TMHydraulicSystemFLT.01en - C ECH FLT - Hydraulic

TECHNICAL MANUAL
FORKLIFT HYDRAULICS
ORIGINAL INSTRUCTIONS
X150366en / C / 21 Apr 2016
TM Hydraulic System FLT.02en
This document and the information contained herein, is the exclusive property of Konecranes Lifttrucks and represents a non-public, confidential and proprietary trade secret that may not be
reproduced, disclosed to other parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Lifttrucks. © 2016 Konecranes Lifttrucks. All rights
reserved. ‘Konecranes’, ‘Lifting Businesses’ and C are either registered trademarks or trademarks of Konecranes Lifttrucks.
TABLE OF CONTENTS TECHNICAL MANUAL
TABLE OF CONTENTS
1 DESCRIPTION.......................................................................................................... 5
1.1 Load-sensing system.............................................................................................. 5
1.1.1 Description................................................................................................... 5
1.1.2 Function....................................................................................................... 6
1.2 Location of components.......................................................................................... 8
2 COMPONENTS DESCRIPTION................................................................................ 9
2.1 Variable piston pump............................................................................................... 9
2.1.1 Parker series P2.......................................................................................... 9
2.1.2 Function....................................................................................................... 10
2.2 Load-sensing system.............................................................................................. 12
2.3 Steering priority valve............................................................................................. 14
2.4 Directional control valve.......................................................................................... 17
2.4.1 Parker L90LS............................................................................................... 17
2.4.2 Parker HV08................................................................................................ 18
2.5 Accumulator charging valve................................................................................... 20
2.5.1 M0382.......................................................................................................... 20
2.5.2 M1040.......................................................................................................... 21
2.6 Hydraulic system principle (Forklift SMV 10-16B)................................................. 23
2.7 Hydraulic system principle with M1040 (Forklift SMV 10-16B)............................. 25
3 MEASUREMENTS AND ADJUSTMENTS................................................................ 27

3.1 Measuring and setting the hydraulic pressure...................................................... 27
3.2 Measuring and setting the stand-by pressure, one pump.................................... 27
3.2.1 Checking the load signal (LS)...................................................................... 27
3.2.2 Adjusting the stand-by pressure................................................................... 28
3.3 Measuring and setting the stand-by pressure, multiple pumps........................... 28
3.4 Measuring and setting the maximum working pressure....................................... 29
3.5 Measuring and setting the delta pressure (DeltaP)............................................... 29
3.5.1 Principle....................................................................................................... 29
3.5.2 Measuring and setting the delta pressure, one pump................................... 30
3.5.3 Measuring and setting the delta pressure, two or three pumps.................... 31
3.6 Releasing the accumulator pressure...................................................................... 32
3.7 Measuring and setting the accumulator pressure................................................. 33
3.8 Measuring and setting the brake pressure switch................................................. 34
3.9 Measuring the accumulator precharged pressure................................................. 34
3.10 Measuring and setting the parking brake pressure............................................... 34
3.11 Adjusting the parking brake.................................................................................... 35
3.12 Measuring the steering pressure............................................................................ 36
3.13 Adjusting the steering priority valve (older machines only)................................. 36
3.14 Adjusting steering priority valve (new machines only)......................................... 36
3.15 Setting the restrictor and non-return valve............................................................ 38
3.16 Measuring and adjusting the attachment pressure (ECB).................................... 38
3.17 Measuring and adjusting the attachment pressure (gantry)................................. 39
4 TROUBLESHOOTING............................................................................................... 41
4.1 Troubleshooting....................................................................................................... 41
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This document and the information contained herein, is the exclusive property of Konecranes Lifttrucks and represents a non-public, confidential and proprietary trade secret that may
not be reproduced, disclosed to other parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Lifttrucks. © 2016
Konecranes Lifttrucks. All rights reserved. ‘Konecranes’, ‘Lifting Businesses’ and C are either registered trademarks or trademarks of Konecranes Lifttrucks.
TECHNICAL MANUAL TABLE OF CONTENTS
4/42
This document and the information contained herein, is the exclusive property of Konecranes Lifttrucks and represents a non-public, confidential and proprietary trade secret that may
not be reproduced, disclosed to other parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Lifttrucks. © 2016
Konecranes Lifttrucks. All rights reserved. ‘Konecranes’, ‘Lifting Businesses’ and C are either registered trademarks or trademarks of Konecranes Lifttrucks.
1 DESCRIPTION TECHNICAL MANUAL
1 DESCRIPTION
1.1 Load-sensing system
1.1.1 Description
In a load-sensing hydraulic system, the pump only supplies the flow required for the functions.
The output of the pump is never greater than the current load. All hydraulic systems in
Konecranes lift trucks are load-sensing.
Load Pump
The advantages of a load-sensing system are the following:
• No flow in the system when it is not used

