CA-Y48E-02
WORKSHOP MANUAL
CAB
CAB
CA-1
CA-Y48E-02
CHAPTER CA
CAB
DATA AND SPECIFICATION......................CA-2
DESCRIPTION.................................CA-3
TROUBLESHOOTING.............................CA-5
CAB DISMOUNTING FROM CHASSIS................CA-8
CAB SUSPENSION.............................CA-11
LEVELING VALVE.............................CA-15
CAB TILT MECHANISM.........................CA-18
TILT CYLINDER..............................CA-21
TILT PUMP..................................CA-24
CAB LOCK MECHANISM.........................CA-27
DOOR.......................................CA-29
WINDSHIELD GLASS...........................CA-33
INSTRUMENT PANEL...........................CA-36
SEAT.......................................CA-38
BLOWER.....................................CA-39
POWER MIRROR...............................CA-40
СА-2
CAB
DATA AND SPECIFICATION
CAB
Type	All steal, welded construction, full floating cab air suspension
Tilt system	Oil jack
Tilt angle	Full tilt 49°
weight (with accessories)	Approximately 615 kg {1,356 lb)
TILT PUMP
PUMP	Type		Single plunger type
	Relief valve pressure		34.3-37.2 MPa {350-380 kgf/cm2, 4,977-5,404 lbf/in2}
	Discharge pressure and discharge quantity	Rating pressure	19.6 MPa {200 kgf/cm2, 2,844 lbf/in2}
		Electric drive	460 cm3/min
		Manual operate	28 cm3/30 stroke or more
MOTOR	Type		Compound winding type
	Nominal output		0.3 kW
	Voltage		24 V
	Rating		Brief time rating (5 minutes)
	Rotating		Clockwise (seen from output shaft)
	Ground type		Body earth
TILT CYLINDER
Type		Double action type
Max. length		710 mm {27.95 in)
Min. length		433 mm {17.05 in)
Max. stroke		277 mm {10.91 in)
Output	Extension	22,600 N {2,300 kgf, 5,071 Ibf} or more
	Retraction	12,800 N {1,300 kgf, 2,866 Ibf} or more
CAB
CA-3
DESCRIPTION
Representative,
Left hand drive vehicle
COIL SPRING TYPE
SM19-610, 681
FRONT CAB SUSPENSION
1.	Air spring
2.	Levering valve
3.	Stabilizer with surge tank
(Surge tank, if so fitted)
4.	Shock absorber
5.	Coil spring
SM19-611, 681
REAR CAB SUSPENSION
1.	Cab lock
2.	Air spring with shock absorber
3.	Surge tank (If so fitted)
4.	Levering valve
5.	Coil spring
6.	Shock absorber
СА-4
CAB
Representative model
1.	Air spring	5.
2.	Shock absorber	6.
3.	Stopper stay	7.
4.	Stopper switch, stroke switch	8.
SM19-612
Tilt cylinder
Stopper release lever
UP-DOWN select lever
Tilt pump
CAB
CA-5
TROUBLESHOOTING
(A)	The cab fails to tilt (fail to rise).
Trouble (Check points)				Possible Causes	Remedy	
©				(i)	Air is drawn into the pump. (ii)	The select lever is set at the 'DOWN' position. (ill)	Poor sealing in pump and valve.	Check the oil level. Operate the pump with the switch lever set at the 'UP' position. Disassemble and check (replace the 'O'-ring, etc.)	
						
				(i)	Crushed or clogged pipe. (ii)	Clogged cylinder orifice. (iii)	Other troubles in the pump and cylinder.	Replace with a new part. Disassemble and check. Check	
© The motor — runs but fails to raise the cab.	scarcely moves.		©			
		®	® - Abnormally	 heavy load			
		noise		(i)	Excessive weight imposed on the cab. (ii)	Clinging snow and ice. (iii)	Seizure of the tilt hinge and pin etc.	Check Check Check	
				(i)	The same as in Ф-Ф-Ф-®. (ii)	Excessively low setting of the pump relief pressure. (iii)	Pump abnormalities (Pressure fails to reach the relief level.) (vi) The cab lock fails to be released.	Check and adjust the relief pressure. Disassemble and check (piston assembly or check valve).	
	I no bdu uiuuy иеушь uui aiupi naiivvdy ui near the point where the lock is released.					-heck the cab lock.	the clearance — Check the horizontal sliding у-	к of the cab.	о	J Check the vehicle horizontality '-/ ! w (Particularly check the left side	pjn running on the curb, etc.) LGrease the pin.
				projection of the cab lock and the floating bar.		
