HYDRAULIC SYSTEM
MA
CONTENTS
1. SERVICE DATA..................................... HD-2
(1) Hydraulic Oil and Oil Level............. HD-2
(2) Accumulator (Smooth Running System)
Specification................................... HD-2
(3) Adjustment Value............................ HD-2
(4) Tightening Torque........................... HD-3
2. SERVICE INFORMATION..................... HD-5
3. HYDRAULIC CIRCUIT DIAGRAM........ HD-6
(1) Standard Specification.................... HD-6
(2) Proportional Valve Specification..... HD-6
(3) Smooth Running System and Automatic
Tilt Horizontal Stop Specifications
(Optional)........................................ HD-7
(4) Attachment Specification................ HD-8
4. HYDRAULIC PIPING............................ HD-9
(1) Layout............................................. HD-9
(2) Piping Components...................... HD-13
(3) Accumulator COMP...................... HD-14
(4) Inspection..................................... HD-14
5. HYDRAULIC PUMP............................ HD-15
(1) External View................................ HD-15
(2) Service Information....................... HD-15
6. CONTROL VALVE.............................. HD-16
(1) External View................................ HD-16
(2) Construction.................................. HD-17
(3) Removal and Reinstallation.......... HD-20
(4) Disassembly and Reassembly...... HD-21
SECTION HD
7. HYD LEVER........................................ HD-23
(1) Standard Lever............................. HD-23
(2) Single Hydraulic Lever (Optional).HD-25
8. CYLINDERS........................................ HD-27
(1) Tilt Cylinder................................... HD-27
(2) Lift Cylinder................................... HD-30
(3) Full-Free Cylinder (2F/3F Mast).... HD-39
(4) Bleeding........................................ HD-41
(5) Down Safety Valve........................ HD-41
9. INSPECTION AND ADJUSTMENT.... HD-42 HD
(1) In Case of Emergency
(Forks/Mast Cannot Be Lowered).. HD-42
(2) Hydraulic Pressure Inspection and
Adjustment.................................... HD-43
(3) Accumulator Inspection and Adjustment
(Smooth Running System)............ HD-45
10. OPTIONAL EQUIPMENT.................. HD-47
(1) Layout........................................... HD-47
(2) Relief Valve................................... HD-49
 SERVICE DATA

1. SERVICE DATA
(1) Hydraulic Oil and Oil Level
Item Truck models Type Type of oils and lubrication Capacity (ℓ)
2W300 21.6 (17.0)

1.0 to 1.75 ton 2F300 22.6 (17.0)

3F470 22.0 (17.0)

2W300 [Standard truck] 23.7 (18.8)

Hydraulic oil Hydraulic oil (ISO VG32)
2.0, 2.5 ton 2F300 24.6 (18.8)
(Hydraulic oil tank) [Cold storage specification truck]
3F470 Hydraulic oil (ISO VG15) 24.0 (18.8)

2W300 28.7 (23.8)

3.0, 3.5 ton 2F300 30.0 (23.8)

3F470 28.5 (23.8)

(2) Accumulator (Smooth Running System) Specification

Item Accumulator for high pressure Accumulator for low pressure
Model Piston accumulator
Capacity (ℓ) 0.2
Filling gas Nitrogen gas
Charging pressure (MPa{kgf/cm2}) 5.0+0.2/-0.1{51+2/-1} 1.0±0.1{10±1}
2
Maximum pressure (MPa{kgf/cm }) 28 {286}
Weight (kg) 2 2.2

(3) Adjustment Value

Control valve
Item Hydraulic pressure standard/adjustment range (MPa{kgf/cm²})
1.0 ton 13.7 {140}
1.5, 2.0 ton 15.7 {160}
Main relief valve
1.75 ton 17.2 {175}
2.5, 3.0, 3.5 ton 18.1 {185}

Tilt cylinder
Item Standard (mm)
Tilt cylinder socket spherical bushing φ34.988 - 35.000
1.0 to 1.75 ton φ31.95 - 32.15
Cylinder frame mounting side bushing
2.0 to 3.5 ton φ31.85 - 32.15

Lift cylinder
Item Standard (mm)
Internal/External drain single-acting piston type (2W mast/3F mast) 23
Cushion stroke
Single-acting ram type (2F mast) 21

HD-2
 SERVICE DATA

(4) Tightening Torque

Item Tightening torque (N-m {kgf-m})
Hose (G1/4) 20 - 25 {2.0 - 2.5}
Hose (G3/8) 27 - 34 {2.7 - 3.5}
Hydraulic piping
Hose (G1/2) 51 - 64 {5.2 - 6.5}
Hose clip mounting bolt 7.9 - 11.7 {0.8 - 1.2}
Elbow (suction side) 97 - 119 {9.9 - 12.1}
Hydraulic pump Elbow (discharge side) 30 - 35 {3.0 - 3.6}
Mounting bolt 20 - 24 {2.0 - 2.5}
Pipe clip mounting bolt 7.9 - 11.7 {0.8 - 1.2}
Accumulator bracket 16 - 23 {1.6 - 2.4}
Accumulator
Elbow 27 - 34 {2.7 - 3.5}
(Smooth running: optional)
Band mounting bolt 8.69 - 13.3 {0.89 - 1.33}
Accumulator plug 20 {2.0}

Solenoid valve Elbow 44 - 54 {4.5 - 5.5}

(Tilt horizontal stop: optional) Mounting bolt 3.1 - 4.7 {0.32 - 0.47}
Connector, nipple (G1/2) 53 - 64 {5.5 - 6.5}
Nipple (G3/8) 36 - 43 {3.7 - 4.3}
Control valve mounting bolt/nut 16 - 23 {1.7 - 2.3}
Standard
Lift sensor mounting bolt 3.1 - 4.7 {0.32 - 0.47}
Specification
Bracket mounting bolt 3.1 - 4.7 {0.32 - 0.47}
Control valve Lever switch mounting nut 5.0 - 6.0 {0.51 - 0.61}
Lift lock release screw lock nut 2.0 - 2.9 {0.21 - 0.29}
Connector, adapter (7/8-14UNF-2B) 56 - 69 {5.8 - 7.0}
Proportional Adapter (3/4-16UNF-2B) 40 - 49 {4.1 - 4.9}
valve
specification Control valve mounting bolt/nut 16 - 23 {1.7 - 2.3}
Lock nut for lift lock release screw and relief valve 6.9 - 8.8 {0.71 - 0.89}

Standard lever Knob fixing screw 0.4 - 0.7 {0.04 - 0.07}

specification Lever bracket 7.9 - 11.7 {0.8 - 1.2}
Knob fixing screw 2.5 - 2.9 {0.26 - 0.29}
Knob fixing screw (for attachment) 0.4 - 0.7 {0.04 - 0.07}
HYD lever Single hydraulic Lever bracket 7.9 - 11.7 {0.8 - 1.2}
lever specification
(optional) Turn buckle length adjustment 29 - 43 {3.0 - 4.4}
Guide plate fixing bolt 3.1 - 4.7 {0.32 - 0.47}
Lift rod fixing bolt 16 - 23 {1.6 - 2.3}

HD-3
 SERVICE DATA

Item Tightening torque (N-m {kgf-m})

Cylinder head 265 - 421 {28 - 42}
1.0 to 1.75 ton Spacer (for backward tilting) 14.7 {1.5}
Lock nut 206 {21}
Tilt cylinder Cylinder head 282 - 424 {29 - 43}
2.0, 2.5 ton
Self lock nut 393 - 479 {41 - 48}
Cylinder head 441 - 539 {45 - 55}
3.0, 3.5 ton
Self lock nut 559 - 677 {57 - 69}
Cylinder head (1.0 to 1.75 ton) 171 - 261 {18 - 26}
Cylinder head (2.0, 2.5 ton) 206 - 312 {22 - 31}
Internal/External
drain single-acting Cylinder head (3.0 ton) 242 - 364 {25 - 37}
piston type Cylinder head (3.5 ton) 234 - 374 {24 - 38}
(2W mast/3F mast)
Plug (Internal drain single-acting
4.75 - 5.25 {0.49 - 0.53}
piston type only)

Lift cylinder Holder (1.0 to 2.5 ton) 167 - 245 {18 - 25}

Cylinder Holder (3.0 ton) 181 - 289 {19 - 29}

Holder (3.5 ton) 234 - 374 {24 - 38}
Single-acting ram
Steel ball set screw 15 - 24 {1.5 - 2.4}
type (2F mast)
Piston set screw 2.94 - 4.90 {0.30 - 0.49}
Check valve (1.0 to 3.0 ton) 161 - 231 {17 - 23}
Check valve (3.5 ton) 201 - 289 {21 - 29}
Cylinder head (1.0 to 1.75 ton) 295 - 469 {31 - 47}
Cylinder head (2.0, 2.5 ton) 326 - 518 {34 - 52}
Full-free cylinder Cylinder head (3.0 ton) 377 - 603 {39 - 61}
Cylinder head (3.5 ton) 408 - 652 {42 - 66}
Plug 4.75 - 5.25 {0.49 - 0.53}
G3/8 (with O-ring at the G3/8 cylinder side) 35 - 39 {3.6 - 3.9}

