Hi-Force OM-SLV-01 Series User manual

Operating Instruction Manual:
OM-SLV-01
Serial Numbers:
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OPERATING INSTRUCTION MANUAL
SLV SERIES | SYNCHRONOUS LIFTING SYSTEM
- VARIABLE SPEED DRIVE
The Hi-Force SLV Synchronous Lifting System with Variable Speed Drive is designed for precise lifting and
lowering of heavy loads, using multiple synchronised hydraulic cylinders. The system can maintain a
tolerance across all cylinders of as low as 1mm. Available as standard with up to 32 outlet ports for
single-acting or double-acting cylinders and a variable speed motor for better operational speed control. In
high-pressure mode, the pump delivers 4.8 lpm of hydraulic oil at a maximum operating pressure of
700 bar (10,000 psi). This manual applies to the Hi-Force SLV Synchronous Lifting System with Variable
Speed Drive. It contains the latest product information available at the time of publication and approval. For
information relating to the servicing of a synchronous lifting system pump, see the servicing instructions,
which are available on the Hi-Force website. Hi-Force reserves the right to make changes to this document
at any time without notice.
This ‘Original instructions’ document assumes that the operator carrying out any operation with this
product is trained and competent to do so. This manual does not attempt to cover all details or variations
in the equipment. Nor does thismanual claim to provide for every possible contingency met in connection
with the installation, operation, or maintenance thereof. Should further information be desired, or should
a particular problem arise which is not covered in sufficient detail, the matter should be referred to
Hi-Force.

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Table of Contents
1.0 Inspection upon Receipt................................................................................4
2.0 Safety Precautions .........................................................................................4
2.1 Introduction ....................................................................................................................................... 4
2.2 Work Area Safety............................................................................................................................... 4
2.3 Electrical Safety Precautions ........................................................................................................... 4
2.4 General Hydraulic System Safety Precautions............................................................................... 5
2.5 Synchronous Lifting System Specific Safety Precautions............................................................ 7
3.0 Declaration of Incorporation/Conformity.....................................................8
4.0 Component Identification ..............................................................................9
4.1 SLV Pump Unit .................................................................................................................................. 9
4.2 Control Unit...................................................................................................................................... 10
4.3 Cylinder and Displacement Sensor ............................................................................................... 11
5.0 Installation/Setup.........................................................................................12
5.1 Before First Use............................................................................................................................... 12
5.2 Filling the Pump with Oil................................................................................................................. 12
5.3 Hydraulic Connections ................................................................................................................... 13
5.4 Connecting Hydraulic Cylinder/s and their Accessories to the Pump Unit ............................... 13
5.5 Electrical Connection...................................................................................................................... 16
5.6 Bleeding Trapped Air from the System......................................................................................... 17
6.0 Operation.......................................................................................................18
6.1 Control Unit - Screen Layouts and Button/Panel Functions ...................................................... 18
6.2 Jack Settings ................................................................................................................................... 24
6.3 Operation Settings .......................................................................................................................... 24
6.4 Calculation of the Jack Force at Max Pressure (kN) & Max Jack Load Values.......................... 25
6.5 Tolerance Setting ............................................................................................................................ 25
6.6 Displacement Sensors.................................................................................................................... 26
6.7 Manual Operation............................................................................................................................ 26
6.8 Automatic Preloading ..................................................................................................................... 27

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6.9 Automatic Lifting............................................................................................................................. 28
6.10 Automatic Lowering...................................................................................................................... 29
6.11 Releasing Hydraulic Pressure from the System......................................................................... 30
6.12 Throttle Flow Control Valves........................................................................................................ 31
6.13 Centre of Gravity ........................................................................................................................... 32
6.14 Data Logging ................................................................................................................................. 34
7.0 Error Reporting.............................................................................................35
8.0 Maintenance and Storage............................................................................36
9.0 Specifications ...............................................................................................38
10.0 Accessories ................................................................................................39
11.0 Troubleshooting .........................................................................................40
12.0 Contact Details...........................................................................................42
NOTE: Images contained within this document are for illustrative purposes ONLY.