• Only the required flow when lifting or moving
• No unnecessary overpressure when lifting small loads
• Smaller losses and less wear to the hydraulic system
• Greater precision and more flexible maneuvering of the machine
• Lower energy consumption
• Less heat development
In a load-sensing system, the load to which the system is subjected is measured, which controls
the output from the hydraulic pump.
The system remains in balance:
• Light load - low output

• Heavy load - high output
Load Pump
The variable piston pump is the main component of the system. When the load on the system
changes, for example, when lifting, a load signal provides the pump with information about the
change. The system makes a corresponding change to the output.
Load Pump
Load signal
The following diagram shows the principle of a load-sensing system. The load signal (LS) which
controls the pump is taken from the directional control valve.
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X150366en / C / 21 Apr 2016 Copyright © (2016) Konecranes Lifttrucks. All rights reserved.
TECHNICAL MANUAL 1 DESCRIPTION
Load Pump
LS
Directional
valve
1.1.2 Function
The truck driver controls the hydraulic functions using joysticks that actuate the directional
control valve.
The system is proportional. A small joystick movement causes a small deflection on the
directional control valve, for small oil flow. A large joystick movement causes a larger deflection
on the valve, for large oil flow.
When the directional control valve is closed, the pump delivers a low basic pressure, which is
known as the stand-by pressure. When the system is activated, oil flows through the directional
control valve, from P to A, and the pressure drops. This pressure drop is called DeltaP.
A LS
P T
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1 DESCRIPTION TECHNICAL MANUAL
The stand-by pressure should be slightly higher than DeltaP. It is important that the pump
provides the correct stand-by pressure in order for the system to work correctly.
When the joystick is in the neutral position and the system is not at work, the load signal is zero.
The output from the pump, which corresponds to the stand-by pressure, is low, and the output
requirement from the diesel engine is also low.
A small joystick movement only causes a small flow, but high pressure. The load signal provides
the pump with information, and the pump then delivers the corresponding output.
45
A large joystick movement causes a large flow and high pressure. The load signal provides the
pump with information, and the pump then delivers the maximum output.
45
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TECHNICAL MANUAL 1 DESCRIPTION
1.2 Location of components
8 9
6 10
5
11
4
12
3
13
2 14
Figure 1. Forklift SMV 10-16B
1. Steer cylinder 8. Side shift cylinder

2. Variable piston pump (105 cc) 9. Directional control valve
3. Gear pump (23 cc) 10. Multi-disc brake
4. Accumulator 11. Parking brake
5. Steering orbitrol 12. Steering priority valve
6. Tilt cylinder 13. Accumulator charging valve
7. Lift cylinder 14. Hydraulic tank
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2 COMPONENTS DESCRIPTION TECHNICAL MANUAL
2 COMPONENTS DESCRIPTION
2.1 Variable piston pump
2.1.1 Parker series P2
4
2
3
5
7
4
8 6
5
6 11 10 9
Figure 2. Variable piston pump
1. Input shaft 7. Servo piston

2. Adjusting screw (DeltaP) 8. Swashplate
3. Adjusting screw (P-max) 9. Pump housing
4. Adjusting screw (displacement) 10. Piston
5. Outlet 11. Barrel
6. Inlet
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TECHNICAL MANUAL 2 COMPONENTS DESCRIPTION
2.1.2 Function
A
V2
V1
The input shaft rotates and drives the barrel and pistons. Oil is drawn into the cylinders through
the inlet side and is pressed out of the cylinders through the outlet side.
The angle of the swashplate (A) determines the volumes (V1) and (V2). The difference between
(V1) and (V2) is the displacement, the volume of oil the pump gives per revolution.
When the actuator pressure is zero, the swashplate (A) is tilted to the maximum. The difference
in volume on the inlet side (V1) and outlet side (V2) is at its most and the pump supplies its
maximum flow. When the load signal is zero, the actuator pressure holds back the swashplate
to the minimum and there is no flow.
V2 A
V1
When less oil is required, the angle (A) of the swashplate is reduced. The difference between
(V1) and (V2) drops and the pump supplies a smaller quantity of oil.
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V2 A
V1
With minimal oil requirement, the angle (A) of the swashplate is virtually zero, the difference
between (V1) and (V2) is at its least, and the pump supplies a small oil flow.
11/42
2.2 Load-sensing system

