smv MULTI-LIFT SYSTEM User manual

MULTI-LIFT SYSTEM
INSTRUCTIONS MANUAL
INSTALLATION - USE - MAINTENANCE
STABILIZER PARKING SYSTEM FOR VEHICLES

2
INDEX
INTRODUCTION 3
RESPONSIBILITY AND GUARANTEE 3
USING THE INSTRUCTIONS MANUAL 5
METHOD OF USE 6
COMPONENTS 7
USING THE REMOTE CONTROL 9
ABSOLUTE “MUST-NOTS”- PROHIBITED USE 11
EMERGENCY MANOEUVRE 13
GENERAL SAFETY MEASURES 14
INSTALLATION 16
HYDRAULIC 27
ELECRTIC 33
RECEIVER 35
AUTOLEVEL SYSTEM 45
AUTOLEVEL SETTING 46
ADVISE 55
CONTACTS 57
BOTH INSTALLER AND USER MUST READ THE FOLLOWING MANUAL CAREFULLY TO ENSURE
CORRECT USE AND MAXIMUM EFFICIENCY OF THE EQUIPMENT

3
INTRODUCTION
SMV recommend that users scrupulously follow the instructions set out in this Manual.
The symbols in the manual are used to focus the attention of the user on safety standards in force and on how to use the
equipment properly and carry out correct maintenance.
Definitions:
Danger!
This symbol is used for safety messages or instructions or, in any case, when potentially dangerous or harmful
situations arise.

Warning
This symbol appears on safety messages with precautions to be taken to avoid damage to the machine or for important
messages to the operator.
This instructions manual should be considered an integrated part of the machine and must remain with the machine for
its entire lifespan.
The instructions manual must be kept in a place that is easily accessible to operators and must be preserved from any
form of deterioration.
The manual must be read carefully by the operator before using the equipment and before carrying out maintenance,
paying maximum attention to the messages in which the danger symbol appears: these contain the necessary
instructions for the correct use of the machine under maximum safety conditions.
RESPONSIBILITY AND GUARANTEE
SMV reserve the right to carry out any modifications and improvements to the machine that are held necessary over
time and without prior notice.
Products manufactured by SMV are guaranteed against any breakdowns that can be attributed to manufacturing defects
or materials used.
SMV guarantee their manufactured products against conformity defects from the delivery date to the first end user
(DIRECTIVE 1999/44/CE OF THE EUROPEAN PARLIAMENT AND COUNCIL 25th May 1999).
Warning
The Guarantee does not cover materials in everyday use such as the brushes on direct current motors, filters, start up
relays. The Guarantee does not apply to products that have been supplied with sealed pressure modulating valve and
sent back with the seal removed.
The Guarantee does not cover direct current motors that will not start up while charging with voltage that is too low,
discharged batteries or unsuitably sized electrical circuits.
The manufacturer will not accept responsibility for damage caused to the machine itself, animals, people and any kind
of guarantee will become automatically null and void unless the following rules are adhered to:
any mechanical intervention under guarantee must be carried out by a Technical Assistance center authorised by SMV
or at our manufacturing plant, where the products must be sent, once authorised by us, in free port with suitable
packaging.

4
The guarantee will be considered null and void in the event of imprudent use, tampering, modifications and/or
repairs carried out by unauthorised persons.

Warning
ATTENTION! The guarantee will become automatically null and void under the following circumstances:
-installation and start up procedures have not been followed according to instructions set out in this manual;
-original SMV spare parts have not been used;
-the presence of hydraulic fluid that is not compatible with the contamination class indicated in this manual
is detected;
-breakdown caused by wrong dimensioning of the electrical command system is detected;
-the maintenance program in the present manual has not been followed;
-damage to the product is revealed because it has been dropped or it has been stocked in a warehouse
without following instructions.
SMV are available to carry out repairs to their own products even after the guarantee has expired.
SMV will carry out repairs after many years of use (as long as it is economically viable).
Availability of spare parts designed and manufactured by SMV is guaranteed up to 5 years from the product being out
of production.
Availability of general components used is ensured until supplies run out.
The cost of repairs to our products no longer under guarantee, is normally calculated once repairs have been carried out.
Any request for estimates must be made expressly at the moment in which the product to be repaired is delivered.
Each product rendered for servicing must be accompanied by the following:
1. Detailed delivery note, as set out according to the law;
Covering letter indicating the fault found and the details of a technician responsible for providing
any clarifications needed.

