1.

Drawings of removed units

1．Bare machine (Mobile shipping style) 2．Split parts of left handrail

Specifications of HM400-3M0 completed truck

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

Self-propelled travel 34120 11105 3450 3735

2. Dimensions of removed units

No. Unit name Weight (kg) Overall length (mm) Overall width (mm) Overall height (mm)

1 Bare machine 34116 11122 3450 3735

2 Exterior parts (2 pcs.) 3.2 - - -

1
 3. Assembly procedure, necessary equipments, and schedule (non travel)
Day 1st day
Hour 1 2 3 4 5 6 7 8

Unit to be
assembled
(1) Placing of (3) Installation of tire (4) Placing of dump body (7) Installation of dump body (10) Inspection
machine
(5) Installation of tire (8) Installation of mirror
(2) Placing of parts shipped
(6) Sub-assembly of dump (9) Adjustment of
separately
body suspension gas
Assembly instruction No.

Worker 2 persons

Meeting before work Completion of

Remarks Unloading assembly
Start of assembly

4. Necessary tools and equipments (non travel)

(1) Necessary tools
No. Name of tool Specifications Q'ty Remarks
1 Box-end combination wrench General tool (wrench set) 1 set For tightening each part
2 Socket 36 mm (inserting angle 25.4) 1 For installing tire
3 Socket General tool (socket set) 1 For tightening each part
4 Impact wrench 1 set For tightening each part
5 Extension bar Inserting angle 25.4 x L160 mm 1 For installing tire
6 Impact wrench GT-S22M and equivalent 1 For installing tire
7 Torque wrench Measurable up to 927 Nm 1 set For installing tire
8 Bar 1 For adjusting hole at installing tire
9 Spray type paint can Clear 1 For touching up the bolt head
10 Spray type paint can for touching up Natural yellow 1 set For touching up dump body/hoist cylinder
11 Grease gun 1 For greasing each part
12 Filling tool for suspension gas 7926-10-1000 1 For adjustment of suspension gas pressure

(2) Necessary equipments

No. Name of facility Specifications Q'ty Remarks
1 Mobile crane 25 ton and above 2 For slinging bare machine
2 Lift truck 2 ton and above 1 For installing tire
3 Compressor Capacity 32 liter and above 1 For impact wrench
4 Stepladder (scaffold) 4 steps (approximately 1.5 m) 1 For work
5 Iron plate t9 x 1219 x 2438 2 For placing of bare machine
6 Wooden block 400 x 400 x 900 12 For placing of bare machine

(2) Lifting tool to be used

No. Name of facility Specifications Q'ty Remarks
1 Nylon sling For 15 ton x L4000 4 For slinging bare machine
2 Tire lifting tool L4000, φ6.3 mm in chain diameter 1 For slinging tire
3 Shackle Proof load 1 ton and above 4 For connecting lifting tools of dump body
4 Eyebolt M20 4 For connecting lifting tools of dump body

1 Length 4,000 mm 2 Chain diameter

Specific load 15 ton φ6.3 mm
Operating load
4
3.20 ton

2
 Assembly procedure No. No．0010 Installation of the sling

1. Positioning bare machine

1. Positioning on the flat ground Lock the machine by using a lock bar

2. Preparation of the sling

Protective plate Protective plate

1. Place protective plate when installing sling.
2. Detail of slinging on front side.

When using single wire When using a double wire Do not interfere the side bumper
Perform slinging with sling angle 60 deg. Sling tools are perpendicular.
Precautions Necessary tools Necessary equipment
Name Q'ty Name Q'ty
Use protective plates not to damage the exterior Nylon sling 15 ton 3 Crane： Min. 25 ton 2
parts when installing sling tools.

Sling tools should not contact the side bumper on

front frame side when slinging the machine.
(It may damage the bumper)
Other remarks
When slinging the machine

3
 Assembly procedure No. No．0100 Positioning bare machine

1. Positioning bare machine

1. Position machine on the flat ground.

Precautions Necessary tools Necessary equipment

Name Q'ty Name Q'ty

Other remarks

4
Assembly procedure No. No．0200 Unfolding of rear view mirror

1. Remove the rear view mirror mounting bolts and change the fixed position of the mirror.

Loosen

Tighten

Remove

Unfold the bracket

and fix it with the
bolts.