The following illustration shows the system with the engine switched off, on the left, and with the
engine running, on the right. When there is no pressure in the system, the spring-loaded
actuator piston (1) of the pump is in the position for maximum pump output.
The line from the spring-loaded actuator piston (1) runs through the valve for maximum
pressure (P-max) and stand-by pressure valve (DeltaP) directly to the hydraulic tank. The
pressure in the stand-by pressure valve (DeltaP) can be adjusted using an Allen key.
A B A B
Directional valve Directional valve

LS P LS P
2
Regulator spole
for DeltaP Regulator spole
for DeltaP
Regulator spole Regulator spole

for Pmax
1 for Pmax
Pump Pump
When the diesel engine starts, the pump delivers the maximum output for a short period ot time,
until the stand-by pressure is reached.
Once the stand-by pressure is reached, the valve (2) adjusts the pump and maintains it at the
set pressure, irrespective of the speed of the diesel engine.
12/42
A B 3 AB

LS P LS P
6
4

for DeltaP for DeltaP
Regulator spole
Regulator spole for Pmax
for Pmax
5
Pump
Pump
When the system is put to work through the joystick, the directional control valve (3) changes
position and the (LS) line is pressurized. The valve (4) is reset, and the pressure in the actuator
piston (5) drops. The pump output then increases, until it corresponds to the load on the
system.
When the pump output corresponds to the load on the system, the valve (6) is adjusted and
maintains the pump at the right output.
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A B 3 A B

LS P LS P
4
Regulator spole
for DeltaP
Regulator spole 7
for DeltaP

for Pmax for Pmax
5 8
Pump Pump
When the cylinder is at the end position, the maximum pressure can be reached. The pressure
in the load signal (LS) increases and the valve (4) is reset. The pressure in the actuator piston
(5) decreases and the pump output increases.
When the pump output is equal to the set maximum pressure for the valve (7), its position
changes. The pressure in the actuator piston (8) increases and the pump output decreases. The
pressure is maintained until the cylinder moves or the directional control valve is switched.
2.3 Steering priority valve

The steering priority valve is preset to give a controlled pressure of 180 ... 200 bar.
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PP
5
4
EF
6 P
CF
3
2 LS
1. Pressure regulator 4. Controlled Flow (CF) to steering orbitrol

2. Load Sensor (LS) - load signal from 5. External pilot signal (PP)
steering orbitrol 6. From the piston pump (P)
3. Excess Flow (EF) to directional control
valve
15/42
8
1
Figure 3. Hydraulic system - steering principle
1. Steer cylinder 5. Shuttle valve

2. Steering orbitrol 6. Restrictor and non-return valve
3. Steering priority valve 7. Variable piston pump (105 cc)
4. Pressure regulator 8. Hydraulic tank
Oil is led from the variable piston pump (7) (105 cc) to the steering priority valve (3). The main
function of the steering priority valve (3) is to supply oil to the steering system ahead of the
machine's other hydraulic functions.
When the engine starts, the pressure builds up to stand-by pressure. The steering priority valve
(3) receives stand-by pressure at port P from the pump. The stand-by pressure is transferred to
CF and further to the steering orbitrol (2).
Return pressure at the steering orbitrol feeds to PP on the priority valve. The valve switches
position so that the stand-by pressure is on EF, to which the directional control valve is
connected. The steering orbitrol feeds a small contracted oil flow through the LS-line into the
tank.
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When the steering orbitrol is activated during steering, the pressure on PP drops and the priority
valve switches position again and oil flows from the pump through the priority valve P to CF, the
steering orbitrol P to the steer cylinder.
The adjustable pressure regulator (4) opens at maximum steering pressure (steering to the end
position).
2.4 Directional control valve
2.4.1 Parker L90LS
4 6
3 5 10
7
2
11
12
8
1
Figure 4. Directional control valve - Parker L90LS
1. Pilot circuit for joysticks (PS) 7. Pump connection (P1)

