts on which slings were installed or which were machined or
bruised. Touch up those parts.
Touch up each part with paint of the color around it. (See 5-2. Touchup paint list.)
(Always touch up parts (1) – (3) shown below. Touch up the other parts if the paint is removed from
them.)
(1) Machined part of tire
(2) Hoist cylinder clamp
(3) Bruised part of pin

Precautions Necessary tools Necessary equipment

* Work on both sides similarly. Name Q'ty Name Q'ty
(See 5-2. Touchup paint
list)

Other remarks

147
 Assembly procedure No. Sticking of front axle decal
1000

Ｙ
Ｙ
Front axle -R.H.

Front axle -L.H.

Sticking of front axle decal

1. Stick the decals to the front axle. (Stick to the cover side.
Front axle R.H. is on the front side and front axle L.H. is on
the rear side.)

50
③General overseas Cover
countries and Indonesia ⑤Japan
③④⑤
④USA & Puerto Rico

View Y

No. Part No. Part Name Q'ty State of part (Parts list No.)
(3) 09659-A0881 Plate 2 Separately Packed （HD785-7-1001）
(4) 09659-33000 Plate 2 Separately Packed （HD785-7-1002）
(5) 09659-A0880 Plate 2 Separately Packed （HD785-7-1000）

Cautions Special tool Necessary Equipment

1. Note that different front axle decals ((3) - Name Q’ty Name Q’ty
(5)) are used for different destinations.
(Necessary quantity: 2 pieces/machine)

Other remarks
Sales code： (3) 2ZZ02 （General overseas countries ）, 2ZZ39 （Indonesia）
(4) 2ZZ03 （USA ＆ Puerto Rico)
(5) 2ZZ01 （Japan）

148
Assembly process No. Operating procedure of prelubrication system
1020-1 (If equipped: Engine prelubrication specification)

Operating procedure of prelubrication system

A. In normal state
1. Turn "ON" the starting switch in
the cab. (See Fig. 1.)
2. Check the state of the prelubrica-
tion indicator on the left side of the
starting switch.
• State of prelubrication indicator
Blinking : Engine needs to be
prelubricated.
Lighting : Engine is being prelubricated.
OFF : Prelubrication is finished (Engine can be started).
3. Start the engine according to the state of the prelubrication indicator.
3-a) Prelubrication indicator is blinking
Step 1. Turn the starting switch to the "START"
position and wait until the prelubrication
indicator stops blinking and lights up and
then release the starting switch. (The
released starting switch returns automati-
cally to the "ON" position.)
Step 2. Prelubrication is finished in 10 – 60 sec-
onds.
(If the engine temperature is low (the cool-
ant temperature is -5 °C or below), the preheater operates automatically after prelu-
brication is finished. Check the state of preheat lamp.) (See Fig. 3.)
• Preheat lamp
ON : Engine is being preheated.
OFF : Preheating is finished.
Step 3. Check the prelubrication indicator.
• If the indicator is blinking, wait for 60 seconds and then repeat steps 1 – 3 (up to 3
times).
• If the indicator is turned OFF, turn the starting switch to the "START" position to
start the engine.
3-b) Prelubrication indicator is turned OFF.
• Turn the starting switch to the "START" position to start the engine.
B. Procedure for connecting emergency start connector (when prelubricator is broken and engine can-
not be started)
1. There are 2 each of the 3-pole connectors tagged with "PRE1" and "PRE2" around the prelubri-
cation controller under the passenger seat, and the connectors of the same tags are connected
to each other.
2. To start the engine without performing prelubrication, disconnect the 2 couples of the connectors
and connect "PRE1 (male)" to "PRE2 (female)" and connect "PRE1 (female)" to "PRE2 (male)".
(See Fig. 4.)
3. Turn the starting switch to the "START" position, and the engine skips prelubrication and starts.
• If prelubrication is skipped while the engine is cold, when the starting switch is turned to the
"ON" position, the preheater operates. (The preheat lamp does not light, however.)