Warning
The Declaration of Conformity will automatically become null and void if any modifications are carried out without
prior written notice to the manufacturer and guarantees of any nature and responsibility of the above will become null
and void.

5
USING THE INSTRUCTIONS MANUAL
SMV recommend that users scrupulously adhere to the instructions set out in this Manual. Before carrying out work of
any kind on components applied to the equipment read the following Instructions Manual carefully. This Instructions
Manual is written for specialised and competent personnel and provides instructions for correct use of the product.
This Instructions Manual cannot substitute the professionality and competence of the installer. This Instructions Manual
may undergo modifications and additions thanks to continuous updating and development of the product but cannot be
classed as out of date or obsolete.

Warning
SMV will not accept responsibility under the following circumstances:
inappropriate use of equipment, meaning any use that is not expressly specified in this Instructions Manual concerning
assembly and installation by unauthorised and non-expert personnel; incorrect assembly and installation defects and
problems caused by the electrical current, failure to adhere to or irregular servicing of equipment program as specified
unauthorised repairs or modifications, failure to adhere to or irregular servicing of equipment as specified in the
periodical maintenance program, unauthorised repairs or modifications, failure to comply with instructions, use of non-
original spare parts and non-specific spare parts for the type of system used, use of equipment for purposes other than
those specified, heavier loads, greater performance requirements and longer operating times than those specified in the
TECHNICAL CATALOGUES of SMV.
Competent Persons
A person who, thanks to technical training and studies and personal experience can be defined as having sufficient
knowledge of the sector.
Danger!
Inappropriate use and the wrong choice of product (including accessories) can result in serious injury to persons
and damage to objects. This Instructions Manual and enclosures, Technical Catalogues along with other
information provided by SMV and Authorised Servicing and Assistance Centres aim to provide further data
and information to users who are competent and familiar with the sector (or have competent personnel at their
disposition).
It is very important that users analyse all possible problems related to the application of the equipment in each particular
case and that the user carries out his own analysis with adequate testing. Moreover, the user is responsible for ensuring
that all safety measures and warnings related to the application of this equipment have been followed (as specified by
the Directive in force).

6
METHOD OF USE
The levelling system for camper vans, motor-homes, trailers etc. provides stability and levelling of the vehicle on four
hydraulic feet, exploiting the run provided by suspensions and shock absorbers. Once levelled on its four feet, the
vehicle becomes much more stable and no longer experiences annoying rocking caused by walking. On 4 feet, 95% of
vehicle weight is removed from the suspensions and leaf springs, providing these parts with a longer lifespan.
Levelling allows all equipment to work correctly (fridge, hobs, water discharge) and for the occupants to sleep
comfortably, eliminating annoying sloping of the vehicle. Last but not least, once parked, it is an excellent thief-proof
mechanism and useful in avoiding tyre deformation when garaging for long periods. The system can be assembled with
three types of jacks: swing jacks (sliding or telescopic), fixed vertical jacks, fixed vertical telescopic jacks.

Warning
The system has a lifting capacity of 8 tons: this, compared with various other manual or electric parking systems, allows
you to increase your stability exploiting the entire weight of the vehicle.
Compared with other electro-mechanical systems, this system is much faster but, at the same time, more gradual and
sensitive in its movements, exploiting the control that it is given by the hydraulic fluid. All things considered, the
weight of the system is acceptable given that the heavy parking feet, characteristic of other systems, have been
completely eliminated.
Levelling is carried out in less than a minute whereas electro-mechanical systems take from 4 to 5 minutes.
With the remote control you can level yourself in any position from inside or outside the vehicle.
You can check the position of each foot from the manually operated control panel.
While the vehicle is moving ,with the system in the off position, any anomalies will be signalled by a buzzer and a led
light controlled by an electronic system. To avoid accidental use, the remote control is programmed to turn itself off
automatically after a variable pre-set time lapse.
All maneuvers MUST be carried out with the engine switched off, significantly curbing the functioning time :
absorption ratio.