2. Tank connection for pilot circuit (TPB) 8. Tank connection (T1)
3. Hydraulic function (B) 9. Electrically controlled proportional valve
4. Hydraulic function (A) 10. Load signal connection (LS), copied
5. Connections from control joysticks 11. Pump pressure (PX)
6. Control for emergency lowering (forklift) 12. Load signal connection (PL), non-copied
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2 3
1 8 7 6 5 4
Figure 5. Schematic - Parker L90LS
1. Valve for maximum pressure 5. Shuttle - gives priority to highest load

2. Copy spool - copies the load signal from signal
hydraulic function to the pump 6. Compensator valve - limits the highest
3. Pressure limiter on load signal - used for permitted pressure for the circuit
extra functions, for example, joystick 7. Non-return valve
steering 8. Maneuver spool - changes the direction of
4. Pressure regulator for pilot pressure the hydraulic flow
2.4.2 Parker HV08
3
1
2
Figure 6. Directional control valve - Parker HV08
1. Function section 3. Tank connection (T)

2. Pump connection (P)
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B b a B A
A 1 3
T2
b a B A a B A b a P2 P1
T1B
T2
T1
AB
TGA
LD
AB
TGA
LSU
LSIB
LSU
LSIB P
P
7 6 2 5 4
10 9 8
Figure 7. Schematic - Parker HV08
A 2 spool sections
B 1 spool section
1. Pressure balance point A-B port 6. Section spool

2. Pump connection spool section (P1) 7. Plug
3. Tank connection (T2) 8. Copy spool
4. Load signal connection (LSU) 9. Non-return valve
5. Load signal, drainage 10. Pump connection (P)
19/42
2.5 Accumulator charging valve
2.5.1 M0382
1
3
5 6 2
3 4
7
PRM ACC
T2
ACCM
ACC1
5
2
6
PM
1
PB T P
8 7
Figure 8. Accumulator charging valve - M0382
1. Parking brake solenoid 6. Restrictor

2. Pressure regulator for parking brake 7. Charge valve
3. Pressure discharge of accumulator 8. Pressure regulator for accumulator
4. Pressure limiting valve (280 bar) charging
5. Non-return valve
20/42
2.5.2 M1040
6 5 1
2 9
8
3
4 7
8 2
3 4
PRM ACC
T2
ACCM
ACC1 5
2
6
PM
1 9
PB T P
8 7
Figure 9. Accumulator charging valve - M1040
1. Parking brake solenoid 6. Restrictor

2. Pressure regulator for parking brake 7. Charge valve
3. Pressure discharge of accumulator 8. Pressure regulator for accumulator
4. Pressure limiting valve (280 bar) charging
5. Non-return valve 9. Pressure limiting valve (210 bar)
The accumulator charging valve receives oil from the gear pump. Oil is distributed in the valve
to the accumulator, service brake, and parking brake.
If there is an engine failure, these functions continue receiving oil from the accumulator through
the accumulator charging valve.
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Item Components Functions

No.
1 Parking brake For parking brake. Electrically controlled valve to activate the
solenoid parking brake. When the valve is not activated, the parking
brake is employed.
2 Pressure regulator For the parking brake circuit. Reduces the pressure from the
for parking brake accumulator to the parking brake circuit.
3 Pressure discharge For pressure release. The accumulator is drained manually

of accumulator using a hex key. Used BEFORE working on the hydraulic
system.
4 Pressure limiting For maximum pressure preset to 250 bar. Prevents excess
valve charging of the accumulator.
5 Non-return valve The non-return valve prevents the accumulator from being
discharged when the engine is switched off. It is located
between the pump and accumulator or service brake.
6 Restrictor Restricts the pressure in the circuit.
7 Charge valve Regulates the pressure to the accumulator circuit. Controlled

by the pressure regulator (8).
8 Pressure regulator For the accumulator. Measures the pressure in the

for accumulator accumulator circuit and controls the valve (7). Accumulator
charging charging starts when the pressure is 20% below the set
pressure.
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2.6 Hydraulic system principle (Forklift SMV 10-16B)
15
14
16
17
11 12
6
13
10
9 4
5
8
7 4
2
1 3
Figure 10. Schematic - hydraulic system
23/42
1. Hydraulic tank 10. Multi-disc brake