2. Perform the same work on the opposite side.

Precautions Necessary tools Necessary equipment

Name Q'ty Name Q'ty
Ring wrench （17mm） 1

Other remarks

5
 Assembly procedure No. No．0210 Installation of left guard

1. Remove parts (3) to (5) installed to the machine.

2. Install the handrails delivered together with the machine.

④⑤ ①

③
④⑤
③

No Part No. Part name Q'ty State of parts (Parts list No.)
(1) 56B-54-37341XC Guard 1 Separately Packed （M43-05-020）
(2) 56B-54-37330XC Guard 1 Separately Packed （M43-05-020）
(3) 01024-81245 Bolt, sems 4 Temporarily installed to chassis
(4) 01643-31232 Washer 4 Temporarily installed to chassis
(5) 01580-11210 Nut 4 Temporarily installed to chassis

Precautions Necessary tools Necessary equipment

Name Q'ty Name Q'ty
Ring wrench （19mm） 2

Other remarks

6
Assembly procedure No. No．0500 Installation of antenna

1. Install antenna to top of cab.

(1) KOMTRAX antenna： Install antenna to top of cab.

(2) Radio antenna： Install antenna to left top of cab.

Part No. Part name Q'ty State of parts (Parts list No.)
(1) 8A13-10-2100 Antenna 1 Separately Packed （M43-05-050）
(2) 20Y-06-41990 Antenna 1 Separately Packed （M43-05-060）

Apply Locktite No.262

or equivalent. ① Remove cap and
install antenna.

Remove vinyl and

install antenna.

View Z

Precautions Necessary tools Necessary equipment

Name Q'ty Name Q'ty

Other remarks

7
 Assembly procedure No. 0610 Sling and put stationary dump body

(1) Sling the dump body.

1) Sling the dump body by using crane.

1. Set 4 nylon slings to the dump body. (Put the pads (4 places) to where the slings
interferes to the dump body.)
2. Install eyebolts to 4 places and put the nylon sling through eyebolt, and sling the dump body.

Nylon sling
L4000 x 4 for 15 ton Eyebolt M20 x 4
1 2

(1) (1)
Without eyebolt, with shackle only
With eyebolt and shackle

No. Part No. Part name Q'ty State of part

(1) 56B-74-32104NK BODY 1 Separate shipment (M45-03-01*)

2) Place the dump body.

・ Place the dump body on the flat ground.

・ Wooden block etc. will make the work easy.

Precautions Special tools Facility to be used

Name Q'ty Name Q'ty
Crane 1
Nylon sling 4
(Wooden block)
Eyebolt 4
Others

7-1
Assembly procedure No. No. 0620 Assembly of dump body subassembly
<1> Assemble the dump body subassembly
1） Install the lock pins. * Same process on
2） Install the mudguards. right and left
3） i .Install plate <13>. (Model without dump body heating)
[Link] tube <8>. (Model with dump body heating) ⑦

④ ⑥
Z

X ③
⑦
⑤
View X
Pass pin through seat attached
to dump body and open its end
⑬
⑧

⑨
* Turn exhaust ⑫ ⑭⑮
outlet down ⑩ ⑪ OPT (Model without ①②
dump body heating)
Part No. Part name Q'ty Part state
(1) 56E-74-27730 PIN 2 Unit shipment
View Y
(2) 56C-74-11580 LINCH PIN 2 Unit shipment
(3) 56B-74-31552 GUARD 2 Unit shipment
(4) 56B-74-11760 PLATE 2 Unit shipment
(5) 56B-74-11770 PLATE 2 Unit shipment
(6) 01024-81235 BOLT,SEMS 12 Unit shipment
(7) 01024-81245 BOLT,SEMS 4 Unit shipment
(8) 56B-02-31380 TUBE 1 Unit shipment
(9) 56D-74-31410 GASKET 1 Unit shipment
(10) 01010-81645 BOLT 4 Unit shipment
(11) 01643-31645 WASHER 4 Unit shipment
(12) 01643-31845 WASHER 4 Unit shipment
(13) 56D-74-31420 PLATE 1 Unit shipment
(14) 01010-81635 BOLT 4 Unit shipment
(15) 01643-31645 WASHER 4 Unit shipment
Precautions Necessary tools Necessary equipment
Name Q’ty Name Q’ty
Impact wrench 1
Socket (19 mm) 1
Socket (24 mm) 1