7
THE SYSTEM INCLUDES
4 hydraulic jacks
1 hydraulic power pack
1 emergency pump
1 electronic control panel
1 remote control
1 black box for control of jacks
4 integrated check valves
4 mechanical limit switches
1 tube and tube fittings kit
Different attachment points and fixing systems are used according to the type of chassis.
CHASSIS: IVECO ISUZU DUCATO MERCEDES FORD RENAULT MAN etc.
The system is removeable at any time and can be reused on a new vehicle. The weight of the system does not modify
the weight distribution on the axles and does not influence the driving trim.
As a rule of thumb, the weight varies according to the type of model from a minimum of 60 kg to a maximum of 85 kg.
Once the vehicle is in the right position pull on the handbrake and switch off the engine.
In the case of AL-KO chassis, it is only necessary to put the vehicle into gear without pulling on the handbrake
to avoid the vehicle moving forward when the system is functioning.
Ensure that there are no persons, obstacles and/or animals under the camper van and that the terrain is compact.
Do not use the system close to the roadside, near precipices or on crumbly or steep slopes. In the correct position and
with the control panel switched to ON we can start stabilizing by lowering the hydraulic feet.

Warning
ALL 4 FEET MUST ALWAYS BE DOWN IN ORDER TO STABILIZE THE VEHICLE WITH THE TYRES
PLACED FIRMLY ON THE GROUND.
The system stabilizes and levels by operating 2 stabilizers at the same time, providing 2 support points and easy
levelling reference.
The 2 front, 2 back and 2 side cylinders on the right and left hand sides and all cylinders in the exit phase and entry
phase can be operated using the remote control. Only use single control buttons in the event of an emergency.
With the fixed control panel it is possible to operate 1/2 feet at a time lifting or lowering the corresponding switch.
The small panel “black box” comprising 1 yellow led, 1 red led for mechanical limit switches and 2 acoustic sounds
will inform you continuously on the functioning of the system.
The red and yellow leds on the fixed control panel check the position of each jack.
Operating the system with the vehicle ignition key and engine switched off.

8
Danger!
STOP THE MANOEUVRE IMMEDIATELY AND VERIFY THE CAUSE OF THE PROBLEM.
In the case of “fixed” vertical jacks we will only see the red led of the mechanical switch limit light up.
When the jacks move, the corresponding red leds light up on the receiver.
With the autolevel system we will see on the receiver the autolevel movements.
Once the vehicle has been levelled, the system is switched off by pressing OFF on the receiver.
In the event of system breakdown, use the emergency pump to put the stabilizers back in their original position.
The system is equipped with independent check valves and, in the event of a breakage of a service pipe, you will still
have 3 support points.
When you wish to start driving again and you turn the ignition key to start up the engine, if one or any of the jacks is not
completely retracted the buzzer will sound and the red led will light up.
Check the position of the jacks on the panel and only when all 4 red led lights are off will the system be ready for
driving the vehicle.
Danger!
BEFORE DRIVING VEHICLE CARRY OUT A VISUAL CHECK THAT ALL 4 STABILIZERS ARE IN THE
RETRACTED POSITION.
Danger!
DO NOT USE THE SYSTEM FOR MAINTENANCE – LYING UNDER THE VEHICLE WITH THE
SYSTEM FUNCTIONING IS FORBIDDEN
USING THE REMOTE CONTROL

9
Commands are transferred by pressing the various operating buttons on the remote control.
The remote control has a pre-set functioning time. Once the time has run out it is necessary to reset the ON-OFF
receiver.
For correct use of the system carefully follow these instructions:
-Park the vehicle in a safe place, turn off engine, pull on the handbrake.
-Check that there are no obstacles and lower the 4 feet to the ground.
-Locate the longitudinal level and begin levelling the 2 feet most distant from each other.
-Locate the side level by pressing the 2 lateral cylinder buttons and you will be level stabilized in a few seconds.
-Once you have finished the manoeuvre, turn the control panel to OFF.
-Only use individual control buttons for small corrections, if necessary.
If for some reason the tyres are off the ground, use the 2 buttons simultaneously to lower them and only when all the
tyres are resting on the ground should you use the button for automatic levelling of all the cylinders.