Down safety G3/8 (for mounting hose) 30 - 58 {3.1 - 5.9}

valve G1/2 (with O-ring at the G3/8 cylinder side) 40 - 44 {4.1 - 4.4}
G1/2 (for mounting hose) 59 - 98 {6.1 - 9.9}
Pressure gauge bracket mounting bolt 7.9 - 11.7 {0.8 - 1.2}
Relief valve bracket mounting bolt 3.1 - 4.7 {0.32 - 0.47}
Clip mounting bolt 3.1 - 4.7 {0.32 - 0.47}
Valve bracket mounting bolt 16 - 23 {1.6 - 2.4}
Relief pipe COMP. 27 - 34 {2.7 - 3.5}
Optional equipment Cover bracket mounting bolt 16 - 23 {1.6 - 2.4}
Plug 20 - 25 {2.0 - 2.6}
Solenoid valve cover (1) upper side 7.9 - 11.7 {0.8 - 1.2}
Solenoid valve cover (1) lower side 3.1 - 4.7 {0.32 - 0.47}
Solenoid valve cover (2) 3.1 - 4.7 {0.32 - 0.47}
Nipple, elbow (G3/8) 27 - 34 {2.7 - 3.5}

HD-4
 SERVICE INFORMATION

2. SERVICE INFORMATION
CAUTION
•• Keep the workplace clean at all times to prevent the entry of foreign matter into the system.
•• When disconnecting pipes, cover the areas around the pipes with shop rags to prevent other
components from being contaminated with oil.
•• When installing pipes, make sure that there is no foreign matter inside them.
•• Disassembled parts should be put on clean paper or cloth. Use caution not to contaminate or
damage them.
NOTE:
•• After finishing the service, make sure to check the hydraulic oil level. If the oil level is low, add the
oil.

HD-5
 HYDRAULIC CIRCUIT DIAGRAM

3. HYDRAULIC CIRCUIT DIAGRAM

(1) Standard Specification

15
17

16 8 10

G A1 B2 A2 B3 A3 B4 A4 B5 A5
5

2 T

3
4
M 6
7 9 11 12 13 14
1 BSM3691

1. Hydraulic oil tank 7. Lift valve 13. 4th valve

2. Hydraulic pump 8. Lift lock solenoid valve 14. 5th valve
3. HYD motor 9. Flow regulator valve 15. Lift cylinder
4. Return filter 10. Check valve 16. Down safety valve
5. Control valve 11. Tilt valve 17. Tilt cylinder
6. Main relief valve 12. 3rd valve

NOTE:
•• Marked ※ : For oil circulation system
•• Attachment for 3rd valve specification: sideshifter, rotating fork, hinged fork, fork positioner (double-
acting system)
•• Attachment for 4th valve specification: fork positioner (single-acting system)
•• Attachment for 5th valve specification: fork positioner with sideshifter (single-acting system)

(2) Proportional Valve Specification

5
8
3
A1 B2 A2 B3 A3 B4 A4
G

10

M
1 2 4 6 7 9
BSM3692

1. Main relief valve 5. Tilt lock valve 9. 4th valve

2. Lift valve 6. Check valve 10. Unload valve
3. Lift lock valve 7. 3rd valve
4. Tilt valve 8. Solenoid valve

NOTE:
•• For part names other than listed above, refer to the standard specification.

HD-6
 HYDRAULIC CIRCUIT DIAGRAM

(3) Smooth Running System and Automatic Tilt Horizontal Stop Specifications
(Optional)

G A1 B2 A2 2

3
P

BSM3693

1. Accumulator 2. Tilt horizontal stop switch 3. Solenoid valve

NOTE:
•• For part names other than listed above, refer to the standard specification.

HD-7
 HYDRAULIC CIRCUIT DIAGRAM

(4) Attachment Specification

Equipped with port relief valve Roll clamp

(3rd valve and 4th valve)
Clamp cylinder
Close Open
B3 A3 B4 A4 Rotator Lever knob Stepless pressure
switch adjustment valve

Solenoid When pressure

valve adjustment valve
is installed
B3 A3 B4 A4

Port relief valve

Bale clamp (single-acting type)

Fork clamp (single-acting type)
Rotating fork clamp
Clamp cylinder
Close Open
Clamp cylinder Clamp cylinder Clamp cylinder
Close Open Lever knob Close Open Close Open
switch
Rotator Lever knob Lever knob
Lever knob
switch switch switch
Solenoid
valve
Solenoid Solenoid Solenoid
valve valve valve
2 B3 A3 B4 A4 2 B3 A3 B4 A4 B5 A5

BSM3694

NOTE:
•• For lift and tilt-related hydraulic circuits other than shown above, refer to the standard specification.
•• When port relief valve is installed:
Attachment for 3rd valve specification: fork positioner (double-acting system), stabilizer
Attachment for 4th valve specification: fork positioner (single-acting system)

HD-8
 HYDRAULIC PIPING

4. HYDRAULIC PIPING
CAUTION
•• Pipe connector screw part tightening torque
Size G1/4 (N-m ｛kgf-m}): 20 - 25 {2.0 - 2.5}
Size G1/8 (N-m ｛kgf-m}): 27 - 34 {2.7 - 3.5}
Size G1/2 (N-m ｛kgf-m}): 51 - 64 {5.2 - 6.5}

(1) Layout
Standard and proportional valve specifications (1.0 to 2.5 ton)
Tilt cylinder Hose clip
Hydraulic Elbow
Yellow tape pump
(identification)
To Control valve

Tilt cylinder side

High-pressure hose (G1/2)
(G1/4)
Yellow tape (identification)
2.0, 2.5 ton only
Elbow D
Tilt pipe COMP. White paint
(facing right)
View C
C
To Mast 90 +5
°
High-pressure
F Hydraulic pump Hydraulic 0
hose
pump (G1/2)

E A

F
Lift hose View D
Suction hose
Hose clip Hydraulic motor White paint (facing up)
㸦16°㸧
Hose clip Tilt pipe COMP.
B
(G3/8)
High-pressure
Return hose hose
Yellow paint (facing up) (G1/2)
Not to interfere with White paint (facing up)
front axle and terminal cap Not to interfere with
hydraulic motor White paint (facing up)
Pressure sensor Control valve
Lift hose
Hose clip (G1/2) (standard)
Hose clip screw tip not to interfere
with nearby parts
White paint (facing up)
㸦27°
㸧
Tilt pipe COMP.
B (G3/8)
White paint (facing up) High-pressure hose
Not to interfere with (G1/2)
hydraulic motor
View E View F
Return hose
Return hose
Hose clip
Hydraulic oil tank side Control valve side
Pressure sensor White paint (facing up)
Lift hose Control valve
Install return hose into Install return hose into (G1/2) (proportional)
tank pipe thoroughly. control valve pipe thoroughly.
View B View A
BSM3695

HD-9
 HYDRAULIC PIPING

Standard and proportional valve specification (3.0, 3.5 ton)

Red tape (identification) 2W/2F mast Hose clip

White tape (identification) 3F mast
Hydraulic

㸦15㸧
Tilt cylinder pump
To Control valve

Tilt cylinder side High-pressure hose

(G1/4) (G1/2)
Red tape
(identification)
Tilt pipe COMP. D
View C White paint
(facing right)
C
Hydraulic Hydraulic
㸦 High-pressure
15
pump pump 0r hose
To Mast 㸧 (G1/2)

Red tape E
(identification) A
Lift hose Suction hose View D
Hydraulic motor

Hose clip
Hose clip White paint (facing up)
㸦16r㸧
Tilt pipe COMP.
B (G3/8)
Return hose
Yellow paint (facing up)
Not to interfere with
front axle and terminal cap White paint (facing up)
Not to interfere with White paint
hydraulic motor (facing up)
Pressure sensor Control valve
Hose clip screw tip not to interfere (standard)
with nearby parts Hose clip
Lift hose
High-pressure
(G1/2)
hose (G1/2)

B White paint (facing up)

Tilt pipe COMP.
View E White paint (facing up)
0r
㸧
(G3/8)
Not to interfere with 12
Install return hose hydraulic motor
㸦
into control valve pipe High-pressure hose
White paint thoroughly (G1/2)
Connector COMP.
Control
valve side Return hose
Yellow paint
Pressure sensor White paint (facing up)
Hydraulic oil Return hose
tank side Lift hose Control valve
(G1/2) (proportional)
Install return hose into
tank pipe thoroughly. View A
View B
BSM3930

HD-10
 HYDRAULIC PIPING

Option (Smooth running system and automatic tilt horizontal stop specifications) (1.0 to 2.5 ton)
Tilt cylinder Hose clip screw tip not to
Yellow tape (identification) interfere with nearby parts
2.0, 2.5 ton only

Tilt cylinder side (G1/4)

Tilt pipe COMP.
View E View F
Accumulator pipe
Accumulator
Solenoid valve Accumulator COMP.
pipe (G3/8)
C Hydraulic pump
To Mast
Accumulator
F COMP.