	®			(i)	Excessive oil feeding. (ii)	Poor oil feeding (air drawn-in). (iii)	Others (Cylinder bites, bend, contact, etc.)	Check the oil level. Adjust the cap position. Added oil. Check, disassemble and repair.	
						
				Blown fuse and poor contact in the contactor.	Check the circuit or replace the fuse.	
		-	The cab lock switch fails to	 function. © -	The cab stopper switch fails	 to function.				
© The motor — fails to run.	© r The buzzer fails — to sound. ©			(i) Poor installation adjustment. (ii) Part failure.	Adjust the switch. Replace the switch.	
				(i) Poor installation adjustment. (ii) Part failure.	Adjust the switch. Replace the switch.	
	- Battery depleted (t				Check and charge the battery.	
						
	® - The power relay produces no operating noise.	Ф - Voltage not applied to the (+) — side of the operating switch terminal. -<2) Pressing the operating switch fails to apply voltage to the relay exciting circuit (+) side.		The motor terminal relay actuated (Motor overheated) Thermal relay failure.	Resume the operation after allowing to stand for 30 minutes (to cool). Check and adjust the motor.	
				Operation switch failure.	Replace the switch.	
				Relay failure.	Replace the relay.	
	(2\					
				Motor thermal relay actuated.	Resume the operation after allowing to stand for 30 minutes (to cool.)	
мииипнопу nut	। не iiiuiui lb иveiiudleu. motor						
СА-6
CAB
(В)	The fails to tilt (fails to lower)
Trouble (Check points)		Possible Causes	Remedy
	Ф	(i) The same as in (А)-Ф-Ф-Ф (ii, ill)	
Ф r The cab	 scarcely moves.	®		
		(I)	The pump select lever is set at the "UP" position. (ii)	Inversely installed piping. Normal 'rise' is assured. (iii)	The same as in (А)-Ф-®-@ (iv)	Erroneous installation of the pump changeover valve.	Operation should be conducted with the select lever at the 'DOWN' position. Correct the piping. Install the valve properly.
Ф The motor — runs but fails to lower the cab. ® L The cab stops -— halfway. Ф r The cab stopper can be pulled.			
	Ф r The cab stopper is actuated	 © -	The cab falls to come down	 completely. -	The same as in (А)--@-Ф~®		(i) Poor stroke of the mechanical stopper.	Adjust the stroke. Link lever	! Clearance Rebound stopper rubber
		(i) Damage or fatigue in the front tilt hinge bushing and the rebound stopper rubber.	Replace the rubber bushing and the , rebound stopper rubber.	Disengaged Cab 4 pin Adjust the switch.	stopper Lever
			
		(i) Idling of disengaged cab stopper and release pin. (ii) The cab lock switch actuated (locked when the cab is raised).	Adjust of release pin assembly. Restore the cab to lock-standby position.
® The motor — fails to run. ® L The cab stopper ca (The cab stopper ft			
		(i)	The cab stopper is nipping the stopper ring badly. (ii)	Stickness in the cab stopper pin performance. (iii)	Stickness in the cab stopper control cable performance.	Lift the cab with the manual pump. Grease the pin. Replace the cable.
	ils to be disengaged)		
(C)	The cabs sags after being tilted. The cab stopper nips after the cab is tilted.
	Trouble (Check points)	Possible Causes	Remedy
(T) Releasing the	Ф r- The sag occurs when the select lever is ——- at the "UP' position.	(i) Simultaneous occur- rence of: (Cylinder	 Check valve failure) (Pump	 Switch valve failure)	Replace the "O'-ring in the cylinder check valve or the pilot and the pump switch valve.
operation switch makes the cab to sag visibly.	® - The sag occurs when the select lever is	 at the "DOWN" position.	(i) Air is drawn in: (ii) Cylinder malfunction: Defective check valve seal Defective pilot piston Defective piston seal	Bleed air out of the cylinder piping. Disassemble and check the cylinder and inpipe cylinder.
The cab sags instantaneously when the select lever is moved	 from the 'UP' to the 'DOWN' position.		(i) Air is drawn in: (ii) Cylinder pilot piston malfunction.	Bleed air. Disassemble and check the cylinder.