2. Gear pump (23 cc) 11. Service brake valve
3. Variable piston pump (105 cc) 12. Accumulator
4. Restrictor and non-return valve 13. Accumulator charging valve
5. Shuttle valve 14. Return filter
6. Steering priority valve 15. Hydraulic functions
7. Steer cylinder 16. Directional control valve (L90)
8. Steering orbitrol 17. Control joysticks
9. Parking brake
24/42
2.7 Hydraulic system principle with M1040 (Forklift SMV 10-16B)
15
14
B A B A B A B A B A PS Tp
T1
P2
P1
LS LSPB
16
17
P
T
11 12
BR T
BL BM
P
PRM ACC
T2
ACCM
ACC1 13
PM
10 T
PP 6
PB P
EF P
CF
LS
9 4
T 5
8
R P 4
LS
L
7 T 3
2
Figure 11. Schematic - hydraulic system
1. Hydraulic tank 5. Shuttle valve

2. Gear pump (23 cc) 6. Steering priority valve
3. Variable piston pump (105 cc) 7. Steer cylinder
4. Restrictor and non-return valve 8. Steering orbitrol
25/42
9. Parking brake 14. Return filter

10. Multi-disc brake 15. Hydraulic functions
11. Service brake valve 16. Directional control valve (L90)
12. Accumulator 17. Control joysticks
13. Accumulator charging valve (M1040)
A gear pump (2) (23 cc) supplies the accumulator charging valve (13) with oil from the hydraulic
tank (1). The pressure is distributed in the valve to the accumulator (12), service brake (11), and
the parking brake (9). Oil from the valve also cools the multi-disc brake (10) in the drive axle.
The gear pump is seated in tandem on the variable piston pump (3) (Parker series P2, 105 cc).
Oil from the piston pump goes to the steering priority valve (6) which distributes the oil to the
steering orbitrol (8) and the directional control valve (16) (Parker L90). The priority valve
ensures that the steering is given priority over the other functions of the machine.
The load signal is led back from the steering orbitrol to the priority valve and to the shuttle valve
(5), where it is compared to the load signal from the directional control valve. After the shuttle
valve, the load signal is led through a restrictor and non-return valve (4) to the piston pump.
The directional control valve is controlled with the joysticks in the cabin. The valve distributes oil
to respective hydraulic functions (15). The return oil from the functions runs through the
directional control valve back to the hydraulic tank where the return filter (14) is located.
26/42
3 MEASUREMENTS AND ADJUSTMENTS TECHNICAL MANUAL
3 MEASUREMENTS AND ADJUSTMENTS

3.1 Measuring and setting the hydraulic pressure
The location of the measuring point and adjustment points differ slightly on the different
machine models. For pressure values not stated in this manual, see the machine card.
3.2 Measuring and setting the stand-by pressure, one pump

The correct stand-by pressure is a prerequisite for hydraulic functions to work properly. The
pressure is measured when the hydraulic system is not working (load signal is zero) and the
diesel engine is in the idle position.
3.2.1 Checking the load signal (LS)

1. Connect a pressure gauge (300 bar) to the
test point (1).
1
2. Start the diesel engine and let it idle.

3. Check that the pump load signal is zero bar, the hydraulics not in use.
4. Perform the troubleshooting action if the load signal (LS) is not at zero bar. For more
information, see Troubleshooting.
NOTE If the load signal (LS) is not at zero bar, then the stand-by pressure cannot be set
correctly.
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TECHNICAL MANUAL 3 MEASUREMENTS AND ADJUSTMENTS
3.2.2 Adjusting the stand-by pressure

test point (2) at the pump outlet.

The pressure rises to 33 bar.
3. If necessary, adjust the stand-by pressure using set screw (3) on the pump marked
'Delta P'.
3.3 Measuring and setting the stand-by pressure, multiple pumps

1. Check that the load signal (LS) is at zero bar. For more information, see Measuring and
setting the stand-by pressure, one pump (page 27).
When setting either the stand-by pressure or the maximum working pressure, always
NOTE adjust the lowest pressure first and then in ascending order of pressure, adjusting
the highest pressure last.
2. Connect a pressure gauge (300 bar) to the test point for outgoing pressure from the pumps.
3. To adjust the pressure, use the upper set
screw (4) marked 'Delta P' on the pump.
4. Unscrew the set screw on all pumps to approximately 15 bar.