E H
G F
A 16 - 23 {1.6 - 2.4}

Lift hose View H

Suction hose
Hose clip insert value Tilt hose (G1/4)
Hose clip
Elbow㸦G3/8㸧

Solenoid valve

㸦12.5°㸧
Yellow paint (facing up) Hydraulic motor 44 - 54
Not to interfere with front {4.5 - 5.5}
Yellow tape (identification) Control valve
axle and terminal cap
2.0, 2.5 ton only

Hose clip
High-pressure hose (G1/2) Pressure sensor
Elbow Yellow tape (identification)

㸦
35
2.0, 2.5 ton only

°㸧
90 +5 To Mast
°
0
3.1 - 4.7
Hydraulic Hydraulic High-pressure {0.32 - 0.47}
pump pump High-pressure hose (G3/8)
Lift hose
hose (G1/2)
View G
White paint
Elbow D (facing right)
Hydraulic oil tank side Return hose
View C
: N-m {kgf-m}
View D Control valve side

: N-m {kgf-m} Install return hose Install return hose

into tank pipe thoroughly. into control valve pipe
(Smooth running system + View B thoroughly.
automatic tilt horizontal stop specifications)
White paint (facing up)
White paint Hose clip 8.8 - 13.2 (Smooth running system) (Automatic tilt horizontal stop specifications)
(facing up)
{0.9 - 1.4} White paint
7.9 - 11.7 White paint (facing up)
Not to interfere {0.8 - 1.2} Not to interfere with hydraulic motor White paint (facing up)
Hose clip
with hydraulic 㸦16°㸧 (facing up) Not
Tilt pipe Tilt pipe 7.9 - 11.7
motor to interfere with
㸦16°㸧 COMP. (G3/8) B COMP. (G3/8)
hydraulic motor {0.8 - 1.2}
B Clip
Clip Tilt pipe
8.8 - 13.2 㸦16°㸧 COMP. (G3/8)
{0.9 - 1.4} B
Accumulator Solenoid valve
pipe (G3/8) Return Accumulator
hose pipe (G3/8)
Return
hose
Pressure
sensor Return Elbow
Pressure
sensor To Hydraulic hose High-pressure
Hose clip pump hose (G3/8)
Hose clip To Hydraulic Pressure Elbow
pump High-pressure sensor
Elbow Install hose㸦G1/2㸧 Hose clip
Install horizontally. To Hydraulic pump
High-pressure
horizontally. hose (G1/2) Accumulator COMP. Lift hose (G1/2) High-pressure
Accumulator COMP. View A hose (G1/2)
BSM3696

HD-11
 HYDRAULIC PIPING

Option (Smooth running system and automatic tilt horizontal stop specifications) (3.0, 3.5 ton)
Tilt cylinder Tilt cylinder side (G1/4) Hose clip screw tip not to
interfere with nearby parts

Tilt pipe COMP.

Accumulator pipe

Solenoid valve View E

C
Hydraulic pump
To Mast
Tilt hose (G1/4)
Accumulator
COMP. Tilt pipe COMP.

Solenoid valve
Red tape G 3.1 - 4.7
(identification) {0.32 - 0.47}
E 㸦12r
㸧
Lift hose Control
A valve
H

㸦5r㸧
Red tape
(identification) Suction hose Pressure sensor
Insert hose 40 mm
(2 positions)
Not to interfere with
Hose clip hydraulic motor. To Mast

Hydraulic motor
Lift hose
Red tape (identification) 2W/2F mast
Hose clip White tape (identification) 3F mast
High-pressure hose (G1/2)
㸦15㸧

Red tape (identification)

View G
Insert return hose 7.9 - 11.7
White paint into control valve {0.8 - 1.2}
㸦15

Hydraulic Hydraulic (facing up) pipe thoroughly.

pump pump
0r㸧

High-pressure
hose (G1/2)
Yellow paint Control
White paint (facing up) valve side
(facing up)
D
Hydraulic oil Return hose
: N-m {kgf-m} View C View D tank side
: N-m {kgf-m} Insert return hose into
tank pipe thoroughly.
(Smooth running system + View B
automatic tilt horizontal stop specifications) (Smooth running system) (Automatic tilt horizontal stop specifications)
White paint (facing up)
Hose clip 44 - 54
3.1 - 4.7 {4.5 - 5.5} Hose clip
{0.32 - 0.47} White paint White paint 3.1 - 4.7
(facing up) (facing up) {0.32 - 0.47}
Tilt pipe Tilt pipe
COMP. (G3/8) COMP. (G3/8)
Return Return Tilt pipe
hose hose COMP. (G3/8)
㸦16r㸧 Clip 㸦16r㸧 Return
B B Clip hose r㸧
B㸦16
Accumulator Accumulator
pipe (G3/8) pipe (G3/8)

To Hydraulic To Hydraulic To Hydraulic

Pressure pump Pressure pump
sensor sensor pump
Pressure Elbow
Hose clip
Hose clip sensor
Hose
Elbow Elbow clip
Install Install
High-pressure White paint
horizontally. horizontally. High-pressure 44 - 54
hose (G1/2) hose㸦G1/2㸧 (facing up) {4.5 - 5.5}
High-pressure
hose (G1/2)
View A 15.7 - 23.5 View A 15.7 - 23.5
{1.6 - 2.4} {1.6 - 2.4} View A
Accumulator COMP. Accumulator COMP.
View H View H BSM3932

HD-12
 HYDRAULIC PIPING

(2) Piping Components

NOTE:
・These are piping components
G1/4

for 1.0 to 2.5-ton trucks.

1

G1/4

20 - 25 3
{2.0 - 2.5}
G3/8

20 - 25
{2.0 - 2.5} 4
G3/8
2
6

G1/4
8
20 - 25
20 - 25 {2.0 - 2.5}
7 {2.0 - 2.5}

5
7.9 - 11.7 G1/4
{0.8 - 1.2}
G1/4
9
20 - 25 17
{2.0 - 2.5} 18 44 - 54
{4.5 - 5.5}
11
20 - 25 10
20 44 - 54
{2.0 - 2.5}
G3/8 G1/4 {4.5 - 5.5}
13
G1/4 19
14
12 16
G3/8
20 - 25
{2.0 - 2.5}
3.1 - 4.7
15 {0.32 - 0.47}
G1/4 G3/8
21
G3/8
G3/8
27 G1/2
29
To Mast G1/2
23
33
24
26
32 28

G1/2
16 - 23
7.9 - 11.7 {1.6 - 2.4} 30
: N-m {kgf-m}
25
{0.8 - 1.2}
31
: N-m {kgf-m}
BSM3697

1. Tilt pipe COMP. 12. Tilt hose 23. Clip

2. Tilt hose 13. 3-way joint 24. Pressure sensor
3. Tilt hose 14. Tilt pipe COMP. 25. Lift hose
4. 3-way joint 15. Tilt hose 26. Accumulator pipe
5. Tilt pipe COMP. 16. 3-way joint 27. Accumulator pipe COMP.
6. Tilt hose 17. Tilt hose 28. Accumulator
7. Tilt hose 18. Elbow 29. High-pressure hose
8. 3-way joint 19. Solenoid valve 30. Accumulator pipe
9. Clip 20. Elbow 31. Elbow
10. Tilt pipe COMP. 21. High-pressure hose 32. Bracket
11. Tilt hose 22. Elbow 33. Band

HD-13
 HYDRAULIC PIPING

(3) Accumulator COMP.

1.0 to 2.5 ton
2

: 27 - 34
{2.7 - 3.5}
: 27 - 34
6
1 7 : 8.69 - 13.3 {2.7 - 3.5}
{0.89 - 1.33} Section Z-Z

4 : 27 - 34
Z {2.7 - 3.5}
3

5
Z

3.0, 3.5 ton

2

: 27 - 34
{2.7 - 3.5}

6 : 27 - 34
{2.7 - 3.5}
1 7 : 8.69 - 13.3
{0.89 - 1.33}
Section Z-Z

4 : 27 - 34
{2.7 - 3.5}
3 Z

: N-m {kgf-m}
: N-m {kgf-m} Z 5 BSM3934

1. Accumulator 4. High-pressure hose 7. Bolt

2. Bracket 5. Accumulator pipe
3. Band 6. Elbow

(4) Inspection
Degraded or damaged hoses and pipes should be replaced.
Leaking connectors should be retightened and any damaged connectors should be replaced.

HD-14
 HYDRAULIC PUMP

5. HYDRAULIC PUMP
(1) External View

Discharge port

Model number stamped

Suction Discharge
port port

Suction port
BSM3699

(2) Service Information

Apply molybdenum grease.
Bolt (Daphne grease M
Suction port : 20 - 24 No.2 or equivalent)
Elbow X {2.0 - 2.5}
: 97 - 119
{9.9 - 12.1}

Hydraulic pump

Hydraulic motor
Discharge port

Elbow
: 30 - 35
Front {3.0 - 3.6}
Section X-X
: Apply grease. X
: N-m {kgf-m} BSM3700

NOTE:
•• The above figures show the installation of a hydraulic pump on 1.0 to 2.5-ton trucks.
(The shape of the suction-side elbow is the only difference from that on 3.0 and 3.5-ton trucks.)
•• For removal and installation of the hydraulic pump, refer to Section RI.
•• Remove the elbow (discharge side) and the elbow (suction side) from the hydraulic pump.
•• Tightening torque (for all models)
Elbow (suction side) (N-m {kgf-m}): 97 - 119 {9.9 - 12.1}
Elbow (discharge side) (N-m {kgf-m}): 30 - 35 {3.0 - 3.6}
Hydraulic pump mounting bolt (N-m{kgf-m}): 20 - 24 {2.0 - 2.5}

HD-15
 CONTROL VALVE

6. CONTROL VALVE
(1) External View
Standard Specification

4 14 8 16
4
9
3
1
5 2
5

10 18

11
17

13

7
6
6 12 15

BSM3701

1. Front cover 7. Main relief valve 13. A2 port (to tilt cylinder)
2. Rear cover 8. 3rd valve 14. B2 port (to tilt cylinder)
3. Combination valve ASSY 9. 4th valve 15. A3 port (to attachment)
4. Flow regulator valve 10. P port (from hydraulic pump) 16. B3 port (to attachment)
5. Lift lock release screw 11. T port (to hydraulic oil tank) 17. A4 port (to attachment)
6. Lift lock solenoid 12. A1 port (to mast) 18. B4 port (to attachment)