Warning
Improper use of these buttons could cause damage to the structure and to persons.
SMV DECLINE ALL RESPONSIBILITY FOR ANY DAMAGE CAUSED BY IMPROPER USE OF THE SYSTEM.
LIFT FRONT
LEFT FOOT
LOWER FRONT
LEFT FOOT
EMERGENCY
BUTTON
AUTO-LEVELLING
(IF SUPPLIED)
SIMULTANEOUS
LIFTING OF 4 FEET
SIMULTANEOUS
LOWERING OF 4 FEET
PRESS SIMULTANEOUSLY
TO LIFT 2 BACK FEET

10
REPLACING THE REMOTE CONTROL BATTERIES
MODELS TXE-B (434,42 MHZ) TXE-G (433,42)
•Remove the screw at the back of the remote control using a philips screwdriver .
•Lift the printed circuit out by gently pushing the screwdriver inside the hole.
•Remove the two batteries.
•Insert 2 new lithium CR 2032 (3 volt) batteries, one at a time, with polarity end ( +) upwards.
•Press any button to check if the red LED light flashes.
•If the red transmission LED light does not flash, remove the replacement batteries and reinsert them, then
press any button to see if the LED flashes.
•If the LED flashes, close the remote control transmitter following the above steps in reverse order.
PLEASE NOTE: the remote control with the receiver switched to ON is programmed to function for a pre-set time, at
the end of which it switches itself off automatically. To turn it on again it must be reset by pressing the ON/OFF
receiver.
A B C
D E F
G H I
L M N
Press this button only to change
combination

11
ABSOLUTE “MUST NOTS”!
•
Use of the machine for unauthorised manoeuvres
, improper use and lack of periodical maintenance
can determine serious danger for persons as well as compromising proper functioning and the intrinsic
safety of the machine.
•
The following list of actions, which obviously cannot completely cover the ent
ire potential range of
possible "misuse” of the machine, include, however, those actions that can be defined "within reason"
the most predictible and are to be considered absolutely prohibited.
•
IMPROPER AND PROHIBITED USE
-NEVER turn on the machine while personnel are in the service area of the machine
-NEVER allow the machine to be used by unqualified or untrained personnel or by persons under the age of 18.
-NEVER use the machine for anything other than it has been designed for, avoid use for any other function.
-NEVER use the machine in areas or places that it has not been designed for.
-NEVER undertake the functional/performance characteristics of the machine and/or its components.
-NEVER modify the safety equipment settings and/or tamper with the machine.
-NEVER force the machine beyond operating capacity.
-
-
IMPROPER USE
-NEVER operate if not equipped with suitable individual protective devices.
-NEVER use the machine or carry out maintenance in badly lit and/or difficult conditions of visibility.
-NEVER carry out temporary or emergency repairs that do not follow instructions.
-NEVER use spare parts that are non-original or not recommended by the manufacturer.
-NEVER have maintenance and repairs carried out by personnel that have not been trained by the manufacturer.
-NEVER use the machine if it does not carry out all its functions perfectly.

Warning The manufacturer declines all responsibility for damage caused to persons and/or things caused by
improper, inadequate use or negligence towards the system.