5. Measure the pressure on the relevant pump.
6. To set the pressure as per the data on the machine card, use the set screw (4) on each
pump.
28/42
3.4 Measuring and setting the maximum working pressure

When using a hydraulic function, the working pressure rises to the level required to carry out the
work. The maximum pressure is only reached at maximum work load or when a hydraulic
function reaches its end position.

measuring point (1).
To achieve the maximum operating
pressure, lift the mast to the maximum
height.
2. To set the pressure of all pumps, screw out the adjusting screw P-max (2) by approximately
one turn.
The maximum pressure is set with the lower adjusting screw (P-max) on the pumps.
NOTE To adjust the pressure of a single pump, reduce the pressure of the other pumps.
Adjust the maximum operating pressure of the pump in the order of increasing
NOTE pressure, starting from the pump with the lowest pressure.
3. To check that the pump is operating properly, set the pressure 10 bar above the maximum
pressure.
After this check, set the pressure according to the machine card.
3.5 Measuring and setting the delta pressure (DeltaP)
3.5.1 Principle
A pressure drop (DeltaP) occurs when oil flows through the directional control valve. If DeltaP is
too low, the pump does not provide sufficient oil flow which results in the incorrect working of
the hydraulic system.
29/42
LS
P1
When the engine speed is low, a too low DeltaP can be unnoticeable. At a high speed, the
symptom of a too low DeltaP is that the system works slowly or not at all.
A too high DeltaP results in the hydraulic functions being difficult to control and reduces the
other advantages of the load-sensing system.
The measuring and setting procedure differs for machines equipped with one variable
NOTE pump or several variable pumps.
3.5.2 Measuring and setting the delta pressure, one pump

1. Connect a pressure gauge to the
measuring point (1) on the outlet of the
pump and to the measuring point (2) on the
LS-line.
2
2. Start the diesel engine and run at 1000 ... 1500 rpm.
3. To run a hydraulic function without a load, but not to the end position, move the joystick
halfway.
4. Read the pressure difference while the function is running.
The pressure difference is DeltaP.
5. If necessary, adjust the delta pressure with the adjusting screw (3) marked Delta P on the
pump.
30/42
3.5.3 Measuring and setting the delta pressure, two or three pumps
When measuring the delta pressure on one of the variable pumps, disconnect and plug the LS-
lines to the other variable pumps. Drain the LS-outlet on the pumps to the tank through extra
hydraulic hoses connected to the LS-outlet and routed to the hydraulic tank.
The following procedure is for one pump. Repeat the procedure to measure the other
NOTE pumps.
1. Connect a pressure gauge to the

measuring point (1) of the LS-line.
3
1
2
3 2
2. Remove the LS-lines from the other pumps and plug the lines (2).
3. Connect extra hoses to the LS-outlets (3).
4. Remove the breathing filters and position
the hoses in the hydraulic tank (4).
31/42
5. Connect the other connection from the

pressure gauge to the measuring point (5)
on the pump to be measured.
6. Start the diesel engine and run at 1000 ... 1500 rpm.
7. To run a hydraulic function without a load, but not to the end position, move the joystick
halfway.
8. Read the pressure difference while the function is running.
The difference is DeltaP.
9. If necessary, adjust the delta pressure with
the adjusting screw (6) marked Delta P on
the pump.
6
3.6 Releasing the accumulator pressure

The accumulator is normally at high pressure. Discharge the pressure in the accumulator before
working on the hydraulic system of the machine.
32/42
1. To loosen the locknut, use a box wrench.
2. To relieve the pressure, loosen the Allen screw.
3.7 Measuring and setting the accumulator pressure

measuring point (1) marked ACCM on the
accumulator charging valve.
1
4

3. Press the service brake repeatedly.
The pressure drops. The diesel engine audibly starts to work and the charging cycle of the
accumulator starts.
4. When the load on the diesel engine decreases, the charging cycle of accumulator ends.
Record the pressure.
5. If necessary, adjust the accumulator pressure setting on the adjusting screw (2).
Turn clockwise to increase pressure and turn anticlockwise to decrease pressure.
6. Repeat steps 3 to 5 until the accumulator has the right pressure.
7. Open and close the drainage plug (3), and recheck the pressure.
33/42
3.8 Measuring and setting the brake pressure switch

measuring point (1) marked ACCM.
For more information, see Measuring and
setting the accumulator
pressure (page 33).
1
4
2. Stop the engine.

3. Switch on the ignition and press the service brake a few times so that the pressure load
decreases.
The warning symbol lights at 120 bar.
4. When necessary, lift the cover of the pressure switch (4) and adjust the pressure with a
screwdriver.
3.9 Measuring the accumulator precharged pressure

measuring point ACCM (1).
1
4
2. Stop the engine.