Proportional valve specification

B 7
18
1 16
24 25 26 27
3 19 22
3
17
View B 7
2
20

8
21

6
15
5 6 6
14
28 29 30 31
23
12
10 11
View A 13
A
BSM3702

1. Air bleeding port 12. A1 port (to mast) 23. Solenoid A

2. Lock nut 13. A2 port (to tilt cylinder) 24. Solenoid B1
3. Emergency valve 14. A3 port (to attachment) 25. Solenoid B2
4. Front cover 15. A4 port (to attachment) 26. Solenoid B3
5. Lock nut 16. 3rd valve 27. Solenoid B4
6. Main relief valve 17. 4th valve 28. Solenoid A1
7. Air bleeding plug 18. B2 port (to tilt cylinder) 29. Solenoid A2
8. T port (to hydraulic oil tank) 19. B3 port (to attachment) 30. Solenoid A3
9. P port (from hydraulic pump) 20. B4 port (to attachment) 31. Solenoid A4
10. Lift valve 21. Rear cover
11. Tilt valve 22. Solenoid B

HD-16
 CONTROL VALVE

(2) Construction
Standard Specification
Front cover

2
3

BSM3703

1. Front cover 3. Stocking plug (Rc1/4)

2. O-ring 4. Relief valve ASSY

Combination valve

1
2 26 27

A A

X X B B

26
3 4 27
7 8 9 25
5 10 11 12 Section X-X

20
6
15

28 13

13 21
14
15 18 16 24
16 15 17 18 19 17 18 22 23 18
Section A-A Section B-B
BSM3704

1. Body 11. Check case ASSY 21. Set screw ASSY

2. O-ring 12. Emergency ASSY 22. Tilt lock spring
3. Bolt with a hexagon socket (M6 x 15) 13. Cap 23. Pilot spool
4. Bolt with a hexagon socket (M6 x 10) 14. Set screw ASSY 24. Tilt spool ASSY
5. Lift lock solenoid valve 15. Retainer spring 25. Bracket
6. Coil ASSY 16. Center spring 26. Load check poppet
7. O-ring 17. Seal plate 27. Load check spring
8. Retainer plug ASSY 18. Dust seal 28. Lift lock solenoid valve ASSY
9. Lift valve spring 19. Lift spool
10. Lock poppet 20. Flow regulator valve

HD-17
 CONTROL VALVE

Attachment section (without port relief)

8
7
6

10

12 16
11 12 14 15
14
13 3 17
2
Section X-X
4

X X

1 5

BSM3705

1. Bolt with a hexagon socket (M6 x 15) 7. O-ring 13. Seal plate
2. O-ring 8. O-ring 14. Dust seal
3. Body 9. Cap 15. Spool
4. Bracket N 10. Set screw ASSY 16. Poppet
5. Bolt with a hexagon socket (M6 x 10) 11. Center spring 17. Load check spring
6. Shut-off plug ASSY 12. Spring retainer

Attachment section (with port relief)

6 6
5 5
4 4

13 14
10 16
9 12 11
10 12
11 15
2 3 Section X-X

X X

1
BSM3706

1. Bolt with a hexagon socket (M6 x 15) 7. Cap 13. Spool

2. O-ring 8. Set screw ASSY 14. Poppet
3. Body 9. Center spring 15. Load check spring
4. Shut-off plug ASSY 10. Spring retainer 16. Bolt with a hexagon socket (M6 x 10)
5. O-ring 11. Seal plate
6. O-ring 12. Dust seal

HD-18
 CONTROL VALVE

Proportional valve specification

24 25 26 27 2 3 1 7 22 22 View G

G
A B C D D
16
3
17
4 E

18

13
12
6
E
A
B C D D 23 23

5 10 28 11 29 30 31 21
Section B-B Section C-C F View F

19 20

21 15 14
6
Section A-A Section E-E Section D-D (3rd and 4th valve)
BSM3707

1. Air bleeding port 12. A1 port (to mast) 23. Solenoid A

2. Lock nut 13. A2 port (to tilt cylinder) 24. Solenoid B1
3. Emergency valve 14. A3 port (to attachment) 25. Solenoid B2
4. Front cover 15. A4 port (to attachment) 26. Solenoid B3
5. Lock nut 16. 3rd valve 27. Solenoid B4
6. Main relief valve 17. 4th valve 28. Solenoid A1
7. Air bleeding plug 18. B2 port (to tilt cylinder) 29. Solenoid A2
8. T port (to hydraulic oil tank) 19. B3 port (to attachment) 30. Solenoid A3
9. P port (from hydraulic pump) 20. B4 port (to attachment) 31. Solenoid A4
10. Lift valve 21. Rear cover
11. Tilt valve 22. Solenoid B

HD-19
 CONTROL VALVE

(3) Removal and Reinstallation

Removal
: N-m {kgf-m} 8
9 11 : 16- 23
9 {1.7 - 2.3}
12
13
Standard specification 10
16

7
1
6

5
2
: 53- 64
{5.5 - 6.5} 14 : 16- 23
{1.7 - 2.3}
4 12
3
: 36- 43
: 53- 64 13
{3.7 - 4.3}
{5.5 - 6.5} 15
4 : 36 - 43 16
4 : 53- 64 {3.7 - 4.3}
{5.5 - 6.5}

Proportional valve specification

17 : 56- 69
{5.8 - 7.0}

14 : 16- 23
{1.7 - 2.3}
18ࠊ19
: 40 - 49 12
{4.1 - 4.9}
13
18ࠊ19 18ࠊ19 15
: 56 - 69 18ࠊ19 : 40 - 49
20 16
{5.8 - 7.0} : 40 - 49 {4.1 - 4.9}
{4.1 - 4.9} BSM3708

1. Lift sensor 8. Plain washer 15. Spring washer

2. Nipple 9. Snap pin 16. Washer
3. Connector 10. Clevis pin 17. Connector
4. Nipple 11. Bolt 18. Adapter
5. Control valve (Standard specification) 12. Grommet 19. O-ring
6. Bracket 13. Spacer 20. Control valve (proportional valve
7. Lever switch 14. Nut specification)

1. Remove the floor mat and floor plate. (Refer to Section RI.)
2. Remove the covers. (Refer to Section RI.)
3. Remove the piping connected to the control valve. (Refer to "4. HYDRAULIC PIPING")
4. For the standard specification control valve, disconnect the load handling lever.
5. Remove the control valve.

CAUTION
•• The control valve is heavy. When removing it, hold it carefully and securely so that it will not slip
from hands.
6. Remove the connector, nipple or adapter from the control valve as necessary.

HD-20
 CONTROL VALVE

Reinstallation
Note the following, and install in the reverse order of removal.
• Ensure that no foreign materials get into the piping and control valve.
• After connecting the piping, apply relief pressure and make sure that no fluid leakage is present.
• For the standard specification control valve, connect the load handling lever and the control valve.
After that, adjust the lever switch (pay attention to the clevis pin orientation).
• Tightening torque
Standard specification
Connector, nipple (G1/2) (N-m {kgf-m}): 53 - 64 {5.5 - 6.5}
Nipple (G3/8) (N-m {kgf-m}): 36 - 43 {3.7 - 4.3}
Control valve mounting bolt (N-m{kgf-m}): 16 - 23 {1.7 - 2.3}
Proportional valve specification
Connector, adapter (7/8-14UNF-2B) (N-m {kgf-m}): 56 - 69 {5.8 - 7.0}
Adapter (3/4-16UNF-2B) (N-m {kgf-m}): 40 - 49 {4.1 - 4.9}
Control valve mounting bolt (N-m{kgf-m}): 16 - 23 {1.7 - 2.3}

(4) Disassembly and Reassembly

4 3
3 4

1 2

BSM3709

1. Lift sensor 3. Bracket

2. Control valve 4. Lever switch

Disassembly
Lift sensor
1. Remove the bolt. Lift sensor
2. Remove the lift sensor.
Harness
Bolt
3.1 - 4.7
{0.32 - 0.47}

Cover

: N-m {kgf-m} BSM3710

HD-21
 CONTROL VALVE

Lever switch, bracket

1. Loosen the lock nut.
Nut
2. Remove the lever switch. Lever switch
5.0 - 6.0 {0.51 - 0.61}

Spool

: N-m {kgf-m} BSM3712

3. Remove the bolt.

4. Remove the bracket. Bolt
3.1 - 4.7
{0.32 - 0.47}
Bracket

Bracket

Seal plate Seal plate

: N-m {kgf-m}
BSM3711

Reassembly
Note the following, and reassemble in the reverse order of disassembly.
Lift sensor
Mounting bolt tightening torque (N-m{kgf-m}): 3.1 - 4.7 {0.32 - 0.47}

Bracket
If the control valve is new, remove the seal plate. (Not used.)
Mounting bolt tightening torque (N-m{kgf-m}): 3.1 - 4.7 {0.32 - 0.47}

Lever switch Nut

Lever switch
1. Temporarily fit the lever switch, adjusting the clearance of 5.0 - 6.0 {0.51 - 0.61}
the switch to 0.1 - 0.6 mm when the spool is neutral.
2. Make adjustment so that the switch is ON when the spool Spool

stroke is within 0.7 - 1.2 mm range.