12
TROUBLESHOOTING
POSSIBILE CAUSE SOLUTION
Remote control with flat batteries
Replace batteries
Remote control with malfunctioning buttons
Replace remote control
Incorrect pressure on buttons
Press exactly in the centre of the button
The remote control doesn't carry out command
Check if the programmed automatic cut off time is over.
Reset the ON
-OFF switch
Vehicle battery flat
Recharge battery.
Check that there is a tension of 11
-12V in the battery
terminals 17(+) e 12(
-) when the electric motor of the
hydraulic power pack starts up .
Power supply connections not working efficiently
Use a suitable section cable:25mm² by up to
10mt. Length
For >10mt length section.35 mm²
Check earthing well
Other radio broadcasting at 433MHz
(visible if the
RECEPTION led is flashing when the remote
control is not in use)
Use manual commands or wait until the disturbance
ends
.
Broken electrical control panel
Replace electrical board

13
AZIONARE LA LEVA DELLA POMPA DI EMERGENZA
TENENDO PREMUTO LO SPINTORE DI GOMMA
PREMERE CON IL DITO LO SPINTORE DELLA
BOBINA DELLE ELETTROVALVOLE
MANOVRA DI EMERGENZA
IN CASO DI NECESSITA’ ESISTE LA POSSIBILITA DI FAR RIENTRARE I CILINDRI USANDO LA FORZA MECCANICA DI UNA POMPA INSERITA NEL COLLETTORE DELLA CENTRALINA IDRAULICA. PREMENDO UNO ALLA VOLTA GLI SPINTORI DI GOMMA INSERITI SULLE GHIERE DELLE ELETTROVALVOLE E AZIONANDO CONTEMPORANEAMENTE LA LEVA DELLA POMPA I CILINDRI RIENTRERANNO.
PRESS THE BUTTON OF THE SOLENOID VALVE
BOBIN WITH YOUR FINGER.
OPERATE THE EMERGENCY PUMP LEVER KEEPING THE
RUBBER BUTTON PRESSED DOWN
EMERGENCY MANOEUVRE
THE JACKS CAN BE RETRACTED, IF NECESSARY, USING THE MECHANICAL FORCE OF THE PUMP IN THE
POWER PACK COLLECTOR. PUSH THE RUBBER BUTTONS LOCATED ON THE METAL RINGS OF THE
SOLENOID VALVES ONE AT A TIME, OPERATING THE PUMP LEVER SIMULTANEOUSLY AND THE JACKS WILL
RETRACT TO THE CLOSED POSITION
THE JACKS CAN BE RETRACTED, IF NECESSARY, USING THE MECHANICAL FORCE OF THE PUMP IN THE
POWER PACK COLLECTOR. PUSH THE RUBBER BUTTONS LOCATED ON THE METAL RINGS OF THE
SOLENOID VALVES ONE AT A TIME, OPERATING THE PUMP LEVER SIMULTANEOUSLY AND THE JACKS WILL
RETRACT TO THE CLOSED POSITION

14
GENERAL SAFETY MEASURES
All installation, assembly, maintenance and disassembly operations of the equipment and components used with the
equipment must be carried out fully respecting safety measures: there must never be any pressure (zero pressure) inside
the hydraulic circuit and no weight of any kind must be placed on the jack springs or the control unit used (zero load).

Warning
Do not tamper with any kind of valve or joint in the system. Do not attempt to modify the anchorage brackets on the
jacks or modify the chassis fixing points supporting the load.
ATTENTION REGARDING ELECTRICAL COMPONENTS
Before carrying out any kind of operation or work on the hydraulic power pack, engines and any other kind of electrical
device must be disconnected from the electrical current; all electrical connecting and disconnecting must be carried out
by competent and specialised personnel. A safety device (fuse, relay) is supplied together with the hydraulic power pack
and the electrical system. Before carrying out any work, motors or devices other than electrical ones (pneumatic,
hydraulic, mechanical etc.) must always be disconnected from their electrical current and placed in a condition so that
they cannot produce energy and, thus movement, even accidentally.