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1.0 Inspection upon Receipt
Upon receipt of the product, visually inspect the item for any evidence of shipping damage. Please note:
the warranty does not cover shipping damage. Notify the courier immediately if shipping damage is found
and refrain from putting the product into service. The carrier is responsible for repair and replacement costs
resulting from damage that occurred in transit.
2.0 Safety Precautions
2.1 Introduction
Read and follow all the instructions and safety warnings carefully before handling, installation or
use of any hydraulic equipment. Failure to do so could lead to equipment damage, equipment
failure, personal injury or even death. Hi-Force will not be held responsible for any damage to the
equipment, injury or death resulting from the unsafe use of, lack of maintenance to, or incorrect operation
of the product. If in doubt onthe correct use of any Hi-Force equipment, contact your nearest Hi-Forceoffice
or distributor. Only qualified personnel should be allowed to operate hydraulic equipment. If an operator has
not been trained on high-pressure hydraulic equipment and its safe usage, consult your local Hi-Force sales
office or distributor who can offer training courses for operators.
Failure to observe and obey the following safety precautions could result
in property damage, equipment damage or minor/moderate personal
injury;
2.2 Work Area Safety
•Keep work areas clean and well lit. Cluttered spaces and inadequate lighting can result in
unnecessary accidents.
•Keep bystanders clear of any hydraulic tool activity. Personnel working in close-range should be
made aware of all high-pressure work before commencing.
•Ensure that the lifting device/s are placed entirely under the load and that lifting is parallel.
2.3 Electrical Safety Precautions
•Electrical power plugs/sockets MUST match the power source outlet socket. Never modify electrical
power plugs or tool/equipment electrics.
•DO NOT abuse cabling. DO NOT use electric cables to carry, move or disconnect tools. Make sure
electrical cabling is clear of heat sources, sharp edges or moving parts.
•When using the unit outdoors, use a suitably rated extension lead (if required) to reduce the risk of
electric shock.

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2.4 General Hydraulic System Safety Precautions
Failure to observe and obey the following safety precautions could result
in property damage, significant personal injury or death;
•When operating any hydraulic equipment, all operators should ensure that all necessary personal
protective equipment (PPE) is worn, as specified by their employer. Steel toe-cap safety shoes,
safety glasses/visor, ear protection and protective gloves should be worn at all times. All relevant
risk assessments should be completed before the use of the equipment.
•Keep hydraulic equipment away from open flames and direct heat.
•NEVER use a coupler as a tool handle, especially if the system is pressurised.
•Inspect hoses regularly for damage and wear.
•NEVER use hoses that are frayed, kinked, abraded or leaking.
•NEVER handle a pressurised hydraulic hose. Hydraulic fluid escaping under pressure from a
ruptured hose can penetrate the skin and lead to a significant medical emergency, and in some
cases, death. Should this incident occur, seek out medical attention immediately.
•Seek medical attention immediately if a hydraulic injection injury (no matter how minor) occurs.
•The system operating pressure MUST NOT exceed the pressure rating of the lowest-rated
component in the system.
Good Practice: Use a pressure gauge to monitor the entire system.
•Only use hydraulic tools/cylinders in a complete and tested, coupled system. NEVER attempt to
use a tool/cylinder that is not correctly coupled to its operational pump.
•NEVER pressurise an unconnected male coupler/s.
•NEVER attempt to disconnect a hose from a hydraulic system until the system’s pressure has been
completely released. Doing so can result in that pressure becoming trapped within the system and
relieving trapped pressure can be dangerous.
•NEVER try to relieve trapped hydraulic pressure in the system by loosening or attempting to remove
the coupler. Trapped hydraulic pressure can cause a loosened coupler to dislodge unexpectedly
with great force. This action could result in serious personal injury or death.
•Loosening a coupler under pressure can result in the escape of hydraulic oil at high pressure, which
can penetrate the skin and cause significant injury or death.