3. After adjustment, apply ThreeBond #1401B (or equivalent)
to the fixing nut before tightening it. 24.6 mm
(Center of
Tightening torque (N-m{kgf-m}): 5.0 - 6.0 {0.51 - 0.61} spool groove)
0.1 - 0.6 mm
: N-m {kgf-m} BSM3748

HD-22
 HYD LEVER

7. HYD LEVER
(1) Standard Lever
Layout
Knob (tilt) A Knob (attachment) Apply adhesive
(ThreeBond #1521 or equivalent)
Knob (lift) to the boot, switch and knob.

: 0.4 - 0.7
{0.04 - 0.07} Apply adhesive
(ThreeBond #1530 or equivalent)
to the knob and lever.
Lever bracket Lever (lift)
COMP.
Lever (tilt)
Lever (attachment)
Lever boot
Apply SUMICO Moly RPS grease
spray or SHELL Alvania grease : 7.9 - 11.7
RA or equivalent before assembling. {0.8 - 1.2}

Lever bracket
Plain washer

Clevis pin

Snap pin

Apply SUMICO Moly RPS grease

Bushing spray or SHELL Alvania grease
RA or equivalent before assembling.

Rod

Control valve Lever cap

Tilt horizontal stop switch

(option)

Horn switch

: Apply grease.
: N-m {kgf-m}
View A
: N-m {kgf-m}
BSM3713

HD-23
 HYD LEVER

Precautions for servicing

B
Tying band

800 - 820
Clamp and
push mount

Fix wire harness

to each lever.

Switch harness
Knob height range Detail of B

Plain washer Clevis pin

Clevis pin

Snap pin Clevis pin to be

assembled from
the direction as
shown.
View C
BSM3714

HD-24
 HYD LEVER

(2) Single Hydraulic Lever (Optional)

Layout

Push the lever leftward to the position

where it has no looseness.
Make adjustment using the turnbuckle.
0-0
.5 .5
1.5 - 2.5 0-0 Stopper

ࠉCAUTION:
Do not operate LIFT (lifting)
lever and TILT (forward tilt)
lever simultaneously.
Section X – X Center of lever to be aligned
Detail of C with center of stopper.
Section Y – Y

Knob

Horn switch

: 2.5 - 2.9
{0.26 - 0.29} : 0.4 - 0.7
{0.04 - 0.07}
Single hydraulic lever
Apply adhesive
(ThreeBond #1530 or equivalent)
Boot to the knob and lever. : 3.1 - 4.7
{0.32 - 0.47}
Lever cover Lever (attachment)
COMP.
Lever boot
Apply SUMICO Moly RPS grease
spray or SHELL Alvania grease Snap pin
C RA or equivalent before assembling.
Y Y
X X
Plain washer

: 7.9 - 11.7
{0.8 - 1.2}
Clevis pin

106.5
Bushing
338.5

Rod

ࠉCAUTION:
Adjust the turnbuckle length
so that the requirement shown in
Detail C shall be strictly observed.
: 29 - 43
{3.0 - 4.4}

Apply SUMICO Moly RPS

grease spray or SHELL
Alvania grease RA or
equivalent before assembling.

: Apply grease.
Control valve
: N-m {kgf-m}
: N-m {kgf-m}
BSM3715

HD-25
 HYD LEVER

Precautions for servicing

: N-m {kgf-m}
Switch harness : N-m {kgf-m}
A CAUTION:
Before starting the service,
756 - 776 the dimensions shown below shall be
established.
Lift rod
Adapter

54 46.5° - 48.5° 54 38.5° - 40.5°

13 10.5 13 10.5
Clamp and push mount

12
12

10
10
Knob height range Detail of A

Clevis pin Right Right φ12

306.5 - 307.5

306.5 - 307.5
screw φ12 screw
Plain washer Clevis pin
Top rod
Left
screw Left
φ14 screw φ14
B

39.5 Both ends of the 39.5

Snap pin turnbuckle shall be
screwed in for the
Clevis pin to be assembled same length.
from the direction as shown.
View B
Lever SUB COMP.

1.5 - 2.5 Lever bracket COMP.

: 16 - 23 .5 0-0
0-0 .5
{1.6 - 2.3}
Y Y Use caution to
X X
install lift rod in
correct direction.
(8) 46 - 48

: 3.1 - 4.7
{0.32 - 0.47}
(192)

Adapter Lift rod Guide plate

Right
353.5 - 354.5

screw : 29 - 43 : 3.1 - 4.7 {0.32 - 0.47}

Top rod {3.0 - 4.4}
Section X – X
Left Turn buckle
screw
Stopper
: 29 - 43
{3.0 - 4.4}
Lever rod

(30.5) 25 - 26
44.5 - 45.5 37.1 - 39.1 Center of lever to be aligned
(71.5) with center of stopper.
83.5 - 85.5 (24.5) Section Y - Y
BSM3716

HD-26
 CYLINDERS

8. CYLINDERS
(1) Tilt Cylinder
NOTE:
•• For removal and reinstallation of the tilt cylinder, refer to Section RI.
•• For adjustment of the mast tilt angle after reinstalling the tilt cylinder, refer to Section LM.
Construction (1.0 to 1.75 ton)

G1/4 port

12-1 12-2 12-3

12-6
12-4 12-5 13
12
d

a
3 265 - 421 {28 - 42} 206 {21}

11 4 5 6 7 9 2 1 14 10 9 b
8 c 15 14.7 {1.5}

16

Detail of A
A

：N-m {kgf-m}
BSM3717

1. Tube sub-ASSY 10. Backup ring 13. Pin bushing (DU bushing)
2. Rod sub-ASSY 11. O-ring 14. Spacer (for forward tilting)
3. Cylinder head 12. Rod head COMP. 15. Spacer (for backward tilting)
4. Bushing 12-1. Rod head 16. Set screw
5. U-ring 12-2. Pin bushing (spherical bushing)
6. Head packing 12-3. Bolt
7. Snap ring 12-4. Washer
8. Wiper ring 12-5. Nut
9. O-ring 12-6. Grease nipple

a: When tightening, apply ThreeBond #1901 or equivalent to the threaded portion.

b: To be caulked at 3 locations.
c: Apply ThreeBond #1324 (5M) or equivalent.
d: Apply NLGI No. 2 or equivalent to the mating parts with bolts.

NOTE:
•• The spacers (part name 14 and 15) differ in size depending on the tilt angle. For the tilt cylinder of 7°
forward tilt and 11°backward tilt, no spacer is specified.
 

HD-27
 CYLINDERS

Construction (2.0 to 3.5 ton)

G1/4 port

14

12 13
15 16

8 3 11 4 6 5 7 9 1 2 17 18 10 20

21-2 21-1 a 282 - 424 {29 - 43} 19 393 - 479 {41 - 48}
(2.0, 2.5 ton) (2.0, 2.5 ton)
441 - 539 {45 - 55} 539 - 677 {57 - 69}
㸸N-m {kgf-m} (3.0, 3.5 ton) (3.0, 3.5 ton)
BSM3939

1. Tube sub-ASSY 9. O-ring 17. Spacer (for forward tilting)

2. Rod sub-ASSY 10. Backup ring 18. Piston
3. Guide 11. O-ring 19. Self-lock nut
4. Bushing 12. Head 20. Packing
5. U-packing 13. Bushing (spherical bushing) 21-1 Grease nipple
6. Backup ring 14. Bolt (2.0 and 2.5 ton)
7. Backup ring 15. Nut 21-2 Grease nipple
8. Dust seal 16. Bushing (3.0 and 3.5 ton)

a: Apply ThreeBond #1344 or equivalent.

NOTE:
•• The spacer (part name 17) differs in size depending on the tilt angle. For the tilt cylinder of 7° forward
tilt, no spacer is specified. However, the tilt cylinder of 7° forward tilt and 3° backward tilt has the
spacer.

Disassembly
1. Secure the cylinder with a vice or other clamp. Blow compressed air first through one of the two elbows
(oil ports) and then the other. Operate the piston rod until the hydraulic oil is removed from the cylinder.
2. Loosen the lock nut and bolt of the tilt cylinder socket (rod
Cylinder head
head). Using a wrench, fix the rod (width across flats: 19 mm Tilt cylinder socket
(1.0 to 1.75 ton), 27 mm (2.0 to 3.5 ton). Remove the tilt (rod head)

cylinder socket from the piston rod.

3. Loosen the cylinder head to remove the cylinder head and rod
from the cylinder tube.

CAUTION Rod sub ASSY

•• Be careful not to damage the O-ring. Bolt

BSM3719

HD-28
 CYLINDERS

4. Pull out the piston rod from the cylinder head, and remove it together with piston and spacer (if equipped).
5. Remove the backup ring and O-ring or packing from the piston.
6. Remove the O-ring and packing from the piston head using a screwdriver.

CAUTION
•• When the O-ring is removed once, always replace it with a new one.