Other remarks

7-2
 Assembly procedure No.060 Connection and adjustment of dump angle sensor

Connection and adjustment of dump angle sensor.

1) Remove the lightly tightened bolt.
2) Connect the dump angle sensor rod.
3) Check that the dump body float caution lamp is unlit after installing the dump angle sensor.

Bracket
Cover (1) Connect to dump body
View A-A Rod
(1)
㻭 01010-81045

Lever

Note A

Nut★

㻭 184 mm

Align holes in lever and bracket with each other.

(Hole center misalignment must be 1 mm or less)

Detail of P
Installation procedure for angle sensor lever
(1) Adjust the dump body shim, then seat the dump body.
(2) Lightly assembly the link with nuts marked with ★ (01583-11006: 2 pieces), and adjust the rod
length to 184 mm.
(3) Lightly install the rod to the chassis, and fix it with bolt (1).
(4) Check that the misalignment of the positioning holes (diameter: 5 mm) in bracket 56B-46-32311
and lever 56B-06-35141 is 1 mm or less. If the misalignment exceeds 1 mm, adjust the rod length
with the nuts ★ (01583-11006: 2 pieces).
(5) Check the voltage with the machine monitor in the cab (Monitoring code: 34603 "Body
[Link]").
The standard range of "Body [Link]" when the dump body is seated is 0.4 V to 0.6 V.
If the voltage is out of the standard range, adjust the rod length with the nuts ★ (01583-11006:
2 pieces).
Reference: Voltage change per turn of nut is 0.1 V
(6) After adjusting the voltage and rod length, tighten bolt (1 ) and nuts ★ (01583-11006: 2 pieces)
to the specified torque and install cover (56B-46-32321).

Part No. Part name Q'ty State of part (part list No.)
(1) 01010-81035 BOLT 1 Temporarily installed to dump angle sensor
Precautions Special tools Facility to be used
• Remove the rod holding jig at part at Name Q'ty Name Q'ty
Note A in the figure. Impact wrench 1
(If the dump body is raised with the jig Socket (17 mm) 1
installed, the rod will be broken.)
• Discard the removed jig.

Rod holding jig

Others

Remove

7-3 2
 Assembly procedure No. 0670 Installation and adjustment of dump body bottom mounting

(1) Install the dump body bottom mounting.

1) Adjust the dump body mounting according to the shim adjustment procedure described
below.

1. Shim adjustment procedure at dump body mounting part

Perform it in order according to the following.
a. Insert a spacer of 58 mm in height to the tip of the dump body.
(2 places on the right and left)
(6) (7) (8) (9) b. Measure clearances δ1, δ2, δ3, δ4, δ5, and δ6 between the
center of bottom mounting installation face (a) and the frame.
t1.0 t1.0 t1.0 t1.0 c. Thickness of the shim to each place is: (δ1-26) mm, (δ2-26) mm,
(δ3-26) mm, (δ4-26) mm, (δ5-26) mm, and (δ6-26) mm respectively.
(2) (3) (4) (5) d. Install the shim and bottom mounting, and remove the spacer.
t1.0 t3.2 t1.0 t1.0 e. Lower the dump body. Check that all 6 places of bottom mounting
contact with the top face of the frame.

(1)

(13)

(12) (11) (10)

*Use the bolt suits to

the shim thickness.