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•NEVER use a hammer and punch to unseat a coupler check valve that is under pressure. Doing so
could result in the sudden, uncontrolled release of hydraulic oil at high pressure, which could cause
significant injury or death.
•NEVER attempt to solve, or clean-up leaks in the system while the system is pressurised.
•Immediately replace any worn or damaged parts using genuine Hi-Force parts only.
•DO NOT use any hydraulic equipment if you are under the influence of alcohol, drugs or medication.
Lack of attentionwhilst operating high-pressure hydraulic tools canresult in personal injury or death.
•NEVER over-stroke failsafe (HFL & HFG) or HSG cylinders. These cylinders are not fitted with a
piston stop ring. Equipment failure and injury can occur.
Failure to observe and obey the following safety precautions could result
in property damage, equipment damage or minor/moderate personal
injury;
•NEVER lift, carry or move any hydraulic components by the hose or hoses connected to them.
•Avoid damaging hydraulic hoses. ALWAYS route hoses to ensure that they are free from sharp
bends and kinks. Using a sharply bent or kinked hose will result in severe back-pressure, which can
lead to hose failure.
•NEVER use a coupler/s to lift, carry or position a tool.
•Servicing of hydraulic equipment must only be undertaken by a qualified technician.
•DO NOT drop or place heavy objects on a hydraulic hose, as this may cause
internal damage, which could result in rupture of the pressurised hose. A
ruptured hose could cause significant damage to components and possible
severe injury to personal operating nearby.
•The manufacturer rated load capacity and stroke length for cylinders represent the maximum safe
limits.
Good Practice: Use 80% of the rated figures, as the maximum values for load capacity and
stroke length.
•Select cylinders with sufficient over-capacity. See guidance above.
For multi-cylinder lifting operations, 50% of the total number of cylinders used should be able to
withstand the full weight of the load being lifted/lowered. I.e. The system capacity should be at least
twice that of the load being lifted/lowered.
•DO NOT let familiarity gained with any hydraulic tools allow you to become complacent.
Complacency with any tooling can result in a lack of discipline toward working guidelines and safety
principles.

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•DO NOT remove any labels from the product. Replace any damaged or unreadable labels
immediately.
•Avoid loose clothing and jewellery that could get caught in moving parts, tie back long hair.
2.5 Synchronous Lifting System Specific Safety Precautions
Failure to observe and obey the following safety precautions could result
in property damage, serious personal injury or death;
•DO NOT mix high-pressure and low-pressure components. All equipment must be rated for the
same operating pressure. I.e. 700 bar (10,000 psi)
•NEVER exceed the maximum rated capacity of any SLV system. Hi-Force manufactures its SLV
unit to operate at a maximum working pressure of 700 BAR (10,000 PSI). Overloading hydraulic
pumps can result in component failure and possible serious personal injury.
•DO NOT connect hydraulic equipment with a lower pressure capacity rating to any Hi-Force Pump
of this model series.
•DO NOT weld any items to the unit or modify it in any way from its delivered condition. Your warranty
may be invalidated, and it could lead to serious personal injury.
•Only use hydraulic cylinders in a complete and tested, coupled system. NEVER attempt to use
cylinders that are not correctly coupled to their operational pump.
•NEVER attempt to connect or disconnect, hydraulic equipment while the system is under pressure.
•NEVER leave a pressurised system unattended. If you must leave the area, release the pressure
and ensure the hydraulic release valve on the pump unit if fully open.
•This pump is NOT ATEX RATED. I.e. NOT suitable for work which takes place in explosive
environments.
Failure to observe and obey the following safety precautions could result
in property damage, equipment damage or minor/moderate personal
injury;
•ALWAYS stand the equipment on a stable, level surface during operation.
•BEWARE of hot surfaces on the motor. DO NOT obstruct the flow of cooling air around the motor.
•To protect your warranty, only use the hydraulic oil grade specified in Section 5.2.

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3.0 Declaration of Incorporation/Conformity
Hi-Force declares that this product has been tested and complies with the standards set out in the
relevant EU directives. The EU Declaration of Incorporation/Conformity is included as Annex A to this
instruction document and is supplied with all shipments of this product.