® The cab sags when allowed to stand for a long time (at 50°) with	 the cab stopper engaged instead of released.		(i) Inadequate	.:	. cab stopper	' c clearance	1 (C size) (ii) The same as in Ф-Ф, @	Check and repair.
CAB
CA-7
(D)	Other abnormalities
Trouble (Check points)		Possible Causes	Remedy		
		(i)	The same as in (A)-®-©-®-® and (АУ-Ф-® (ii)	Drop of battery voltage. (iii)	Motor performance deteriorated. (iv)	Increased resistance due to oil of irrelevant type (low temperature, high viscosity, etc.)	Check and charge the battery. Charge and adjust the battery. Check and adjust the motor.		
© Tilting speed differs — from normal rate	©				
		(i) Poor sealing in the cylinder, check valve, or piston.	Disassemble and inspect the cylinder.		
					
					
	(D	(i) Poor fitting of pipes and joints.	Re-tighten or replace	“		
		(ii) Impairment of the hose and *0’ ring.	tne pipe.		“I	
	®		—				
			Replace the ‘O'-ring.	uj		-^1
					Seal
		(i) Defects in the U-cup sealing, end tube and the “O' ring. (ii) Impairment of the outer cylinder 'O' ring.	Replace the seal (U cup). Replace the cylinder body and assembly.		
\&) МП 16ЭК					
	®				
		(i) Impairment or the '0' ring (pump) and the oil seal (motor).	Replace the *0* ring (pump) and the oil seal (motor).		
® The buzzer does not stop © The cab tilts but the buzz					
		(i)	Poor adjustment or failure of the switches (cab stopper or cab lock). (ii)	Cab lock failure. (iii)	Cab stopper failure.	Inspect and adjust. Inspect the cab lock and replace with a new part. Inspect and adjust.		
					
		(i) Bad contact in the terminal. (ii) Defective buzzer.	Inspect the connector. Replace the buzzer.		
	©				
		(i)	Play in the cylinder pin. (ii)	Play in the shock absorber pin. (iii)	Play in the tilt hinge pin.	Inspect, repair or replace. Inspect, repair or replace. Inspect, repair or replace.		
® Abnormal noise	carriage beneath the cab front. ®				
		(i)	Slapping of the cab lock pin due to damaged rubber piece. (ii)	Play in the shock absorber pin. (iii)	Play in the lateral rod pin. (iv)	Cab lock failure (the cab lock was applied with the cab being tilted).	Inspect, repair or replace. Inspect, repair or replace. Inspect, repair or replace. Restore the cab lock to the normal position (lift and release).		
					
	the cab rear. Ф				
© Driving discomfort	 (related only with the cab suspension)	г Discomfort the drive feeling -— ®	(i) Sticky motion in the tilt hinge.	Disassemble and apply grease.		
		(i) Excessive cab weight (additionally imposed).	Weight adjustment (inspect the bumper and clearance).		
	(impact to the stopper rubber)				
		(I) Oil leak from the shock absorber.	Replace the shock absorber.		
	®				
		(i) Lateral rod bushing damaged.	Inspect and replace.		
	Treat lateral rolling.				
		(i) Link lever rubber bushing damaged.	Inspect and replace.		
	Cuitaideiable rolling.				
СА-8
CAB
CAB DISMOUNTING FROM CHASSIS
IMPORTANT POINT(S) - DISMOUNTING
AIR HOSES AND CABLE
Disconnect the all connections between the cab and chassis.
•	Air hoses	• Meter cable
•	Clutch oil hose	• Accelator cable
NOTE: When loosening flare nuts, be carefully not to twist pipes.
Cover the connecting portions for the dust, after
disconnecting.
STEERING SHAFT YOKE
Before separate, make alignment marks on both the steering
shaft and shaft yoke.
BATTERY GROUND TERMINAL
When you remove electric parts or connectors before that you
must pull the ground cable out from ground terminal of
battery for keep it protection.
HEATER HOSES
Do not remove the heater hoses by pulling or twisting forcibly.
If the hoses are not easily removed, cut the hoses horizontally
to remove.
CAB
CA-9
LEVELING VALVE (AIR SUSPENSION)
Remove the turnbuckle from front levering valve.
TILT CYLINDER
Remove the upper setting pin of the tilt cylinder.
PROCEDURE OF THE CAB DISMOUNTING
1.	Open the doors and hook the hooks of a cab lifting device.
2.	Be sure to block the front wheels.
3.	Bring the cab to slight tension.
NOTE: Cab weigh approxim ately 615 kg (1,355 lb} with accessories.