Part No. Part name Q'ty State of part (part list No.)
(1) 56B-74-11410 PAD 6 Separate shipment (M45-03-030)
(2) 56B-74-11610 SHIM (t 1.0 mm) 10 Separate shipment (M45-03-030)
(3) 56B-74-11620 SHIM (t 3.2 mm) 6 Separate shipment (M45-03-030)
(4) 56B-74-11680 SHIM (t 1.0 mm) 4 Separate shipment (M45-03-030)
(5) 56B-74-11690 SHIM (t 1.0 mm) 4 Separate shipment (M45-03-030)
(6) 56B-74-11740 SHIM (t 1.0 mm) 2 Separate shipment (M45-03-030)
(7) 56B-74-11720 SHIM (t 1.0 mm) 8 Separate shipment (M45-03-030)
(8) 56B-74-11750 SHIM (t 1.0 mm) 4 Separate shipment (M45-03-030)
(9) 56B-74-11710 SHIM (t 1.0 mm) 8 Separate shipment (M45-03-030)
(10) 01010-81645 BOLT 24 Separate shipment (M45-03-030)
(11) 01010-81640 BOLT 24 Separate shipment (M45-03-030)
(12) 01010-81635 BOLT 24 Separate shipment (M45-03-030)
(13) 01643-31645 WASHER 24 Separate shipment (M45-03-030)

Precautions Special tools Facility to be used

Name Q'ty Name Q'ty
Impact wrench 1
Socket (24 mm) 1
Others

7-4
 Assembly procedure No. No. 0675 Adjustment procedure for exhaust box stroke (Specification with dump body heater)

<1> Adjust the exhaust box stroke.

1) Adjust stroke (a) of the flange of exhaust box (A) (56B-02-31901) to 15 to 20 mm by adjusting the
installation position of tube (B) (56D-02-31380).
Adjust the installation position of tube (B) into the range of -5 to +24 mm from standard dimension (b).
Caution: Do steps No. 0670 (Installation and adjustment of dump body bottom mounting) and
No. 0680 (Installation of dump body stopper) before doing this step.

View Z

D
FW
Z

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Impact wrench 1
Socket (24 mm) 1

Other remarks
Sales code: 4HCBH-H: BODY HEATING

7-5
 Assembly procedure No. 0680 Installation of dump body stopper

(1) Install the bracket for dump body stopper. *Work on right and left sides similarly
1) Install the bracket so that the clearance between bracket and frame is 1 to 2 mm.

View Z

Clearance to frame:
1 to 2 mm
FWD

(4) Z

(1)
(3)

(2)

Part No. Part name Q'ty State of part (part list No.)
(1) 56C-74-11270 BRACKET 2 Separate shipment (M45-03-060)
(2) 01010-81655 BOLT 8 Separate shipment (M45-03-060)
(3) 01643-31645 WASHER 8 Separate shipment (M45-03-060)
(4) 56B-74-21180 SEAT 4 Separate shipment (M45-03-060)

Precautions Special tools Facility to be used

Name Q'ty Name Q'ty
Impact wrench 1
Socket (24 mm) 1
Others

7-6
 Assembly procedure No. No．0685 Dump body control calibration

Procedure for calibration of the dump body control

(Hydraulic oil temperature: 80 to 90 ° C)

After completing the adjustment of the dump body shim, perform the following
procedure.
(1) Start the engine with the dump body fully seated, and keep the control lever in the
FLOAT position for 5 seconds or more with the engine at low idle (850 rpm or less).
(Confirm that the float caution is turned off.)
(2) Keep the engine at low idle (850 rpm or less), and the control lever in the
"RAISE" position for 5 seconds or more while raising the dump body up to the cylinder
stopper with the engine at high idle.
(3) After raising the dump body until the stroke end with the engine at high idle, while
the control lever is in "FLOAT" position, lower it to the seating position with the engine
at low idle (850 rpm or less). Repeat this operation 5 to 10 times.
(4) After raising the dump body until the stroke end with the engine at high idle, lower
it to the seating position with the "LOWER" position of the control lever while keeping
the engine at high idle. Repeat this operation 5 to 10 times.