3. Press the service brake repeatedly.
The pressure decreases.
4. The pressure drops immediately from 100 bar to zero bar.
This indicates that the accumulator pre-pressure is 100 bar. If the pressure goes below 95
bar before it drops to zero bar, this indicates that the accumulator pre-pressure is too low.
The accumulator is precharged with 100 bar. The precharged pressure can vary
NOTE depending on the surrounding temperature.
3.10 Measuring and setting the parking brake pressure

1. Check the accumulator pressure as set in preceding procedure.
34/42

measuring point (5) marked PRM on the
5
accumulator charging valve.

4. Read the pressure. Check that the pressure is 110 bar.
5. If necessary, adjust the parking brake pressure setting on the adjusting screw (6).
6. Turn clockwise to increase the pressure and turn anticlockwise to lower the pressure.
3.11 Adjusting the parking brake

The following adjustment controls the application of the parking brake to make engagement of
the brake softer. This function is only included on smaller machines.
1. Screw the restrictor and non-return valve

(7) to its bottom position and open it 1/4th
7
turn.
2. Slowly run the machine forward and apply the parking brake.
3. The brake should engage softly and not cause the machine to grind to a halt.
NOTE The more screwed in the valve is, the softer the parking brake engages.
35/42
3.12 Measuring the steering pressure

test point (1) on the load signal wire of the
control pump.
2. Start the diesel engine.

3. Steer to the end position and hold.
4. Read the pressure (180 ... 200 bar).
3.13 Adjusting the steering priority valve (older machines only)

1. To adjust the pressure, remove the hose
(2) and turn the adjusting screw inside the
valve with a hex key (3) (7/32 in).
3 2
3.14 Adjusting steering priority valve (new machines only)

1. Loosen the hydraulic hose that is connected to the pressure regulator.
36/42
2. Screw out the pressure regulator (4).
3. Use a screwdriver to turn the adjusting

screw (5) on the pressure regulator (4).
4
4. One half turn corresponds to a pressure change of about 40 bar.

4.1 Turn clockwise to increase the pressure.
4.2 Turn counterclockwise to decrease the pressure.
5. Tighten the pressure regulator (4).
6. Connect the hydraulic hose to the pressure regulator.
7. Check and measure the pressure. For more information, see Measuring the steering
pressure (page 36).
37/42
3.15 Setting the restrictor and non-return valve

1. Tighten the restrictor and non-return valve
(6) mounted on the load signal line of the
priority valve and lock it with the Allen
screw.
2. Check that the restrictor and non-return valve (6) is correctly tightened as follows:
2.1 Connect a pressure gauge (300 bar) to the load signal line on the pump connected to
the priority valve and turn the steering wheel to its end position.
2.2 The pressure increases to 180–200 bar.
2.3 Let go of the steering wheel and note the pressure drop.
Correctly adjusted, the pressure should be gone within 5-10 sec.
2.4 If the pressure drops faster, the restrictor and non return valve is not tightened enough.
2.5 If the pressure is dropping slowly the valve is tightened too much.
3.16 Measuring and adjusting the attachment pressure (ECB)

On ECB machines, the L90 valve is equipped with a pressure reducer that is set to 140 bar. The
setting does not normally need to be changed.
1. Connect the pressure gauge to the test

point (1) on the attachment.
2
2. To build up the pressure (140 bar), maneuver the attachment to 20 feet.

Throughout the entire adjustment procedure, keep this function activated.
3. Break the plastic seal of the L90 valve.
38/42
4. Adjust the pressure reducer ECB90 (3) or

ECB 80 (4).
5. Check that the pressure is 140 bar.

4
6. If a whistling noise comes from the attachment by-pass (2) once at the 20 foot position,
screw it in until the whistling stops and then turn an extra half turn.
3.17 Measuring and adjusting the attachment pressure (gantry)

1. Connect a pressure gauge to the test point
(1) on the attachment.
2. To build up the pressure (140 bar), maneuver the attachment to 20 feet.

Throughout the entire adjustment procedure, keep this function activated.
39/42
3. Check that the pressure is 140 bar.