СА-10
CAB
Remove the tilt hinge bracket bolts.
5. Before lift the cab, don't forget to release the safety lock and
make sure all the disconnections between the cab and chassis.
WARNING
Never go under the cab while suspending the cab as it is very
dangerous.
CAB
CA-11
CAB SUSPENSION
NOTE: Tighten the bolts to the following tightening torque.
Bolt diameter (mm)		8	10	12	14	16
Tightening torque	Nm	14-18	37-49	64-85	110-150	170-230
	kgfcm	140-180	380-500	650-870	1,100-1,500	1,700-2,300
	Ibf-ft	11-13	28-36	47-62	80-108	85-166
СА-12
CAB
SM19-623
AIR SUSPENSION PIPING DIAGRAM
1.	Front air suspension
2.	Cab stabilizer (with surge tank
or without surge tank)
3.	Leveling valve
4.	Protection valve
5.	Surge tank (If so fitted)
6.	Rear suspension with shock absorber
7.	Leveling valve
8.	Air tank
CAB
CA-13
Representative,
Left hand drive vehicle
IMPORTANT POINT(S) - ASSEMBLING
CAB STABILIZER AND HINGE BRACKET
Adjust the cab hinge bracket of driver side by shim.
Clearance: Less than 1 mm {0.039 in}
If the clearance is not correct, adjust the clearance by de-
creasing or increasing the shim.
The following shims are available.
2.1 mm {0.083 in}, 1 mm {0.039 in}
Position the rubber side of the cushions next to the cab
stabilizer
TENSION ROD HOSE (AIR SUSPENSION)
Clamp the air hose under the cab stabilizer upper face.
(With surge tank type only)
REAR AIR SUSPENSION HOSE (AIR SUSPENSION)
Install the air suspension hose as shown.
СА-14
CAB
CAB HEIGHT ADJUSTMENT BY LEVELING VALVE
(AIR SUSPENSION)
Adjust the front and rear cab height by turning the turn-
buckle.
Front Height: 116 mm {4.57 in)
Rear Height: 150.5 mm {5.93 in)
NOTE: Air pressure above 490 kPa {5 kgf/cm2, 71 lbf/in2}
SM19-628
CAB
CA-15
LEVELING VALVE
T=34.1-43.9 {350-450, 26-32}
SM17-719
T = Tightening torque: N-m {kgf cm, Ibf ft}
1.	Bolt	9.	Body	17.	Band
2.	Lever	10.	Return spring	18.	Cap
3.	Washer	11.	Piston	19.	Valve
4.	Oil seal	12.	Spool	20.	Valve spring
5.	Shaft	13.	Nut	21.	Valve seat
6.	Stopper bolt	14.	Dust seal plate	22.	Shim
7.	O-ring	15.	Dust seal rubber	23.	Spacer
8.	Collar	16.	Dust seal cover		
СА-16
CAB
IMPORTANT POINT(S) - DISASSEMBLY
REMOVAL OF THE OIL SEAL
1.	Using a screw driver, remove the oil seal.
NOTE: Take care not to damage the body.
IMPORTANT POINT(S) - ASSEMBLY
When reassembling the leveling valve, replace all О-ring with
new ones.
1.	Be sure wash the each parts before assembling,
NOTE: Never wash the plastic parts with organic solvent.
2.	Applying place of grease.
Grease: 89770-1110
a.	The inside diameter of the body and the outside diameter
of the piston.
b.	Oil seal lip
c.	The outside diameter of the shaft and the bearing
d.	The inside diameter of spacer
e.	The inside diameter of valve seat and the base
f.	O-ring
g.	The outside diameter of spool
h.	Collar
3.	Filling place of grease
i.	Fill up the shaft pin gap in the piston with grease
INSTALLATION OF THE LEVER AND SHAFT.
1.	Adjust the direction of the lever and shaft and tighten the bolt.
Front: 49770-1285
Rear: 49770-1295
CHECKING FOR AIR LEAKAGE
1. EXHAUST SIDE
Turn the lever upward.
Apply soapy water with a brush for outlet port and exhaust
port and supply the compressed air of 834 kPa (8.5 kgf/cm2,
120 lbf/in2) from the inlet port than check the leakage.
NOTE: Do not connect the air line for outlet port.
CAB
CA-17
SM 17-730
2. INLET SIDE
Connect the air line for outlet port.