Precautions Necessary tools Necessary equipment

Name Q'ty Name Q'ty

Other remarks

8
 Assembly procedure No. 0690 Installation of the blind bolt and washer after installing the dump body

(1) Install the blind bolt and washer after installing the dump body.

◆ mark 4 places
(1)
(2)

No. Part No. Part name Q'ty State of part (part list No.)
(1) 01010-82050 BOLT 4 Separate shipment (M45-03-090)
(2) 01643-32060 WASHER 4 Separate shipment (M45-03-090)

Precautions Special tools Facility to be used

Name Q'ty Name Q'ty
Impact wrench 1
Socket (30 mm) 1
Others

8-1
Assembly procedure No. No. 0696 Installation of tie-off bracket

1 Stick the decals to the tie-off bracket.

2 Install the tie-off bracket to the dump body.

④ ③

Details of sticking
positions

④
①② ④

Part No. Part name Q'ty State of part (part list No.)
① 1955454930NK BRACKET 2 Loose supply
② 0102481235 BOLT,SEMS 4 Loose supply
③ 0985000641 PLATE, SAFETY 2 Loose supply
④ 0995100281 MARK 2 Loose supply

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty

Other remarks
4HA999 without dump body

8-2
Assembly procedure No. No. 0697 Sticking of certificate decals (dump body) for KAL

1 Stick decals (2 places) to the dump body.

Details of sticking
king
positions

30
17 17

Part No. Part name Q'ty State of part (part list No.)
① 56B9351120 PLATE 2 Loose supply

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty

Other remarks
5AC64A Tie-off compliant with Australian Regulations
4HA999 without dump body

8-3
 Assembly procedure No. 0700 Touch up painting of dump body

(1) Touch up the dump body.

Touch up 4 places (interference part with dump body slings) with natural yellow paint.

(2) Touch up the hoist cylinder.

Touch up 2 places (ground contact part of hoist cylinder fixing jig) with natural yellow paint.

Precautions Special tools Facility to be used

Name Q'ty Name Q'ty
Mask the frame, etc. of different Touch up spray 4
color, so that the paint does not
stick on it.
Others

8-4
Assembly procedure No. No．0710 ADT assembly - Bushing installation (optional)
1 Install the bushing to the dump body.

* (4) Tightening torque:

455 to 565Nm (46.5 to 58kgm)
A
Apply LT-2
A
* Follow the same procedure
F for right and left.

④, ⑤

View F Cross section A-A

Part No. Part name Q'ty State of part (part list No.)
(1) 56B-83-56450NK BRACKET 2 Separate shipment (M43-03-200)
(2) 56B-83-51450 BUSHING 2 Separate shipment (M43-03-200)
(3) 04065-09030 RING-SNAP 2 Separate shipment (M43-03-200)
(4) 01010-82050 BOLT 8 Separate shipment (M43-03-200)
(5) 01643-32060 WASHER 8 Separate shipment (M43-03-200)

Precautions Necessary tools Necessary equipment

Name Q'ty Name Q'ty

Other remarks Sales code: 4HCTG24A-A: ADT tailgate

(4HCTG25A-F: ADT tailgate KIT)

9
 Assembly procedure No. No．0720 ADT assembly - Side arm installation (optional)

1 Install the side arms.

A ①

* Follow the same procedure for right and left.

Apply G2-LI. ⑥

⑤
③
④
Plate side Sponge side ⑦, ⑧
*
Detail of P
P Cross section A-A

Part No. Part name Q'ty State of part (part list No.)
(1) 56B-83-56120 ARM,L.H. 1 Separate shipment (M45-03-200)
(2) 56B-83-56130 ARM,R.H. 1 Separate shipment (M45-03-200)
(3) 56B-83-56460 WASHER 2 Separate shipment (M45-03-200)
(4) 56B-83-56160 SEAL 2 Separate shipment (M45-03-200)
(5) 56B-83-57210NK PIN 2 Separate shipment (M45-03-200)
(6) 56B-83-56490 WASHER 2 Separate shipment (M45-03-200)
(7) 01010-61255 BOLT 6 Separate shipment (M45-03-200)
(8) 01643-31232 WASHER 6 Separate shipment (M45-03-200)

Precautions Necessary tools Necessary equipment

Name Q'ty Name Q'ty
* (7) Refer to the tightening
procedure No.0725.