149
Assembly process No. Operating procedure of prelubrication system
1020-2 (If equipped: Engine prelubrication specification)

Operating procedure of prelubrication system

STARTING SWITCH CONNECTOR

FOR EMERGENCY
PURELUBE SET ON RELAY

ENGINE CONTROLLER
PURELUBE OIL
PREHEAT SIGNAL PRESSURE SWITCH

PRE1 PRE1
(FEMALE) (MALE)

(BATTERY) PREHEAT RELAY

PRE2 PRE2
(MALE) (FEMALE)
TO DRIVE RELAY

PURELUBE
CONTROLLER

STARTER RELAY

ENGINE START
AUTHORIZE RELAY

PURELUBE START
CONNECTOR AUTHORIZE RELAY
FOR EMERGENCY

PURELUBE PUMP PURELUBE RELAY

PRE1 PRE1
(FEMALE) (MALE)

PRE2
PRE2
(FEMALE)
(MALE)

CONNECTING EMERGENCY START CONNECTOR

Fig. 4

CHECK VALVE

PRESSURE HOSE PRELUBE PUMP

ENGINE

OIL FILTER

SUCTION HOSE

150
Assembly process No. Installation of chocks (If equipped)
1100

Installation of chocks

1. Install the bracket to the front of the frame.

2. Install the chocks

Part No. Part name Q'ty Condition of parts

(1) 569-98-63110 Bracket 1 Loose-supply item (Separately packed)
(2) 569-95-46820 Stopper, (Tire) 2 Loose-supply item (Separately packed)
(3) 01010-81625 Bolt 4 Loose-supply item (Separately packed)
(4) 01643-31645 Washer 4 Loose-supply item (Separately packed)

Precautions Necessary tools Necessary equipment

Name Q'ty Name Q'ty

Other remarks

151
Assembly process No. Installation of radiator curtain (If equipped)
1200

Installation of radiator curtain

1. Remove the installed snaps (2)

and washers (3).

2. Install curtain (1) with the snaps (2)

and washers (3) removed in step 1.

Point marked with

: 22 places

Point marked with

: 22 places

Section A-A

Part No. Part name Q'ty Condition of part (Parts list No.)
(1) 561-84-81810 Curtain 1 Packed separately (HD785-7-1200)
(2) 409-03-19130 Snap 22 Installed to machine
(3) 01602-20720 Washer 22 Installed to machine

Precautions Necessary tools Necessary equipment

Name Q'ty Name Q'ty

Other remarks

152
Assembly process No. Decal pasting of fire extinguisher location
1260

Pasting of boom decal

1. Put a decal of fire extinguisher location to the designated position in the following figure.

FWD
fire extinguisher location
(Hiding with a fire extinguisher
is available)
①

(For Russia)
* Take care of the top and bottom and the left and right.

Part No. Part name Q’ty State of part (Part list No.)
(1) 09950-00001 PLATE, INSTRUCTION 1 Parts shipped with machine

Precautions Necessary tools Necessary equipment

Name Q'ty Name Q'ty

Other remarks

153
Assembly process No. Installation and connection of beacon lamp
1300 (If equipped: Yellow beacon lamp specification)

Tighten together with

Installation and connection of beacon lamp beacon lamp mounting nut.
Connect: PR04B (Ground)

Connect: PR04 (Beacon lamp)

Section B-B

1. Remove the nut of beacon lamp (1)

and install it to bracket (2).
Section A-A
2. Install cover (4) to the beacon lamp with
Detail of part P
bolts (5).
3. Install the beacon lamp to the right platform with bolts (3).
4. Fix the beacon harness coming out of the right front support with
clips (6).
1 place: Tighten with beacon lamp mounting nut.
1 place: Fix with bolt (10).
5. Connect the beacon harness coming out of the right front support.
CN PR04 : Beacon lamp
CN PR04B : Ground ... Install with bolt (7), washer (8) and nut (9).
* If the ground connecting part is stained or painted, remove all the
View Z
stain or paint.
Part No. Part name Q'ty Condition of parts
(1) 08154-12400 Lamp, beacon 1 Packed separately (HD785-7-1300)
(2) 561-85-81340 Bracket 1 Packed separately (HD785-7-1300)
(3) 01024-81020 Bolt, sems 4 Packed separately (HD785-7-1300)
(4) 569-85-88570 Cover 1 Packed separately (HD785-7-1300)
(5) 01024-81025 Bolt, sems 2 Packed separately (HD785-7-1300)
(6) 04434-50810 Clip 2 Packed separately (HD785-7-1300)
(7) 01024-80825 Bolt, sems 1 Packed separately (HD785-7-1300)
(8) 01643-30823 Washer 1 Packed separately (HD785-7-1300)
(9) 01580-10806 Nut 1 Packed separately (HD785-7-1300)
(10) 01024-81016 Bolt, sems 1 Packed separately (HD785-7-1300)
Precautions Necessary tools Necessary equipment
Name Q'ty Name Q'ty