Turn the lever downward.
Apply soapy water with a brush for the exhaust port and
supply the compressed air of 834 kPa {8.5 kgf/cm2,120 lbf/in2}
from the inlet port than check the leakage.
ADJUSTMENT
1.	Remove the dust cover.
2.	Loosen the nut with a spanner.
3.	Fix the spool with a Phillips screw driver, then turn the nut
with a spanner and adjust it.
4.	After adjusting, remove the Phillips screw driver from the
spool, then tighten the nut with a spanner.
5.	After tightening, confirm the air flowing out from outlet port
at the lever is 1°-5° below a horizontal position.
6.	Install the dust cover and tighten the band.
СА-18
CAB
CAB TILT MECHANISM
T=110-150 {1100-1500, 80-108}
T = Tightening torque: Nm {kgf-cm, Ibf-ft}
1.	Tilt cylinder bracket	7.	Pin holder
2.	Tilt cylinder	8.	Stopper switch
3.	Lock cap	9.	Release cable
4.	Stopper stay	10.	Release lever
5.	Stroke switch	11.	Tilt pump
6.	Stopper pin	12.	Bracket
NOTE: Tighten the bolts to the following tightening torque.
Bolt diameter (mm)		8	10	12	14	16
Tightening torque	Nm	14-18	37-49	64-85	110-150	170-230
	kgf-cm	140-180	380-500	650-870	1,100-1,500	1,700-2,300
	Ibf-ft	11-13	28-36	47-62	80-108	85-166
CAB
CA-19
ELECTRICAL WIRING DIAGRAM
1.	Battery
2.	Fusible link
3.	Starter switch
4.	Cab lock swtich
5.	Cylinder stroke switch (Min. "OFF")
6.	Stopper switch (Release "ON")
7.	Neutral switch (Neutral "ON")
8.	Buzzer
9.	Tilt siwtch (Natural "OFF")
10.	Relay
11.	Thermal safety switch
12.	Tilt motor
SM19-631
OIL PIPING DIAGRAM
1.	Tilt cylinder check valve	6.	Pump motor
2.	Tilt cylinder	7.	Hand pump
3.	Up-Down select lever	8.	Relief valve
4.	Check valve	9.	Check valve
5.	Pump		
СА-20
CAB
IMPORTANT POINT(S) - DISMOUNTING
TILT PUMP
1.	Set the select lever to the "UP" position.
NOTE: This is done to prevent oil flowing from the reservoir tank.
2.	Disconnect the oil pipes between the pump and the cylinder
at the pump side.
NOTE: О Before disconnection of the pipes, clean the connection
parts.
О Seal the removed pump and the pipe connector parts
with tape etc.
RELEASE CABLE STOPPER
Adjust the release cable stopper, the stopper prevents the
lever from over-extending and damaging the mechanism.
CAB
CA-21
TILT CYLINDER
SM 19-635
T = Tightening torque: N m {kgf-cm, lbf-ft}
1.	Piston rod	8.	O-ring	15.	O-ring
2.	Stop ring	9.	Spring	16.	Cylinder
3.	Gasket	10.	Check valve ball	17.	Oil seal ring
4.	Oil seal	11.	Ball joint bearing	18.	O-ring
5.	Tube end	12.	Spring	19.	Oil seal ring
6.	O-ring	13.	O-ring	20.	Piston
7.	O-ring	14.	Filter		
СА-22
CAB
IMPORTANT POINT(S) - DISASSEMBLY
TILT CYLINDER
1. Remove the check valves.
2. Loosen the stop ring.
3.	Pull out the piston rod assembly.
NOTE: Take care not to damage the piston rod, and remove the
rod over an oil pan, as oil will leak out.
IMPORTANT POINT(S) - ASSEMBLY
TILT CYLINDER STOP RING
Using a press, install the gasket into the stop ring.
NOTE: After the gasket has been pressed in, fill the inside with
lithium grease.
Afterwards, apply lithium grease to О-rings and seals.
TILT CYLINDER TUBE END
Assemble the seal ring and О-rings to the tube end.
NOTE: Pay attention to the seal ring direction.
When assembling the tube end, use the new seal ring.
CAB
CA-23
TILT CYLINDER PISTON
Assemble seal rings and О-ring to the piston.
NOTE: When assembling the piston, use the new О-ring and seal
rings.
Apply adhesive (Three Bond No. 1374 or it equivalent) between
the piston and the piston rod.