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4.0 Component Identification
4.1 SLV Pump Unit
1
Hydraulic Oil Drain Plug
6
Hydraulic Oil Level Gauge
2
Hydraulic Control Manifold *
7
Electrical Control Box
3
Motor
8
Hydraulic Outlet Couplings
4
Oil Filler Breather Cap
9
Pressure Relief Valve
5
Oil Reservoir
10
‘Return Line Filter’Pressure Gauge
* Can be configured for single-acting or double-acting cylinders.
For single-acting systems, excess outlets are sealed with blanking plugs.
Figure 4.1: Component Identification - Pump Unit
(Illustration Purposes Only)

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4.2 Control Unit
1
Control Unit
6
Control/Settings Screen
2
Jack/Cylinder Screens *
7
Emergency Stop
3
Data Logging “Upload” Port
8
Motor ‘Start’
4
Operate ‘Start’
9
Motor ‘Stop’
5
Operate ‘Stop’
10
Motor Variable Speed Control
*Quantity and Layout dependant on no. of outlet ports.
Figure 4.2: Component Identification - Control Unit

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4.3 Cylinder and Displacement Sensor
1
Cylinder Body
7
Mounting Kit - Base Plate
2
Female Coupler
8
Displacement Sensor
3
Lifting Eye
9
Over-Stroke Port *
4
Mounting Kit - Cylinder Saddle
10
Advance Coupler
5
Mounting Kit - Cylinder Saddle Bar
11
Retract Coupler
6
Mounting Kit - Band
12
Pressure Relief Valve
NOTE: For cylinder specific component identification, see cylinder’s instructions manual.
*HFL, HFG & HSG cylinder series only.
Figure 4.3: Component Identification - Cylinder & Displacement Sensor

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5.0 Installation/Setup
IMPORTANT: Images used through-out thismanual are for illustrative purposes ONLY. Imagesmay display
a different system configuration and different tools or accessories to those being used.
Additionally, some details may have been removed for clarity purposes.
5.1 Before First Use
1. Immediately after unpacking, examine the unit for signs of transit damage and if found contact the
shipping company.
2. Remove the temporary transit fitting/plate which is fitted in the position of the oil filler breather cap
(4) and fit the oil filler breather cap which is packed separately.
3. Establish the oil level in the oil reservoir (1) using the level gauge (6). Depending on the shipping
method used, the reservoir may either be supplied full or empty. If the reservoir is empty, it must be
correctly filled before use (See section 5.2). If the reservoir was supplied full of oil, no further action
is required.
IMPORTANT: Running the pump without oil will result in damage.
4. Make sure that the voltage indicated on the motor rating plate correspondswith the available supply.
5.2 Filling the Pump with Oil
IMPORTANT: The SLV Range of Pumps uses ISO46 Grade Hydraulic Oil.
•Stand the pump on a firm, level surface.
•Remove the filler cap (4) from the filler breather.
•Fill the reservoir with clean, high-quality ISO46 hydraulic oil via the filler breather until the oil level
reaches the upper-level indicator (6).
•Replace the filler cap (4) on the filler breather.
Ensure the oil level does not fall below the minimum level, as shown by the lower-level
indicator (6). Running the pump without oil will result in damage.
IMPORTANT: Only add oil to the reservoir when all connected cylinders are fully retracted. Failure to do
so will result in the system containing more oil than the reservoir can hold.

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5.3 Hydraulic Connections
Connect the hydraulic hose/s between the cylinder/s and the pump outlet/s (8), ensuring that the coupler/s
are fully hand-tightened ONLY. To do so: [1] Press the male coupler into the female coupler, [2] then turn
the threaded-collar clockwise (by hand) until the threads are fully engaged.
NEVER use wrenches in an attempt to connect the coupling/s. Incorrectly connected
couplers are one of the most common causes of faulty operation.
IMPORTANT: Make sure that all coupler threads are fully engaged. (See figure 5.1, panel 3)
5.4 Connecting Hydraulic Cylinder/s and their Accessories to the Pump Unit
1. Fit the correct, complete (SLMK-*) sensor mounting kit to each cylinder in the system. A detailed
table of cylinders and their applicable sensor mounting kits can be found on the Hi-Force website or
in the latest Hi-Force Catalogue.
Fit the Sensor Mounting Kit as follows:
•Fit the mounting kit saddle (4).
•If necessary, loosen the Mounting Kit Band (6) until it is loose enough to fit over the cylinder
body.
•Hook the Mounting Kit Base Plate into the Mounting Kit Band and slide the band over the
cylinder body. (See figure 5.2)
Figure 5.1: Hydraulic Connection