7. Remove the piston as necessary.

8. If the spherical bushing needs to be replaced, remove it from
the tilt cylinder socket (rod head).
Grease groove

Tilt cylinder socket

(rod head)

Bushing
(spherical bushing)
BSM3720

Inspection
• Check the packing, O-ring and other rings for damage and deterioration. Replace if any abnormal
condition is found.
• Check the rod plating for scratch or flaking. Also check inside of the cylinder tube. Replace if any
abnormal condition is found.
• Tilt cylinder socket spherical bushing
Replace with a new one if worn or damaged.
Standard (mm): φ34.988 - 35.000
• Cylinder frame mounting side bushing
Replace with a new one if worn or damaged.
Standard (mm): φ31.95 - 32.15 (1.0 to 1.75 ton)
φ31.85 - 32.15 (2.0 to 3.5 ton)

Assembly
Note the following, and reassemble in the reverse order of disassembly.
• For each part, lubricate with hydraulic oil.
• When assembling, be sure to prevent foreign matter such dust from entering.
• Install O-ring, preventing it from being twisted.
• When installing the cylinder head to the piston rod, avoid damaging O-ring, wiper ring, etc. with screw
thread.
• When assembling the spherical bushing with the tilt cylinder socket (rod head), ensure that grease groove
on the rod head will align with the groove on outer periphery of the spherical bushing. 

HD-29
 CYLINDERS

(2) Lift Cylinder

Construction (Internal drain single-acting piston type (2W mast, 3F mast))

171 - 261 {18 - 26} (1.0 to 1.75 ton)

a 206 - 312 {22 - 31} (2.0, 2.5 ton)
3 242 - 364 {25 - 37} (3.0 ton)
234 - 374 {24 - 38} (3.5 ton) 13 4.75 - 5.25
{0.49 - 0.53}
b
5 7 4 8 14 2 1 15 16 9 10 11 12
6

：N-m {kgf-m} 23 mm
c
：N-m {kgf-m} Cushion stroke
BSM3721

1. Tube sub-ASSY 7. O-ring 13. Plug

2. Rod sub-ASSY 8. O-ring 14. Gasket
3. Cylinder head 9. U-ring 15. Spacer
4. Bushing 10. Slide ring 16. O-ring
5. X-ring 11. Cushion ring
6. Wiper ring 12. Snap ring

a: When tightening, apply ThreeBond #1901 or equivalent to the threaded portion.

b: Apply grease on the entire periphery before reassembling the lift cylinder.
c: Pack approx. 1 g of NLGI No. 2 or equivalent (adherence to the bushing is allowed).

NOTE:
•• The length of spacer (15) varies with the cylinder length. Some types of cylinder may not have spacer
(15).
 

HD-30
 CYLINDERS

Construction (External drain single-acting piston type (2W mast, 3F mast))

171 - 261 {18 - 26} (1.0 to 1.75 ton)

a 206 - 312 {22 - 31} (2.0, 2.5 ton)
3 242 - 364 {25 - 37} (3.0 ton)
234 - 374 {24 - 38} (3.5 ton)
b
5 7 4 8 2 1 15 13 14 9 10 11 12
6

23 mm
c
：N-m {kgf-m} Cushion stroke
BSM3722

1. Tube sub-ASSY 6. Wiper ring 11. Cushion ring

2. Rod sub-ASSY 7. O-ring 12. Snap ring
3. Cylinder head 8. O-ring 13. Spacer
4. Bushing 9. U-ring 14. O-ring
5. X-ring 10. Slide ring 15. Wear ring

a: When tightening, apply ThreeBond #1901 or equivalent to the threaded portion.

b: Apply grease on the entire periphery before reassembling the lift cylinder.
c: Pack approx. 1 g of NLGI No. 2 or equivalent (adherence to the bushing is allowed).

NOTE:
•• The length of spacer (13) varies with the cylinder length. Some types of cylinder may not have spacer
(13).
 

HD-31
 CYLINDERS

Construction (Single-acting ram type (2F mast))

18 15 - 24 {1.5 - 2.4}

17

c
b 167 - 245 {18 - 25} (1.0 to 2.5 ton) 12 2.94 - 4.90 {0.30 - 0.49}
5 181 - 289 {19 - 29} (3.0 ton)
234 - 374 {24 - 38} (3.5 ton)
d 161 - 231 {17 - 23} (1.0 to 3.0 ton)
13 201 - 289 {21 - 29} (3.5 ton)
a 7 6 3 9 4 2 1 16 14 11 10
8 21 19 20
15

21 mm Equipped with spacer

：N-m {kgf-m}
Cushion stroke
：N-m {kgf-m}
BSM3723

1. Tube sub-ASSY 8. Wiper ring 15. Spring

2. Piston rod 9. O-ring 16. Snap ring
3. Cylinder head 10. Piston 17. Steel ball
4. Bushing 11. Slide ring 18. Set screw
5. Holder 12. Set screw 19. Spacer
6. U-ring 13. Check valve 20. Snap ring
7. Backup ring 14. Cushion spool 21. Wear ring

a: When press-fitting, apply liquid packing.

b: When tightening, apply ThreeBond #1901 or equivalent to the threaded portion.
c: After tightening, caulk 2 locations using a punch.
d: When assembling, pay attention to the direction (slit surface must face the spring).

NOTE:
•• The length of spacer (19) varies with the cylinder length. Some types of cylinder may not have spacer
(19).

Cushion construction of lift cylinder

The lift cylinder function automatically decelerates the fork
lowering speed just before the fork contacts the ground. It is
activated when the piston reaches 23 mm (21 mm for the 2F lift
cylinder) from its bottom stroke end.
1. When the rod piston position is higher than the point 23 mm
(21 mm for the 2F lift cylinder) upward from the bottom
stroke end, the hydraulic oil below the piston flows out freely.
 
Bottom
Oil flow projection

BSM3724

HD-32
 CYLINDERS

2. When the piston moves further down, the bottom projection

gets into the cushion bearing, creating a new hydraulic
oil chamber. In this state, the hydraulic oil in the cushion
chamber must pass through the narrow ring-like gap between
the cushion bearing and the bottom projection, resulting in
Narrow ring-like gap
slowdown of the piston movement.
Cushion chamber

BSM3725

3. The piston slows down through the last 23 mm (21 mm for

the 2F lift cylinder) of its stroke. Piston rod

Cushion stroke

BSM3726

Removal
Before removing the lift cylinder, follow the steps below.
• Remove the lift bracket together with the fork. (Refer to Section RI.)
• Jack up the truck front so that about 120 mm ground clearance is created under the outer mast bottom end.
(Refer to Section AZ.)
• Operate the HYD lever, tilting the mast fully backward and lowering it to the bottom stroke end. Place the
mast in neutral position and turn the key switch OFF.

CAUTION
• • Always lower the lift cylinder to the bottom stroke end to release any residual pressure from the
piping.

2W lift cylinder, 2F lift cylinder

1. Disconnect the lift hose connected to the lift cylinder, and
plug the hose.

Lift hose

BSM3727

HD-33
 CYLINDERS

2. Remove the fixing bolt at bottom of the lift cylinder. Installation of lower end Installation of upper end
Loosen the lock nut and remove the fixing bolt at top of the
lift cylinder. (The right sketch shows the appearance of the 2W
mast.)

BSM3475

3. Lift the inner mast with a nylon sling or wire.

CAUTION
•• Do not lift the inner mast higher than is necessary.

4. Remove the lift hose, return hose (2W mast outer return
cylinder) and lift pipe (2F mast) from the lift cylinder.
5. Remove the parts fixing the cylinder bracket at top of the lift Band spacer Cylinder bracket
cylinder. (The right sketch shows the appearance of the 2W Cushion Shim
mast.)
Collar

CAUTION
Cushion
•• When removing the lift cylinder from the cylinder
bracket, always support the lift cylinder so that it will
not fall down.
Seat
Bolt washer
6. Remove the lift cylinder from the mast. BSM3476

The shim used at top of the lift cylinder should be kept in

a safe place to prevent it from being mixed up with other
shims.

CAUTION
•• When removing the mast cylinder, always work with an
assistant. The cylinder is very heavy.

3F lift cylinder
1. Disconnect the lift hose connected to the lift cylinder, and
plug the hose.
2. Lift the inner mast so that the inner mast lower beam is
located above the outer mast tilt beam.

CAUTION
•• While lifting the inner mast, ensure that the slack chain
and hose do not get caught on each other. Lift hose

BSM3727

3. Remove the chain anchor at the inner mast side and separate the mast chain from the inner mast.
4. Remove the hydraulic piping from the bottom of the full free cylinder.
5. Remove the hose pulley support from the top of the middle mast and remove the chain wheel.

HD-34
 CYLINDERS

6. Place a square wood block of 100 mm in height under the inner mast and lower the inner mast.

CAUTION
•• When lowering the inner mast, ensure that the chain and hose do not get caught on each other.

7. Attach the lifting hook to the upper beams of the inner mast
and middle mast.
8. Remove the fixing bolt at bottom of the lift cylinder. Installation of lower end Installation of upper end
Loosen the lock nut and remove the fixing bolt at top of the
lift cylinder.

BSM3728

9. Lift the inner mast and middle mast together and remove the
lift cylinder top.
10. Remove the return hose (outer return cylinder) from the lift
cylinder.
11. Remove the parts fixing the cylinder bracket at top of the lift
Cylinder bracket
cylinder.
Cushion
CAUTION Shim
• • When removing the lift cylinder from the cylinder
Cushion
bracket, always support the lift cylinder so that it will
Seat
not fall down.
Bolt washer

12. Remove the lift cylinder from the mast.

Collar
The shim used at top of the lift cylinder should be kept in a BSM3729

safe place to prevent it from being mixed up with other shims.

CAUTION
•• When removing the mast cylinder, always work with an assistant. The cylinder is very heavy.
 