CHECK VALVE
Apply lithium grease to the O-rings.
СА-24
CAB
TILT PUMP
T=7.4-9.8 {75-100, 5.43-7.23}
9
8
7
6
5
4 -
T=4.9-6.9 {50-70, 3.62-5.06}
T=44.1-53.9 {450-550,
32.55-39.78}
12
15
T=7.8-10.8 (80-110, 5.79-7.95}
25
T=4.9-6.9 (50-70, 3.62-5.06)
31
T=11.8-19.6 (120-200, 8.68-14.46)
39.2-49.0 (400-500, 28.94-36.16}
SM19-644
13
14
T=11.8-14.7 (120-150, 8.68-10.84}
T=2.5-3.4
(25-35,
1.81-2.53}
30 ©-----29
©----30
T=4.9-7.4 {50-75,
3 62-5.42}
T = Tightening torque: N m (kgf-cm, Ibf-ft}
1.	Reservoir tank	13.	Back up ring	25.	Gasket
2.	O-ring	14.	Gasket	26.	Back up ring
3.	Filter	15.	Bracket	27.	Bracket
4.	Gasket	16.	Gasket	28.	UP-DOWN select lever
5.	Filler cap	17.	Bearing	29.	Filter
6.	Pump cylinder	18.	O-ring	30.	O-ring
7.	Spring	19.	Motor	31.	Joint
8.	Plain washer	20.	Plug	32.	Plug
9.	Piston	21.	Spring	33.	Relief valve
10.	Dust cover	22.	Check valve ball	34.	Select lever lock bolt
11.	Manual pump lever	23.	O-ring		
12.	Piston	24.	Valve		
CAB
CA-25
IMPORTANT POINT(S) - DISASSEMBLY
RELIEF VALVE
Never disassemble the relief valve when removing the relief
valve.
NOTE: The relief valve has been adjusted.
34.3 MPa {350 kgf/cm’, 4,980 Ibf/in2}
TILT MOTOR
Never open the tilt motor cover.
If the motor is fault, replace the motor assembly.
UP-DOWN SELECT LEVER
1.	Remove the lock bolt.
2.	Remove the bracket fitting bolts.
3.	Pull the select lever with the bracket.
IMPORTANT POINT(S) - ASSEMBLY
TILT MOTOR
Apply lithium grease to the O-ring.
MANUAL TILT PUMP
Apply lithium grease to the gasket.
СА-26
CAB
SM19-645
CHECK VALVES
Coat the plug with seal tape when installing.
UP-DOWN SELECT LEVER
Apply lithium grease to the gasket.
Install the select lever then lock the lock bolt.
CAB
CA-27
CAB LOCK MECHANISM
T=0.6-1.2 {6-12, 0.44-0.86}
3.	Dust cover
4.	Cab lock rod
5.	Stopper
SMI 9-646
T = Tightening torque: Nm {kgf-cm, Ibf-ft}
СА-28
CAB
IMPORTANT POINT(S) - MOUNTING
CAB LOCK SWITCH
Adjust the dimension L, 20 mm {0.787 in} in the elongated
hole of the switch, at the cab is locked position.
Tight the installing bolts properly torque.
SAFETY HOOK
Adjust the dimension A (between the rod and the safety hook)
2 mm {0.079 in) in elongated hole of the safety hook.
Tight the installing bolts properly torque.
SM 19-033
LUBRICATION
Apply chassis grease to * marked position.
CAB
CA-29
DOOR
SM19-648
T = Tightening torque: N m {kgf-cm, Ibf-ft}
1.	Ventilator	8.	Door inside hole cover	15.	Ashtray
2.	Weather strip	9.	Door pull handle	16.	Ashtray case
3.	Window glass	10.	Door lock	17.	Power window switch
4.	Lock cylinder	11.	Door lock (key less entry type)	18.	Upper trim
5.	Outside handle	12.	Door pocket	19.	Window regulator
6.	Oscillate-proof	13.	Case		
7.	Door striker	14.	Inside trim		
СА-30
CAB
IMPORTANT POINT(S) - DISASSEMBLY
INSIDE TRIM
Remove under procedure.
1.	Ashtray.
2.	Inner oscillate-proof.
3.	Upper trim (with power window switch)
Upper handle and lock handle bezel
5. Inside trim (with pocket)
IMPORTANT POINT(S) - ASSEMBLY
SERVICE HOLE COVER
Stick butyl rubber tape along lowertangent line of drain hole
of the door.