Other remarks

154
Assembly procedure No. Assembly of power ladder step -1 (If equipped)
1400

Assembly of power ladder step -1 Fig.1 Set edge

1. Install the handrail to the ladder. Up side up.
* When installing clamp (3), see "Fig. 1".

Set rear side

⑥⑦ down.
Photo of clamp (3)

① Weight： 76.69 kg

③④⑤ ★ marks ： 3 places

Part No. Part name Q'ty State of parts (Parts list No.)
(1) 561-89-86933 Step 1 Packed separately （HD785-7K-020）
(2) 561-89-86961 Guard 1 Packed separately （HD785-7K-020）
(3) 561-54-61910 Clamp 3 Packed separately （HD785-7K-020）
(4) 01010-81635 Bolt 6 Packed separately （HD785-7K-020）
(5) 01643-31645 Washer 6 Packed separately （HD785-7K-020）
(6) 561-89-86810 Plate 1 Packed separately （HD785-7K-020）
(7) 01024-81025 Bolt, sems 2 Packed separately （HD785-7K-020）

Precautions Necessary tools Necessary equipment

Name Q'ty Name Q'ty
Nylon sling 1 Crane （25 ton） 1
（250 mm wide x 5 m）

Other remarks
Sales code : 6HB55A

155
Assembly procedure No. Assembly of power ladder step -2 (If equipped)
1410

Assembly of power ladder step -2

1. Install the step to the under mirror.
* When installing mirror, see "Fig. 1".
Fig.1 63

90°
View Z
①

Detail of part A

Ｚ
②
⑤⑥
③④ View Z

Part No. Part name Q'ty State of parts (Parts list No.)
(1) 561-89-8693A Step assembly 1 See field assembly procedure No.0481.
(2) 561-89-8A780 Stay 1 Packed separately （HD785-7K-010）
(3) 07283-32236 Clip 2 Packed separately （HD785-7K-010）
(4) 07283-52232 Seat 2 Packed separately （HD785-7K-010）
(5) 01643-31032 Washer 4 Packed separately （HD785-7K-010）
(6) 01597-01009 Nut 4 Packed separately （HD785-7K-010）
(7) 569-54-8C330 Mirror 1 Packed separately （HD785-7K-010）
Precautions Necessary tools Necessary equipment
Name Q'ty Name Q'ty
Nylon sling 1 Crane （25 ton） 1
（250 mm wide x 5 m）

Other remarks
Sales code : 6HB55A

156
Assembly procedure No. Assembly of power ladder step -3 (If equipped)
1420

Assembly of power ladder step -3

1. Install the handrail to the ladder.
* When installing clamp (3), see "Fig. 1".

③④⑤
★ marks ： 3 places

A
①
Weight ：74.10 kg

⑦⑧⑨
◆ marks ： 3 places

⑥
Detail of part A

Part No. Part name Q'ty State of parts (Parts list No.)
(1) 561-89-86911 Ladder 1 Packed separately （HD785-7K-020）
(2) 561-89-87170 Guard 1 Packed separately （HD785-7K-020）
(3) 561-54-61910 Clamp 3 Packed separately （HD785-7K-020）
(4) 01010-81635 Bolt 6 Packed separately （HD785-7K-020）
(5) 01643-31645 Washer 6 Packed separately （HD785-7K-020）
(6) 561-89-87180 Guard 1 Packed separately （HD785-7K-020）
(7) 01024-81245 Bolt, sems 3 Packed separately （HD785-7K-020）
(8) 01643-31232 Washer 3 Packed separately （HD785-7K-020）
(9) 01580-11210 Nut 3 Packed separately （HD785-7K-020）
Precautions Necessary tools Necessary equipment
Name Q'ty Name Q'ty
Nylon sling 1 Crane （25 ton） 1
（250 mm wide x 5 m）