Warning
Use protective safety equipment;
Work in conditions of maximum hygiene;
Work under maximum safety conditions;
Use suitable and clean instruments, equipment and work benches;
During the following operations:
- engine start-up
- every day work
- maintenance
- regulating and air release of the system
- work on and operating of valves and various control elements
- leaking and splattering of hydraulic fluid in the system may occur if work is done on the hydraulic tube fittings
Ensure that there is no pressure in the circuit.
Empty the system completely before changing the hydraulic fluid.
Danger!
Hydraulic fluid can be a health hazard. Contact with the eyes or the skin can cause serious damage.
Scrupulously follow the protective and safety indications imposed by the hydraulic fluid manufacturer shown on the
technical and toxicological product diagram.
Hydraulic fluid can be a polluting product. Avoid hydraulic fluid leakages by using basins and use oil-absorbing
products in the event of accidental leakages of the hydraulic fluid.

15
DISPOSAL OF HYDRAULIC FLUID
Hydraulic fluids have special waste disposal rules: disposal of hydraulic fluid into the environment is prohibited by law,
thus disposal must adhere to manufacturer indications and laws concerning this subject.
CHOICE OF HYDRAULIC FLUID
Any mineral based hydraulic fluid is suitable for use. When choosing a hydraulic fluid, it is necessary to keep in mind
optimum temperature/viscosity when the system is functioning, operating data and the temperature of the environment.
Specific synthetic or glycol water oils may be used if authorised by the technical department but their use must be
evaluated each time.
WARNING! CHANGE THE OIL AFTER THE FIRST 100 HOURS OF SERVICE OR AFTER THE FIRST
1000 OPERATING CYCLES AND THEN EVERY 3000 HOURS
CLEAN THE PUMP SUCTION FILTER (OR, IF NECESSARY, DISCHARGE FILTER) AT THE SAME TIME AS
THE OIL IS CHANGED AND, IF NECESSARY, REPLACE IT WITH A NEW ONE.
WARNING: THE FLUIDS USED MUST CORRESPOND TO THE CONTAMINATION CLASS SPECIFIED IN
THE FOLLOWING TABLE
CONTAMINATION – FILTRATION
SYSTEM TYPE
MINIMUM VALUE
REQUIRED
RECOMMENDED VALUES
VALVE TYPE
NOMINAL FILTRATION
(micron)
ABSOLUTE
FILTRATION
GRADE/LEVEL
ISO4572
BETAx 75
CONTAMINATION
CLASS SECOND
ISO4406
NAS1638
System or components
operating at
HIGH PRESSURE >250 bar
High frequency cycles
System with components that
are HIGHLY sensitive to
contaminants.
PROPORTIONAL VALVES
10 X= 10-12 17/14 8
Systems or components
operating at MEDIUM
PRESSURE < 250 bar
15 X= 12-15 18/14 9
DISPOSAL OF HYDRAULIC POWER PACK
The hydraulic power pack is made up mainly of aluminium alloy, steel alloy and plastic. These materials can be
disposed of as with any normal metal or plastic after careful emptying of the hydraulic fluid (to be disposed of
according to law) from the various components such as: pumps, tanks, tubes, filters, valves, etc...

16
TRANSPORT AND STORAGE
The hydraulic power pack and its components must be managed with care and attention. Certain parts, particularly
exposed parts that stick out, may be subject to breakages such as the cap of the fill/bleed plug on the tank or the
electrical connection box located on alternating current motors.
Another “weak” point is, without a doubt, the tank, which is subject to knocks and bumps, if made of sheet metal, or to
breakages if made of plastic.
Particular attention should be paid towards the flange, its valves and its controls, as they are particularly subject to
knocks and bumps. When the hydraulic power pack is equipped with blocks, they must be protected from knocks and
bumps and dangerous bending, which could cause irreversible damage.
Because the motor is the heaviest part of the hydraulic power pack, it is essential that it be stored in a horizontal
position (never vertically with the tank under the motor).
Hydraulic power packs must be stored in a protected (possibly closed) environment, away from humidity and adverse
weather conditions, at a temperature of between -15°C a 50°C.
The tank must be emptied of hydraulic fluid.
The hydraulic power pack must be protected from dust and external agents using nylon sacks or similar protective
covering.
When the tank is not supplied or not directly assembled on the power pack, it is indispensable to protect the exposed
parts, particularly filters and tubes.
Moreover, the exposed parts must be protected from loss of hydraulic fluid from the power pack and from foreign
bodies which could compromise good working order and the lifespan of the equipment.
The hydraulic power pack cannot be stored for a period longer than a year, in that, not being able to store it full of oil,
the gaskets could dry.
DESCRIPTION, ASSEMBLY AND INSTALLATION
The versatile and modular nature of the SMV hydraulic system, gives rise to a compact, versatile and easy-to-install
unit.
An essential condition for ensuring that the hydraulic power pack and the system to which it is applied work well, is
that assembly and installation are carried out under conditions of maximum cleanliness.
The power pack must be assembled so that it is accessible to commands, inspection, repairs, maintenance or assembly
of accessories; however, it is essential that the power pack is assembled in a position that ensures it is protected from
accidental knocks and bumps and away from possible physical contact with persons, as the temperature reached could
cause burns.
The power pack must be fixed to the equipment or vehicle using “solid” fixing points such as the chassis side-members,
loadbearing chassis, bulkheads etc... and not in contact with protective sheet metal or parts that might vibrate, transmit
or amplify noise and vibrations.
In order to obtain good performance from your hydraulic power pack all the assembly and start up phases must be
carried out correctly.