Other remarks Sales code: 4HCTG24A-A: ADT tailgate

(4HCTG25A-F: ADT tailgate KIT)

10
Assembly procedure No. No．0725 ADT assembly - Assembling procedure of side arm mounting bolt

Tightening procedure of mounting bolt

Tighten the bolts a, b and c in three separate steps according to the following procedure to
prevent loosening.
* Follow the same procedure for right and left.
(1) Apply LT-2 to all bolts.
(2) Tighten the bolts in order of bolt a → bolt b → bolt c, and tighten with a torque of 69 to
86 Nm (7 to 8.8 kgm).
(3) Tighten the bolts in order of bolt a → bolt b → bolt c, and tighten with a torque of 98 to
123 Nm (10 to 12.5 kgm).
(4) Tighten the bolts in order of bolt a → bolt b → bolt c, and tighten with a torque of 98 to
123 Nm (10 to 12.5 kgm).

* Follow the same

procedure for right and left.

View Z

(7) and (8)

of
No. 0720
a b

Precautions Necessary tools Necessary equipment

Name Q'ty Name Q'ty

Other remarks Sales code: 4HCTG24A-A: ADT tailgate

(4HCTG25A-F: ADT tailgate KIT)

11
 Assembly procedure No. No. 0750 Assembled at ADT: Installation of tailgate (optional)

1 Install wires to the tailgate

g arm.

Same process on right and left

③④
Apply G2-L1
PIN = Yellow ②
Length: 50 mm

560 ⑤※
Ring and jaw type
Length adjustment range: 460 to 570
Adjustment dimension
Apply G2-L1 Apply G2-L1
⑥ PIN = Black
① Length: 55 mm
Reference: PIN grease application position ③④

* Install <5> to length of 560 mm on both right and left sides. Raise the dump body
slowly. When the tailgate starts opening (dump body angle is approximately 4
degrees), tighten the turnbuckles so that the tensions of R.H. and L.H. wires are
even.
Lock nut tightening torque: 196 to 333 Nm (20 to 34 kgm)

Part No. Part name Q'ty State of part (part list No.)
① 56B-83-36190 WIRE 2 Separate shipment (M45-03-210)
② 56D-83-16210 PIN 2 Separate shipment (M45-03-210)
③ 01010-81220 BOLT 4 Separate shipment (M45-03-210)
④ 130-43-64260 WASHER 4 Separate shipment (M45-03-210)
⑤ 56B-83-36430 JOINT A.,TURNBUCKLE 2 Separate shipment (M45-03-210)
⑥ 56B-83-56210 PIN 2 Separate shipment (M45-03-210)

Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty

Other remarks
Sales code: 4HCTG24A-A: ADT tail gate
(4HCTG25A-F: ADT tail gate kit)

11-1
 Assembly procedure No. No．0760 ADT assembly - Lubrication piping installation

Install the left and right lubrication piping.

P (1)
Part No.
56B-52-12410
Part name Q'ty
ELBOW
State of part (part list No.)
2 Separate shipment (M43-03-210)
(2) 56B-52-31450 HOSE 2 Separate shipment (M43-03-210)
(3) 566-52-43290 NIPPLE 2 Separate shipment (M43-03-210)
(4) 423-09-12110 CONNECTOR 8 Separate shipment (M43-03-210)
(5) 56B-83-50040 TUBE 2 Separate shipment (M43-03-210)
(6) 56B-83-50020 TUBE 1 Separate shipment (M43-03-210)

Q (7)
(8)
56B-83-50030
04434-50612
TUBE
CLIP
1 Separate shipment (M43-03-210)
16 Separate shipment (M43-03-210)
(9) 01024-81220 BOLT 16 Separate shipment (M43-03-210)
(10) 07020-00000 FITTING 2 Separate shipment (M43-03-210)
(11) 07043-70108 PLUG 4 Separate shipment (M43-03-210)