Other remarks
Sales code : 6HB55A

157
Assembly procedure No. Assembly of power ladder main part -1 (If equipped)
1430

Assembly of power ladder main part -1

1. Install the step assembly to the front side of the cab.

①
⑧ ⑤
④
③
②

④
⑦ ⑥

Part No. Part name Q'ty State of parts (Parts list No.)
(1) 561-89-869A Ladder assembly 1 See field assembly procedure No.1410.
(2) 566-54-12212 Cushion 4 Packed separately （HD785-7K-030）
(3) 566-54-21910 Bushing 2 Packed separately （HD785-7K-030）
(4) 566-54-21920 Plate 4 Packed separately （HD785-7K-030）
(5) 01011-82015 Bolt 2 Packed separately （HD785-7K-030）
(6) 01580-12016 Nut 2 Packed separately （HD785-7K-030）
(7) 01643-32060 Washer 2 Packed separately （HD785-7K-030）
(8) 566-54-21931 Plate 2 Packed separately （HD785-7K-030）

Precautions Necessary tools Necessary equipment

Name Q'ty Name Q'ty
Nylon sling 1 Crane （25 ton） 1
（250 mm wide x 5 m）

Other remarks
Sales code : 6HB55A

158
Assembly procedure No. Assembly of power ladder main part -2 (If equipped)
1440

Assembly of power ladder main part -2

1. Install the rod assembly to the front side of the cab.

④
⑤
⑦ ②
④
③ ⑦
A-A ⑥

④
A
⑥ ②

① ⑦
A
③
B B-B

④ ⑦ ⑤
B

Part No. Part name Q'ty State of parts (Parts list No.)
(1) 561-89-6A970 Rod 1 Packed separately （HD785-7K-050）
(2) 566-54-12212 Cushion 4 Packed separately （HD785-7K-050）
(3) 566-54-21910 Bushing 2 Packed separately （HD785-7K-050）
(4) 566-54-21920 Plate 4 Packed separately （HD785-7K-050）
(5) 01597-02016 Nut 2 Packed separately （HD785-7K-050）
(6) 01583-12012 Nut 4 Packed separately （HD785-7K-050）
(7) 01643-32060 Washer 4 Packed separately （HD785-7K-050）
Precautions Necessary tools Necessary equipment
Name Q'ty Name Q'ty
Nylon sling 1 Crane （25 ton） 1
（250 mm wide x 5 m）

Other remarks
Sales code : 6HB55A

159
Assembly procedure No. Assembly of power ladder main part -3 (If equipped)
1450

Assembly of power ladder main part -3

1. Install the ladder assembly to the front side of the cab.

★ ★ ★

★ ★ ★

View Z

②
★ marks ： 6 places

Part No. Part name Q'ty State of parts (Parts list No.)
(1) 561-89-8691A Ladder assembly 1 See field assembly procedure No.1420.
(2) 01024-81235 Bolt, sems 6 Packed separately （HD785-7K-030）

Precautions Necessary tools Necessary equipment

Name Q'ty Name Q'ty

Other remarks
Sales code : 6HB55A

160
Assembly procedure No. Assembly of power ladder main part -4 (If equipped)
1460

Assembly of power ladder main part -4

1. Install the bumper to the step sub-assembly.

Section A-A

③④ ②④
2 places ★ marks ：
6 places

A
①
Weight ： 212.8 ㎏

Part No. Part name Q'ty State of parts (Parts list No.)
(1) 561-89-87031 Step sub-assembly 1 Packed separately （HD785-7K-020）
(2) 01010-81645 Bolt 6 Packed separately （HD785-7K-020）
(3) 01010-81655 Bolt 2 Packed separately （HD785-7K-020）
(4) 01643-31645 Washer 8 Packed separately （HD785-7K-020）

Precautions Necessary tools Necessary equipment

Name Q'ty Name Q'ty

Other remarks
Sales code : 6HB55A

161