17
PROCEDURAL STANDARDS FOR CORRECT INSTALLATION
FILLING TANK
If the power pack is supplied with the tank, fill it with hydraulic oil filtered during racking to a filtration value of 25
micron or lower and check the level using the level rod located on the filling cap or by using the visual level, if present.
If the power pack is not equipped with a tank, install the collector in its dedicated space checking that the collector ring
on the connection interface is tight enough; then fill as indicated above.
ELECTRICAL CONNECTION
Read the hydraulic diagram and the electrical diagram, if provided
(for further information please contact our technical department);
Check that the dimensions of the electrical system are suitable for the electrical input of the various uses (motor-valves-
electrical panel-relay-etc.).
When first starting up the motor, check that the pump rotates in the correct direction. Check that the motor voltage and
the electrical components respond to conformity requirements.
ROTATION DIRECTION
In the case of direct current motors, the rotation direction is established by the manufacturer during the assembly phase.
In our case, the rotation direction needs to be verified.
CONNECTING UP WORKING PARTS
Avoid, at all times, the removal of plastic caps that act as protection for the outlets until the electrical current cables are
connected.
Connect the cables making sure that the entire operation is carried out in conditions of complete cleanliness: we remind
you that starting up fittings with dents on the male thread causes chipping in the seat and is the main cause of solenoid
valve blockages or leakages of the check valves.
Moreover, we advise you to carefully check the cleanliness of all tubes (both rigid and flexible) and of the various
working parts (jacks, hydraulic motors).

Warning
DURING INSTALLATION, CLEANLINESS IS THE MAIN ASSURANCE FOR THE GOOD WORKING
ORDER OF YOUR HYDRAULIC SYSTEM.

18
SYSTEM START UP
Once the system has been started up, check the exact functioning of all the command switches and the calibration of the
adjustable valves, using the pressure gauge outlet. If not specified when ordered, the pressure gauge plug should be
inserted to complete the system. In this case, it should be inserted taking the signal next to the valve that is being
checked.
If it is necessary to regulate the pressure relief valve, be extremely careful not to screw the register beyond the
calibration limit of the spring.
SCREWING THE PRESSURE RELIEF VALVE TO THE LIMIT SWITCH WILL CAUSE SERIOUS
DAMAGE TO ALL THE SYSTEM COMPONENTS (pump breakage and risk of tubes and collectors bursting);
We remind you that safety regulations in force specify that the pressure relief valve of the power pack must be lead
sealed to avoid tampering with the pre-established calibration. We invite you, therefore, to carry out lead sealing of the
pressure relief valve if the power pack is not delivered with the seal already in place

Warning
The Guarantee does not apply to products that have been supplied with the pressure relief valve sealed and sent
back with the seal removed
During the filling phase, ensure that the oil level in the tank is not affected by blow by (if necessary, top up the level).