Detail of P part
★
★ ★

⑧, ⑨
⑤
★ marks: 16 places (right and left)

★
④
Apply LG-5

Apply LG-5

③ ④
① Apply LG-5
Apply LG-5 Detail of Q part
② L.H.⑥
R.H. ⑦
Apply LG-5 ★

④
Special tools Facility to be used
Name Q'ty
★

★
Apply LG-5 ★

⑨
⑩ Apply LG-5
Precautions Necessary tools Necessary equipment
Name Q'ty Name Q'ty
Install the piping so that the left and
right are a mirror-image.

Other remarks Sales code: 4HCTG24A-A: ADT tailgate

(4HCTG25A-F: ADT tailgate KIT)

12
 Assembly procedure No. No．0800 Adjusting Nitrogen gas of front and rear suspensions

1. Adjusting Nitrogen gas of front and rear suspensions

Adjust the quantity of Nitrogen gas (front and rear, 4 places).

Installing position of Nitrogen Installing position of Nitrogen

gas pouring tool gas pouring tool
Nitrogen gas pouring valve

Nitrogen gas pouring valve

Air bleeding

Air bleeding valve

Before adjusting Nitrogen gas, remove the Before adjusting Nitrogen gas, remove the
cover. After adjusting install it. cover. After adjusting install it.

← Chassis side
Rear suspension cylinder
← Chassis side

Front suspension cylinder

Axle side →
Axle side →
A

A
80

70

Dimension A (Front side) Dimension A (Rear side)

When cylinder is retracted fully: MIN (40 ± 1) When cylinder is retracted fully: MIN (36 ± 1)
Specified quantity of filled oil: OIL 101 ± 3 Specified quantity of filled oil: OIL 76 ± 3
When empty: EMPTY (176 ± 10) When empty: EMPTY (106 ± 5)
When cylinder is extracted fully: MAX (217 ± 1） When cylinder is extracted fully: MAX (126 ± 1）

1. Loosen the air bleeding valves of the right and left front suspension cylinders and bleed air thoroughly. (Check that air does not
come out any more (and only oil flows out) and tighten the valves again. Tightening torque: 39.2 - 49.0 Nm {4 - 5 kgm})
2. Check that the valves are closed and install the suspension gas pouring tool to the gas cylinder.
3. Connect the hoses of the Nitrogen gas pouring tool to the nitrogen gas pouring valves. (Since there are 2 hoses, connect them
to the right and left suspension cylinders and pour the nitrogen gas simultaneously so that pressure will be applied to both
cylinders evenly.)
4. Open the valve of the Nitrogen gas pouring tool gradually.
5. When the suspension cylinders rise to the specified level shown above, close the valve. (Pour the gas to the front suspension
cylinders until they rise to the level indicated by the decalcomania. Pour the gas to the rear suspension cylinders until they rise to
the level shown in the above figure.)
6. Remove the hoses from the nitrogen gas pouring valves and move the machine forward and in reverse to the suspension cylin-
ders and then stop without applying the brake. (Finally, stop the machine without applying the brake to prevent an uneven load
caused by braking.)
7. Apply the parking brake and check the length of the suspension cylinders.
8. If the length of the suspension cylinders is out of the standard range, repeat steps 3 -7. (Usually, adjustment is completed by
repeating those steps 3 - 4 times.)

Precautions Necessary tools Necessary equipment

1. Bleed air from the cylinders. Name Q'ty Name Q'ty
2. Pour nitrogen gas in the right and left suspension Suspension gas pouring tool 1
cylinders simultaneously. (7926-10-1000)
3. Do not extend the suspension cylinders to the
stroke end.
4. After moving the machine forward and in reverse,
stop it without applying the brake.
5. Do not steer the machine before finishing this
Adjustment. (If it is steered, the piping may be broken.) Other remarks

13
 Assembly procedure No. No．1000 Sticking of decal

1. Stick the decals to the body. (Right and left)

④
②
③

Ｚ
①
③

29 MARK: MODEL (R.H.)

MARK (L.H & R.H.) MARK: MODEL (L.H.)