CAB
CA-31
DOOR LOCK
Mount the door lock and check the smoothly operation of the
door lock or unlock.
ADJUSTMENT
DOOR HINGE
1. Remove the comer panel.
2. Make vertical and horizontal adjustments by loosening the
hinge bolts at the doors.
3. Make depth adjustments by loosening the hinges bolts at the
body side.
STRIKER
Check the engagement between the door lock and the striker.
Make the top and bottom contact even.
Perform adjustment so that the outside of the door and the
outside of the rear quarter panel are flush with each other.
After adjustment, properly tighten the bolts.
NOTE: When adjustment the door in the vertical direction, do not
force it into alignment using the door lock striker.
СА-32
CAB
OUTSIDE HANDLE
Adjust the push bolt so that the door latches securely and
releases without excessive play in the thumb button.
CAB
WINDSHIELD GLASS
SM19-658
1.	Weather strip
2.	Front windshield glass
3.	Quarter window glass
4.	Back window glass
5.	Tube
СА-34
CAB
IMPORTANT POINT(S) - DISMOUNTING
WINDSHIELD GLASS
Cut the lip of weather strip with a knife.
The glass is bonded to the weather strip with adhesive.
Take off the glass.
Cut weather strip away completely with a cutter, leaving no
pieces on the body.
IMPORTANT POINT{S) - MOUNTING
FRONT GLASS
1.	Assemble the glass and weather strip.
2.	Wrap a working string into the groove of the weather strip.
3.	Fit the glass assembly to the cab.
Pull the working string from the inside of the cab, and
gradually install the lip of the weather strip on the flange of
the window opening. During this operation, strike the glass
from the outside using a rubber hammer to ensure that the
weather strip fits properly against the cab.
CAB
CA-35
4.	Mask the front glass upper by masking tape along the weather
strip.
Apply adhesive between the front glass upper and the weather
strip as shown in figure.
NOTE: Use Cemedine 366ET, IMRON SEALANT or equivalent as
adhesive.
5.	Allow the adhesive to dry for approximately 15 hours.
Once the adhesive has dried, remove the masking tape.
NOTE: Handle the adhered portions with care for about one
month until the adhesive completely hardens.
BACK WINDOW
Do not align the weather strip drain hole to body drain hole.
СА-36
CAB
INSTRUMENT PANEL
Representative,
Left hand drive vehicle
T = Tightening torque: N m {kgf-cm, Ibf-ft}
1.	Switch panel	8.	Resister
2.	Blower duct	9.	Side cover
3.	Instrument panel housing cluster	10.	Instrument panel cover
4.	Meter hood	11.	Lower center cover
5.	Resister	12.	Switch board panel
6.	Instrument panel pad	13.	Steering column cover
7.	Upper panel	14.	Pedal bracket
CAB
CA-37
IMPORTANT POINT(S) - DISASSEMBLY
METER PANEL
1. Pull the meter hood.
2. Remove the bolts.
3. Disconnect the wiring connectors and air hose at the back of
the meter.
THROTTLE CONTROL KNOB
Insert a pin into the side hole of the knob.
Pull the knob out, pressing a pin.
SM 19-664
СА-38
CAB
SEAT
SM 19-665
T = Tightening torque: N-m {kgf-cm, Ibf-ft}
CAB
CA-39
BLOWER
Representative,
Left hand drive vehicle
T = Tightening torque: N-m {kgf-ft, lbf-in}
1.	Controller
2.	Duct
3.	Nozzle
4.	Heater radiator
5.	Control duct
6.	Blower
СА-40
CAB
Representative,
Left hand drive vehicle
POWER MIRROR
SM 19-667
T = Tightening torque: IM-rn (kgf-cm, Ibf-ft}
1.	Mirror stay
2.	Assistant side mirror
3.	Under view mirror
4.	Sub stay
5.	Bracket
6.	Mirror stay
7.	Side under view mirror
8.	Outer view mirror
CAB
CA-41
IMPORTANT POINT(S) - DISMOUNTING
POWER MIRROR
Dismount the power mirror in "SET" position.
NOTE: Do not dismount the power mirror in "CLOSE" position.
IMPORTANT POINT(S) - MOUNTING
POWER MIRROR
1. Assemble the sub stay and mount the sub stay to the cab.
(Power mirror "SET" position)
2. Mount the power mirror to the cab in "SET" position.
SM 19-668