4. Adjust the pressure on the pressure
reducer (2) in the chassis.
2
40/42
4 TROUBLESHOOTING TECHNICAL MANUAL
4 TROUBLESHOOTING
4.1 Troubleshooting
Problem Possible cause Solution
Low lifting speed Pumps are not working Check each pump individually
Incorrect stand-by or delta Measure and adjust the

pressure pressure
Load drops Leakage in lift cylinder Check for leakage, replace

seals
Machine cannot lift load Pump not giving maximum Adjust the pressure
pressure
Steers heavily Variable piston pump Check standby or delta

(steering pump) pressure, maximum pressure
Orbitrol, steering priority valve Check load signal to pump,

check orbitrol and steering
priority valve
Leakage in steering cylinder Check for leakage, replace

seals
Steering bites Pump pressure varies Adjust the one-way restrictor

on the load signal to the left
pump
No pressure in the 25cc gear pump defective Check the pump

accumulator
Accumulator charging valve Check the valve
defective
Load signal does not go down Directional control valve does Check the directional control
to zero bar not go to neutral valve
Load signal does not go up to Leakage in load signal Fault trace leakage on load
maximum pressure
Pump defective Check standby or delta
pressure, maximum pressure
Attachment runs slowly Reduction valve for Check the pressure, 140 bar
attachment on attachment
Loading valve for attachment Check the load signal to the

pump
Attachment pump Check standby or delta

pressure, maximum pressure
41/42
TECHNICAL MANUAL 4 TROUBLESHOOTING
42/42
www.konecranes.com
Corporate HQ
Region EMEA HQ
Hyvinkää, Finland
Region Americas HQ
Springﬁeld, Ohio Region APAC HQ
Shanghai, China
Main production sites

Sales and service locations
This document and the information contained herein, is the exclusive property of Konecranes
Lifttrucks and represents a non-public, confidential and proprietary trade secret that may not be
reproduced, disclosed to other parties, altered or otherwise employed in any manner whatsoever
without the express written consent of Konecranes Lifttrucks. © 2016 Konecranes Lifttrucks. All rights
reserved. ‘Konecranes’, ‘Lifting Businesses’ and C are either registered trademarks or trademarks of
Konecranes Lifttrucks.Copyright © (2016) Konecranes Lifttrucks. All rights reserved.

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TECHNICAL MANUAL

3 MEASUREMENTS AND ADJUSTMENTS................................................................ 27

The advantages of a load-sensing system are the following:

• No flow in the system when it is not used

The system remains in balance:

• Light load - low output

1.2 Location of components

Figure 1. Forklift SMV 10-16B

1. Steer cylinder 8. Side shift cylinder

2.1.1 Parker series P2

Figure 2. Variable piston pump

1. Input shaft 7. Servo piston

2.2 Load-sensing system

Directional valve Directional valve

Regulator spole Regulator spole

Directional valve Directional valve

Regulator spole Regulator spole

Directional valve Directional valve

Regulator spole Regulator spole

2.3 Steering priority valve

1. Pressure regulator 4. Controlled Flow (CF) to steering orbitrol

Figure 3. Hydraulic system - steering principle

1. Steer cylinder 5. Shuttle valve

2.4 Directional control valve

2.4.1 Parker L90LS

Figure 4. Directional control valve - Parker L90LS

1. Pilot circuit for joysticks (PS) 7. Pump connection (P1)

Figure 5. Schematic - Parker L90LS

1. Valve for maximum pressure 5. Shuttle - gives priority to highest load

2.4.2 Parker HV08

Figure 6. Directional control valve - Parker HV08

1. Function section 3. Tank connection (T)

Figure 7. Schematic - Parker HV08

1. Pressure balance point A-B port 6. Section spool

2.5 Accumulator charging valve

Figure 8. Accumulator charging valve - M0382

1. Parking brake solenoid 6. Restrictor

Figure 9. Accumulator charging valve - M1040

1. Parking brake solenoid 6. Restrictor

Item Components Functions

3 Pressure discharge For pressure release. The accumulator is drained manually

6 Restrictor Restricts the pressure in the circuit.

7 Charge valve Regulates the pressure to the accumulator circuit. Controlled

8 Pressure regulator For the accumulator. Measures the pressure in the

2.6 Hydraulic system principle (Forklift SMV 10-16B)

Figure 10. Schematic - hydraulic system

1. Hydraulic tank 10. Multi-disc brake

2.7 Hydraulic system principle with M1040 (Forklift SMV 10-16B)

Figure 11. Schematic - hydraulic system

1. Hydraulic tank 5. Shuttle valve

9. Parking brake 14. Return filter

3 MEASUREMENTS AND ADJUSTMENTS

3.2 Measuring and setting the stand-by pressure, one pump

3.2.1 Checking the load signal (LS)

2. Start the diesel engine and let it idle.

3.2.2 Adjusting the stand-by pressure

2. Start the diesel engine and let it idle.