HD-35
 CYLINDERS

Disassembly (Internal drain single-acting piston type (2W mast, 3F mast))

6
5

3
10
9
7
8
13 4
11

12
15

16
14

1 2

BSM3730

1. Tube sub-ASSY 7. O-ring 13. Plug

2. Rod sub-ASSY 8. O-ring 14. Gasket
3. Cylinder head 9. U-ring 15. Spacer
4. Bushing 10. Slide ring 16. O-ring
5. X-ring 11. Cushion ring
6. Wiper ring 12. Snap ring

NOTE:
•• The length of spacer (15) varies with cylinder length. Some types of cylinder may not have spacer (15).
•• Check the tightening torque or greasing points that are indicated in the drawing of Construction.
 

HD-36
 CYLINDERS

Disassembly (External drain single-acting piston type (2W mast, 3F mast))

6
5

10
9 7
8
4
11 15

12 13

14

2
1

BSM3731

1. Tube sub-ASSY 6. Wiper ring 11. Cushion ring

2. Rod sub-ASSY 7. O-ring 12. Snap ring
3. Cylinder head 8. O-ring 13. Spacer
4. Bushing 9. U-ring 14. O-ring
5. X-ring 10. Slide ring 15. Wear ring

NOTE:
•• The length of spacer (13) varies with cylinder length. Some types of cylinder may not have spacer (13).
•• Check the tightening torque or greasing points that are indicated in the drawing of Construction.

HD-37
 CYLINDERS

Disassembly (Single-acting ram type (2F mast))

18

17 21
2
19

20

8
11
5 12 1
10

16
7 13
6 15
9
14
4

BSM3732

1. Tube sub-ASSY 8. Wiper ring 15. Spring

2. Piston rod 9. O-ring 16. Snap ring
3. Cylinder head 10. Piston 17. Steel ball
4. Bushing 11. Slide ring 18. Set screw
5. Holder 12. Set screw 19. Spacer
6. U-ring 13. Check valve 20. Snap ring
7. Backup ring 14. Cushion spool 21. Wear ring

NOTE:
•• The length of spacer (19) varies with cylinder length. Some types of cylinder may not have spacer (19).
•• Check the tightening torque or greasing points that are indicated in the drawing of Construction.
Reassembly
Note the following, and reassemble in the reverse order of disassembly.
• For each part, lubricate with hydraulic oil.
• When assembling, be sure to prevent foreign matter such dust from entering.
• Install O-ring and U-ring, preventing them from being twisted.
• Avoid damaging O-ring, U-ring, wiper ring, etc. with screw thread.
Reinstallation
Note the following, and install in the reverse order of disassembly.
• When installing the lift cylinder to the mast, check the tightening torque of the parts indicated in Section
LM.
• When adjusting the lift cylinder height or perpendicularity after installing the lift cylinder to the mast, refer
to Section LM.
• When installing the lift cylinder to the mast, check the tightening torque of the piping and the connectors
indicated in Section HD.

HD-38
 CYLINDERS

(3) Full-Free Cylinder (2F/3F Mast)

Construction

2F mast and 3F mast (1.0 to 1.75 ton)

3F mast (2.0 to 3.5 ton)

295 - 469 {31 - 47} (1.0 to 1.75 ton)

326 - 518 {34 - 52} (2.0, 2.5 ton)
b 377 - 603 {39 - 61} (3.0 ton)
3 408 - 652 {42 - 66} (3.5 ton)
16 4.75 - 5.25 {0.49 - 0.53}
a
6 8 5 7 4 17 2 1 c 11 10 9 10 13 12
15
14
d
: N-m {kgf-m}
: N-m {kgf-m}
BSM3733

1. Tube sub-ASSY 7. O-ring 13. O-ring

2. Rod sub-ASSY 8. O-ring 14. Plate
3. Cylinder head 9. X-ring 15. C-shaped snap ring
4. Bushing 10. Slide ring 16. Plug
5. U-ring 11. Check valve 17. Gasket
6. Wiper ring 12. Housing ASSY

a: When press-fitting, apply liquid packing.

b: When tightening, apply ThreeBond #1901 or equivalent to the threaded portion.
c: Fill in cushioning oil (hydraulic oil) as follows:
• 100 ml (1.0 to 1.75 ton)
• 120 ml (2.0, 2.5 ton)
• 160 ml (3.0 ton)
• 180 ml (3.5 ton)
d: Chamfer side

Removal
1. Remove the lift bracket together with the fork. (Refer to Section RI.)
2. Operate the HYD lever, tilting the mast fully backward and lowering it to the bottom stroke end. Place the
mast in neutral position and turn the key switch OFF.

CAUTION
•• Always lower the lift cylinder to the bottom stroke end to release any residual pressure from the
piping.

3. Remove hydraulic pipe from the full free cylinder. Plug the pipe openings to prevent hydraulic oil leakage.
4. Lift the full free cylinder with a nylon sling or wire.
5. Remove full free cylinder-retaining bolt, and remove the full free cylinder by lifting up. (Refer to Section
LM.)

HD-39
 CYLINDERS

Disassembly

9 4

7
10
8
16

17
2

13
12

Note) Remove plug before pulling 11

out piston rod. 14
15
BSM3734

1. Tube sub-ASSY 7. O-ring 13. O-ring

2. Rod sub-ASSY 8. O-ring 14. Plate
3. Cylinder head 9. X-ring 15. C-shaped snap ring
4. Bushing 10. Slide ring 16. Plug
5. U-ring 11. Check valve 17. Gasket
6. Wiper ring 12. Housing ASSY

• Check the tightening torque or greasing points that are indicated in the drawing.
Reassembly
Note the following, and reassemble in the reverse order of disassembly.
• For each part, lubricate with hydraulic oil.
• When assembling, be sure to prevent foreign matter such dust from entering.
• Install O-ring and U-ring, preventing them from being twisted.
• Avoid damaging O-ring, U-ring, wiper ring, etc. with screw thread.
Reinstallation
Note the following, and install in the reverse order of disassembly.
• When installing the full-free cylinder to the mast, check the tightening torque of the parts indicated in the
LM section.
• When adjusting the full-free cylinder height or perpendicularity after installing the full-free cylinder to the
mast, refer to Section LM.
• When installing the full-free cylinder to the mast, check the tightening torque of the piping and the
connectors indicated in Section HD.

HD-40
 CYLINDERS

(4) Bleeding
1. Add hydraulic oil to the upper limit of the level gauge.
2. Raise the mast slowly. Then lower it slowly.
3. After lowering the mast to the bottom stroke end, check the hydraulic oil level in the tank. If hydraulic oil
is reduced, add it to the upper limit of the level gauge.
4. Repeat steps 2 and 3 until the hydraulic oil level in the tank is kept unchanged.
5. Raise and lower the cylinder to check for smooth operation.
NOTE:
•• There is no need to bleed the full free cylinder. Operate it through its full stroke repeately 7 to 8 times.

(5) Down Safety Valve

The down safety valve operates as a safety device in case of damage on the high pressure hose which
connects the left and right lift cylinders. The down safety valve is assembled in the bottom part of the lift
cylinder and lowers the forks slowly.
Construction

For lift cylinder For full-free

cylinder

BSM3735

Removal and Reinstallation

• Lift cylinder down safety valve
Mounting tightening torque (N-m {kgf-m}):
35 - 39 {3.6 - 3.9} (with O-ring at the G3/8 cylinder side)
30 - 58 {3.1 - 5.9} (for mounting G3/8 hose)

Lift cylinder
Hydraulic
hose
Down safety
valve
BSM3736

• Full-free cylinder down safety valve

Mounting tightening torque (N-m {kgf-m}): Hydraulic hose
40 - 44 {4.1 - 4.4} (with O-ring at the G1/2 cylinder side)
59 - 98 {6.1 - 9.9} (for mounting G1/2 hose)

Down safety valve

Full-free cylinder
BSM3737

HD-41
 INSPECTION AND ADJUSTMENT

9. INSPECTION AND ADJUSTMENT

(1) In Case of Emergency (Forks/Mast Cannot Be Lowered)
• Move the truck to a safe place and park it.
• Make sure that there is no one or obstacle under the forks.
• Remove the covers. (Refer to Section RI.)
Releasing the lift lock valve
Standard control valve:
1. Loosen the lift lock release screw lock nut.
2. Tighten the lift lock release screw.

CAUTION Lift lock release screw

•• Do not overtighten the lift lock release screw; otherwise
the internal circuit can be damaged.
Lock nut

3. Place the lift lever in the “down” position to lower the forks.

BSM3741

Proportional control valve:

1. Loosen the emergency valve release screw lock nut.
2. Tighten the emergency valve releasing screw slowly.
The forks are lowering. Emergency valve release screw

CAUTION Lock nut

• • Rapid tightening of the emergency valve releasing bolt
will cause a sudden lowering of the fork. Tighten the
releasing bolt slowly.

BSM3742

HD-42
 INSPECTION AND ADJUSTMENT

Restoring the lift lock valve

After finishing the service, make sure to loosen the releasing bolt until it locks and then fix it with a lock
nut.
• Lock nut tightening torque
Standard control valve (N-m{kgf-m}): 2.0 - 2.9 {0.21 - 0.29}
Proportional control valve (N-m{kgf-m}): 6.9 - 8.8 {0.71 - 0.89}

CAUTION
•• Safety functions will not work unless the lift lock valve is restored. Always restore the lock valve.