Warning
Check that the tank size is correct.
When the system is first switched on, the air contained in the circuit must be bled to avoid the formation of foam in the
tank and any unwanted and uncontrolled movement of the working parts;
After carrying out testing a few times, check the level and the state of the oil in the tank (check that there is no foam
present) and the tightness of various fittings (check for the presence of any blow by and eliminate).
Actuators must be connected with tubes that have a diameter that corresponds to or is larger than the connection inlet of
the power pack. As a rule, adhere to the following fluid speed parameters inside the tubes:
delivery: 4=6 m/s , return: 1.5=3 m/s . Particularly with hydraulic power packs, which have small displacement pumps
(05 power unit), it is necessary, in the start up phase, to opt for priming of the pump by momentarily loosening the
check cap and, if necessary, the pressure relief valve.
The temperature that tanks and motors can reach (especially in direct current), in many cases, go beyond the “Burns
threashold”, as defined by the UNI EN 563 standard; because “the reduction of the surfaces temperature” (UNI EN 563,
appendix “C”) cannot be pondered as a technical solution, the user must evaluate protective measures (screens or
barriers), warning signals and individual protective measures (gloves).

19
CONTROL AND MAINTENANCE
Safety and the good working order of the system also depend on correct and scheduled maintenance .

Warning
After a brief period of running in of the system, check that the screws, nuts, fittings and tubes are correctly tightened:
vibrations can cause dangerous loosening of the above mentioned components.
- Check the correct functioning of the jacks and the chassis brackets.
- Check that there are no oil leakages in the hydraulic system
- Check that the micro-mechanics and position sensors are functioning by checking the LEDS on the
receiver.
- Check that the buzzer on the black box is functioning by turning the vehicle ignition key to give +12 to
the control panel
- Check that the emergency hand pump is functioning
MAINTENANCE AND DIAGNOSIS OF MAIN TROUBLESHOOTERS
a) Replace oil after the first 100 Hours of service or after the first 1000 cycles and then every 3000 Hours. For
particular and heavy use (automatic and continuous service systems), the oil must be replaced more frequently.
b) Clean the pump suction filter (or, if necessary, the discharge filter) at the same time as the oil is replaced and,
if necessary, replace with a new filter.
c) The guarantee of the Bosch Rexroth – Oil Sistem product will expire if manufacturer specifications are not
followed.

Warning
ALL OPERATIONS DESCRIBED IN THIS MANUAL MUST BE CARRIED OUT BY PROPERLY TRAINED
AND SPECIALISED PERSONNEL. (CONTACT THE SUPPLIER IF NECESSARY).

20
BREAKDOWN
PROBABLE CAUSES
POSSIBLE SOLUTIONS
Pump does not supply
the required flow
-
blocked filter
-
disassemble and clean (or replace)
- air intake in the suction tube
- Check closure grip
-Collector leakage caused by fusion defect
-Replace collector
- Breakage of coupling for pump-motor
- Disassemble and replace
connection
- Damage to pump-collector connection gasket
- Disassemble collector pump and replace
gasket
- Worn out pump
- Replace
Pump does not supply
the right pressure
-
Calibration error on pressure relief valve
-
Re-set required calibration
(calibration too low)
Pump does supply
the right pressure
-
Worn out pump
-
Replace
- Insufficient motor power
- Assemble more powerful motor
- Excessive loss of charge in circuit
- Check for possible bottlenecks
or excessive oil viscosity
Pump does not supply
the right pressure
-
Leakage from the valves
-
Check that the valves are tightened
Valve blockages
or leakages
-
Leakage -check valve
-
Disassemble and blow
(replace if necessary)
- Electric seat valve leakage
- Disassemble and blow
(replace if necessary)
-
Electric valve excitation faulty
-
Check that the minimum required voltage is
reaching the bobin
Minimum required voltage
(90% of normal voltage)
- Blockage of slide valve caused by
- Disassemble and blow
Dirt in the circuit
(replace if necessay)
- Try to add filtering elements to the
circuit, to obtain better filtering (25 micron)