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•Fasten the Mounting Kit Band to the cylinder body so that the top of the base plate sits approx.
120mm below the top face of the cylinder body (See figure 5.3). This should position the
displacement sensor the correct distance below the saddle bar, to achieve the minimum
sensor cable extension required for the control unit to register the sensor. (See step 5)
•Fasten the saddle bar into the threaded hole on the mounting saddle. (See Figure 5.3)
2. With cylinders setup in their correct operating positions, use Hi-Force HC*C type hoses to make
hydraulic connections between the cylinders and the pump (See section 5.3).
The SLV outlet ports are labelled V1 →V#. The outlet port number is important, as it is how each
cylinder will be identified by the control unit (E.g. Outlet port V1 will be Jack 1) and it will dictate
which electrical socket the displacement sensor of each cylinder must be connected to.
E.g. The cable from the displacement sensor on the cylinder connected to outlet port V1, must be
plugged into socket D1 on the electrical control box. (See Figure 5.4)
3. Attach displacement sensors to all cylinders fitted with a sensor mounting kit. Magnets on the bottom
of the displacement plate connect the sensor to the base plate and hold it in place during operation.
Figure 5.4: Hydraulic outlet port & Sensor Socket Matching
Figure 5.2: Mounting Kit Base Plate Installation.
Figure 5.3: Mounting Kit Saddle Bar Installation &
approx. Base Plate Position

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4. Use sensor signal cables to connect each displacement sensor to the corresponding port on the
electrical control box. (See figure 5.4)
To connect each cable, line up the keyways on the male and female connector/s for correct
orientation and press together. Turn the collar/s on the cable connector/s clockwise to fully engage
the connector/s and secure the cable connection/s.
NOTE: Should the connector/s on the electrical box rotate while fitting a cable, stop and have the
connector tightened. Allowing the connector to be rotated excessively will damage the electrical
connection to the connector.
5. With all sensors and sensor cables correctly fitted, make the sensor connections between the
cylinder bodies and the piston saddle bars. (See figure 5.5)
•Rotate the saddle so that the saddle bar sits directly above the sensor.
•While holding the displacement sensor body steady, gently pull the sensor wire cable out from
the sensor and slip the connector ring over the mounting kit saddle bar. Position the ring on
the bar so that the wire cable exits the sensor body as straight as possible. Skewed cable wire
can affect the accuracy of the sensor.
IMPORTANT: DO NOT jerk the wire cable when extending it, or release it and allow the wire
cable to retract uncontrollably, as doing so will damage the unit.
NOTE: When connected to the saddle bar, the wire cable must be pulled a minimum of 20mm
from the sensor body. Less than this will result in an ‘under range’ fault being displayed
on the control unit and the pump will not operate with this jack enabled.
(See figure 5.6)
When using failsafe lock ring cylinders, DO NOT cover the over-stroke port (9) with the
SLMK-* mounting kit. Covering the over-stroke port could cause unseen piston
over-stroke, overflow of hydraulic oil and pressure build-up between the cylinder and
the mounting kit, resulting in cylinder/equipment damage and/or possible serious
injury.
Figure 5.5: Displacement Sensor Mounting
(Signal Cable not shown)
Figure 5.6: Minimum Sensor Cable Extension