(2) Hydraulic Pressure Inspection and Adjustment

CAUTION
•• When checking the hydraulic pressure, always wear protective goggles. High-pressure hydraulic
oil may blow out and hit eyes. There is a possibility of high-pressure operation oil leaking and
causing blindless if it gets into eyes.
•• This inspection includes mast-raising operations. Ensure that sufficient clearance is secured
around the truck.

Hydraulic pressure inspection

1. Turn the key switch OFF and remove the battery plug.
2. Remove the floor mat and floor plate. (Refer to Section RI.)
3. Remove the pressure sensor from the lift hose.
4. Install the adapter connector to the pressure sensor mounting Pressure switch
position and connect an oil pressure gauge. Control valve
5. Connect the battery plug and turn the key switch ON. Operate
the control lever and check the pressure reading. Measure
the hydraulic pressure in the raising, forward tilting, and
backward tilting positions respectively.
• Raising, forward tilting, backward tilting positions
Standard (MPa{kgf/cm2})
1.0 ton: 13.7 {140}
1.5, 2.0 ton: 15.7 {160}
1.75 ton: 17.2 {175}
2.5, 3.0, 3.5 ton: 18.1 {185}
6. If the measured pressure is outside the specified range, adjust
Lift hose
the hydraulic pressure.

BSM3743

HD-43
 INSPECTION AND ADJUSTMENT

Hydraulic pressure adjustment

1. Loosen the lock nut on the main relief valve. Standard control valve
2. While operating the lever, adjust the hydraulic pressure to the
standard value by turning the adjustment screw of the main
relief valve.
To raise the pressure: Turn clockwise Main relief valve
To lower the pressure: Turn counterclockwise

Lock nut
CAUTION
•• Remember that one turn of the adjustment screw causes Adjustment screw
a pressure change of 6.9 to 7.8 MPa {70 to 80 kgf/cm2}.
Do not attempt to turn the adjustment screw to a large Proportional control valve
angle in one step.
•• Make sure to turn the adjustment screw little by little
while observing the pressure gauge reading. Main relief valve

3. After adjustment, hold the adjustment screw securely and

Lock nut
tighten the lock nut.
4. Check the pressure again. Adjustment screw

BSM3744

HD-44
 INSPECTION AND ADJUSTMENT

(3) Accumulator Inspection and Adjustment (Smooth Running System)

Removing and reinstalling accumulator and pressure check

CAUTION
•• The accumulator is filled with high-pressure nitrogen gas. Do not hit it or bring open flame near it.
Do not machine or weld the device; otherwise it can cause a fire or explode.
•• Do not fill gases other than nitrogen gas, such as oxygen, into the accumulator. There is a danger
of exploding.
•• Be sure to remove pressure from the hydraulic system before checking the gas pressure in the
accumulator or filling nitrogen gas into the accumulator.
•• Use specified service tools when working on the accumulator.

A
1
6
9
7

A 5

8
4

Top view Section A - A

Charging test unit Accumulator

BSM1520

1. Correction of filling pressure according to gas temperature

If the gas temperature is not 20℃ during filling nitrogen gas, the filling gas pressure should be corrected
using the following equation:
(t0 ＋ 273)
Equation: P = P1 ×
(20 ＋ 273)
where: P0: Filling gas pressure
P1: Charging
‌ pressure (accumulator specification value: high pressure 5.0 MPa, low pressure
1.0 MPa)
t0: Gas temperature in filling (almost the same as ambient temperature) ℃
2. Preparations
1. ‌Operate the lift lever to retract the lift cylinder completely (i.e. lower the forks completely), thus
reducing the pressure in the accumultor to "0".
2. Turn the key switch OFF and disconnect the battery plug.
3. Remove the two accumulators (for high and low pressure) from the truck.
4. ‌Remove the protection cap (1). Using an Allen wrench SW6 (3), loosen the plug (2) by turning it about
1/2 turns counterclockwise.
5. Install the cap nut (4) of the charging test unit to gas valve (5) of the accumulator.
3. Checking accumulator pressure
1. Tighten the pressure release valve (6) of the charging test unit.
2. Turn the handle (7) counterclockwise until the pointer of the pressure gauge (8) starts moving.
3. Check the gas filing pressure from the reading of the pressure gauge.

HD-45
 INSPECTION AND ADJUSTMENT

4. Reducing the accumulator pressure

1. Open the pressure release valve (6) of the charging test unit to release the nitrogen into the atmosphere.
5. After completion of the work
1. Tighten the handle (7) clockwise to the full.
2. ‌Open the pressure release valve (6) of the charging test unit to remove the pressure. Remove the
charging test unit.
3. ‌Tighten the accumulator plug (2) to specified torque. After tightening, check for any gas leaks applying
soap water.
Tightening torque (N-m {kgf-m}): 20 {2.0}
4. Make sure that O-ring (9) is securely in position and install the protection cap.
5. Install two accumulators (for high and low pressure) on the truck.
Filling nitrogen gas

5
2
3
7

1
6 4

Nitrogen gas cylinder Accumulator

BSM1521

1. Referring to the preceding section, install the charging test unit to the accumulator.
2. Connect the cap nuts (2) of the charging hose (1) to the nitrogen gas shut-off valve, pressure reducing
valve (6), and gas pressure valve.
3. Connect the cap nut (3) of the charging hose (1) to the charging test unit (4).
4. Turn the handle (5) of the charging test unit (4) two turns counterclockwise to open the gas valve inside
the accumulator.
5. Open the nitrogen gas cylinder shut-off valve slowly with care not to damage the accumulator gas valve.
Set the filling pressure obtained in section “Correction of filling pressure according to gas temperature” for
the pressure reducing valve (6).
6. Close the nitrogen gas cylinder shut-off valve and check the pressure on the pressure gauge.
7. Repeating steps 5 and 6 given above, fill nitrogen gas into the accumulator to the specified pressure is
reached.
8. Five minutes after the specified pressure is reached, check the pressure again. If the measured value is
higher than specified, open the pressure release valve (7) to reduce the pressure for adjustment.

Inspection
Inspect the pressure of the accumulator filling gas every year, using a pressure gauge. If the pressure is
lower than specified, fill nitrogen gas.

HD-46
 OPTIONAL EQUIPMENT

10. OPTIONAL EQUIPMENT

(1) Layout

Bracket 7.9 - 11.7

{0.8 - 1.2}
Pressure
gauge Front pillar
(right side)

High-pressure
hose Clip

3.1 - 4.7
Tilt pipe COMP. I {0.32 - 0.47}
Fix high-pressure
A hose with band
Relief valve
16 - 23
F {1.6 - 2.4}
Spiral tube

Bands
E
B

Valve bracket

3.1 - 4.7 Joint bracket

{0.32 - 0.47}

Tighten valve
bracket and joint
bracket together.
Install joint bracket
outside.
High-pressure
hose
View A

Details of E (For quintuple piping)

ࠉCAUTION:
: N-m {kgf-m}
(1) Hose connector tightening torque: 27 - 34 N-m {2.7 - 3.5 kgf-m}
: N-m {kgf-m} (2) Wrap seal tape around tapered threads.
BSM3945

HD-47
 OPTIONAL EQUIPMENT

1.0 to 2.5 ton 27 - 34

{2.7 - 3.5}
Relief pipe COMP.
Remove plug
and install Hydraulic oil tank C Cover bracket
return hose. 3-WAY joint

20° Plug 20°

20 - 25
Elbow
{2.0 - 2.6}
For oil circulation For internal drain
system
Details of C
3.1 - 4.7
{0.32 - 0.47}
: N-m {kgf-m} Clip
: N-m {kgf-m} View B
BSM3946

3.0, 3.5 ton Plug

Remove plug 20 - 25
{2.0 - 2.6} Hydraulic oil tank
and install Relief pipe COMP.
return hose.
3-WAY joint C Cover bracket

Elbow
For oil circulation system For internal drain
Details of D
27 - 34
Elbow {2.7 - 3.5}
16 - 23
45r

45r

{1.6 - 2.4}
D
3.1 - 4.7
{0.32 - 0.47}

Clip
For oil circulation system For internal drain

Details of C
: N-m {kgf-m} View B
: N-m {kgf-m}
BSM3947

HD-48
 OPTIONAL EQUIPMENT

3.1 - 4.7
{0.32 - 0.47}

Solenoid valve 7.9 - 11.7

cover (2) {0.8 - 1.2}

Solenoid valve
cover (1)

3.1 - 4.7
{0.32 - 0.47}

Detail of F View G View H

(Detail of cover)
Truck outside
To bracket Single-acting type Double-acting type
20° 20°
Nipple Elbow Elbow
G3/8
G3/8
3-WAY joint
25°

Nipple

Elbow 30° Check valve

Elbow Plug
Elbow 20 - 25
{2.0 - 2.6}
°

G3/8
20

To Relief pip COMP. Check valve

Elbow
ࠉCAUTION:
Detail of I (1) Tightening torque of threaded area
°

(Detail of valve mounting parts) (G3/8) without any instructions:

20

27 - 34 N-m {2.7 - 3.5 kgf-m}

: N-m {kgf-m} (2) Use caution to install check valve
in correct direction.
: N-m {kgf-m}
BSM3746

(2) Relief Valve

Specification
Model: Pilot-operated relief valve
Pressure adjustment range (MPa {kgf/cm²}): 3.5 - 20.5 {35 - 210}

Pressure adjusting
handle Tank port PT1/4

Pressure port Pressure port

Vent port PT1/4

BSM3747

HD-49
MEMO

HD-50