MARK (LOGO)
35 500

53 63

View Z （Location to stick)

No. Part No. Part Name Q'ty State of part (Parts list No.)
(1) 56B-93-31310 Mark L.H. 1 Separately Packed （M43-03-100）
(2) 56B-93-31320 Mark R.H. 1 Separately Packed （M43-03-100）
(3) 56B-93-31330 Mark 2 Separately Packed （M43-03-100）
(4) 09690-P1800 Mark 2 Separately Packed （M43-03-100）

Precautions Necessary tools Necessary equipment

After bonding ｆit each decal perfectly and leave Name Q'ty Name Q'ty
no bubbles.

Other remarks

14
 Assembly procedure No. No．1010 Check inflation pressure of tires, inflate

CHECK
Use a tire pressure gauge to measure the tire inflation
pressure before starting operations when the tires are cool.

G0159583

INFLATION OF TIRES
Adjust the inflation pressure properly.
When inflating a tire, use an air chuck which can be fixed to the air valve of the tire as shown in the figure. Do
not work in front of the rim but work on the tread side of the tire.
The proper inflation pressure is shown in table below.

Inflation pressure kPa {kgf/cm2, PSI}

Tire size
Front tire Center tire Rear tire
29.5–R25 (standard) 375 {3.8, 54.0} 390 {4.0, 56.8} 390 {4.0, 56.8}
875/65R29
440 {4.5, 63.9} 440 {4.5, 63.9} 440 {4.5, 63.9}
(if equipped)

NOTICE
If the tires are used when the inflation pressure is less than the value given in the table above, the rim
may be damaged.
Always keep the tire inflation pressure within ±10 kPa {0.1 kgf/cm2, 1.42 PSI} of the value in the table
above.

Precautions

• When inflating the tires, check that no other person is standing near the tire, and install an air chuck
with a clip that can be fixed to the air valve.
• While inflating the tire, check the inflation pressure occa-sionally so that it will not rise too much.
• If the rim is not fitted normally, it may be broken and scat-tered while the tire is inflated. Accordingly, place a
guard around the tire and do not work in front of the rim but work on the tread side of the tire.
• Abnormal drop of inflation pressure and abnormal fitting of the rim indicate a trouble in the tire or rim. In this
case, be sure to ask a tire repair shop for repair.
• Be sure to observe the specified inflation pressure.
• Do not adjust the inflation pressure of the tires just after high-speed travel or heavy-load work.

15
HM400-3M0 Mirror adjustment A B C
Referring to the following figures, adjust the
mirrors.
Watch each mirror from the operator's seat. G
GROUND CONTACT POINT OF TIRE

J
MIRROR NUMBER RANGE OF VIEW
GROUND POINT
SEE THE AREA A.

SEE THE AREA B.

SEE THE AREA C , THE GROUND CONTACT POINTS OF

TIRE G , AND GROUND POINT J .

SEE THE AREA D.

F
Assembly procedure No.

SEE THE AREA E , THE GROUND CONTACT POINTS OF

TIRE H , AND GROUND POINT K .

SEE FORWARD OF MACHINE.

REAR MONITOR SEE THE AREA F.

ADJUST MIRRORS ACCORDING TO THE RIGHT K

TABLE TO SEE THE ARBITRARY 200MM AREA
WITHIN 1500MM (*MARKED) FROM GROUND GROUND POINT
AND TO SEE A PART OF THE MACHINE.
Attached sheet

H
GROUND CONTACT POINT OF TIRE

E
D
Mirror adjustment procedure
Assembly procedure No. Attached sheet Mirror adjustment procedure (WIDE)

1. Mirror adjustment

Referring to the following figures, adjust the mirrors.

Watch each mirror from the operator's seat.

Adjust each mirror so that it will reflect a part of the machine as shown below.

④ ②

C B

Precautions Necessary tools Necessary equipment

Name Q'ty Name Q'ty
Others