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5.5 Electrical Connection
Before making an electrical connection, refer to the data plate located on the motor (3) for voltage and
current requirements. Once satisfied that the supply is suitable, an electrical connection can be made using
the 415V 32A cable ‘end socket’provided. (See figure 5.7)
NOTE: Supply voltages vary from country to country. Hi-Force pumps will operate within the normalvoltage
tolerance ranges. But in extreme cases where they are operated for long periods at high pressures
and in low voltage conditions, the motor may overheat and shut down.
NOTE: A common cause of pump failure is the use of long extension cables to connect the pump to the
mains supply. The pump should be situated as close as possible to the primary power source.
•Pull out the top shelf that the control unit sits on and connect the control unit to the electrical control
box with one of the 2 (different lengths) control unit cables provided. (See figure 5.8)
Figure 5.9: Mains Power Switch
Figure 5.8: Control Unit Connection
Figure 5.7: Mains Connection

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5.6 Bleeding Trapped Air from the System
Hydraulic cylinders and hoses are not always completely filled with oil when new. For safe and efficient
operation, the air must be removed (bled) from the system.
Single-Acting Cylinders
It is not usually necessary to bleed air from single-acting cylinders. However, you MUST ensure that all
hydraulic hoses are pre-filled with oil before connection, to ensure no additional air is introduced into the
system.
NEVER over-stroke failsafe (HFL & HFG) or HSG cylinders. These cylinders are not
fitted with a piston stop ring. Equipment failure and injury can occur.
Double-Acting Cylinders
To bleed the air from the system, select manual mode and fully advance & retract the connected
jacks/cylinders, under no-load conditions. Repeat this process several times until all jacks/cylinders
operate smoothly. Visually check the system for leaks. (See section 6.7 for manual operation)
IMPORTANT: Outlet ports (jacks) that are not connected, MUST be disabled. (See section 6.1.3, pg 23)

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6.0 Operation
6.1 Control Unit - Screen Layouts and Button/Panel Functions
6.1.1 Settings Screen

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Settings Screen - Button/Pane Functions
Image
Description
Applicable to:
Type
Range
Jack Name
(Press to change)
Individual Jack
Setting
Button
9 Character
input
Press to set the
X-coordinate of the jack.
(for Centre of Gravity)
Individual Jack
Setting
Button
0 - 99999mm
Press to set the
Y-coordinate of the jack.
(for Centre of Gravity)
Individual Jack
Setting
Button
0 - 99999mm
Factory set to the maximum
working pressure of the
pump. (700 bar)
Global System
Setting
(Fixed)
Display
-
Press to set the Maximum
Capacity (kN) at Max bar. **
Global Jack
Setting
Button
0 - 20000kN
Factory set to the length of
the supplied sensor.
Global Jack
Setting
(Fixed)
Display
-
Press to set the Maximum
Jack Load. **
Global Jack
Setting
Button
0 - 20000kN
Press to enable/disable
individual jacks.
Individual Jack
Setting
Toggle
Button
-
Press to zero the
displacement value on
selected jack Only.
Individual Jack
Setting
Button
-
Press to zero the
displacement value on all
jacks.
Global Jack
Setting
Button
-
Allows operator to select
which units system pressure
is displayed in.
Global System
Setting
Selector
Pane
-
** These values are for calculation purposes ONLY. They cannot be used to restrict
operation/capacity in any way. Incorrectly entered values will result in the control
unit returning incorrect readings and the system/components operating at a
pressure/load different to that expected/displayed.

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Settings Screen - Button/Pane Functions (continued…)
Image
Description
Applicable to:
Type
Range
Allows operator to select
which units individual jack
loads are displayed in.
Global System
Setting
Selector
Pane
-
Allows operator to select
which units total system
load is displayed in.
Global
System Setting
Selector
Pane
-
Press to set the lifting
target.
Automatic
Lifting Only
Button
-635mm -
635mm
Press to set the lowering
target.
Automatic
Lowering Only
Button
-635mm -
635mm
Press to set the tolerance
the system will maintain
across all enabled jacks
during automatic operation.
Automatic
Lifting &
Lowering Only
Button
1 - 50mm
Press to set the force that
will be applied during the
preload operation.
Automatic
Lifting &
Lowering Only
Button
0 - 9813kN
Returns the operator to the
Control Screen.
-
Button
-