HL 07.

01-1/7
Rev:C
Date:11-00

INSTALLATION OF JOINTED HYDRAULIC JACKS

Warning: This instruction gives useful indication for the assembling and installation of the
juncted jacks. The following operations must be executed according to current
safety rules.

For better clarity, the terms in the text are used as follows:
hydraulic jack - to define the whole jack
cylinder - to define the fixed external part of the jack
ram - to define the moving part, sliding inside the cylinder.

The half upper cylinder has fitted inside the half upper ram.
The half lower cylinder has fitted inside the half upper ram (Fig. A).

Actions

– Fit the pulley block, with a max load of 2000 kg, as high as possible inside the shaft. (It
is strongly recommended to use a chain pulley block for a smoother operations; an
irregular operation could damage the threads).
– Put the two half-jacks inside the pit or on a support surface, vertically positioned and
well fixed to the surrounding structure (Fig. A).
– Make sure that the pulley block chain is perfectly aligned with the lower half jack.

RAM JOINING

A - setting of the lower part

1. Take away the iron upper sealing and the rubber ring (bond to the ram with a red
stripe) and protect the ram thread with wipers.
2. Pull out completely the ram using the hole through the ram head.
3. Clean the ram surface with clean wipers and check that there are neither bumps nor
scratching; otherwise, fix them with the included emery cloth.
4. Insert the ram into the cylinder, taking care not to damage it, until it stands out from the
cylinder for about half a meter.
5. Tighten the specific tool on the ram, then slowly lower the tool until it sets upon the
cylinder head; put a protection between the two parts (Fig. B).
 HL 07.01-2/7
Rev:D
Date:09-08

JOINT WITH RING MONOBLOC JOINT

Fig. A
B- setting of the upper part

1. Take away the screws that fix the upper clamp to the oil collector ring of the half upper
jack (Fig. A).
2. Hook up the upper clamp (Fig. A), then pull completely away the ram, being very care-
ful not to damage the ram surface, then repeat A-3.
3. Cover with wipers the head of the upper cylinder to avoid damages.
4. Put the upper ram about half a meter over the lower ram (Fig. B).
5. Tighten to the upper ram the specific tool about 20 cm from the lower end (Fig.B).
6. Clean and degrease with a brush and thinner the thread and the joining settle of the
upper ram (Fig. B) and let dry.
 HL 07.01-3/7
Rev:D
Date:11-04

Tool

Clean and de-

grease well
Degrease and put
adhesive
“O-RING”

Protection

Fig. B

C - Joining of the two parts

1. Take away the O-RING from the male joining of the lower ram, degrease and clean the
thread and the O-RING grove.
2. Make a trial joining, lowering down slowly the upper ram, until the male end fits into
the female: before doing this, check cleverly that the upper and lower half rams are per-
fectly aligned.
3. Once the thread starts to grip, keep on lowering slowly the upper ram, screwing it on
the lower ram.
N.B. : Attention! The revolving hook of the pulley block must rotate together with the
ram to avoid chain twisting.
 HL 07.01-4/7
Rev:E
Date:09-08

4. Screw until the two parts are completely joined, without tightening.
N.B. : the joining operation must be done at least by two persons in visual contact: the
first must operate the pulley block, the second must turn the ram. In this way it
is possible to avoid unwanted movements that could damage the thread. For a
smoother operation, put some oil on the thread.
N.B. : the pulley block operator must also check that the chain is always tight, to avoid
damages to the thread, or a dangerous unhitching
5. Once the trial joining is done, unscrew the two parts and lift the upper part of the ram
until it is about half a meter above the lower one.
6. After checking that the two parts of the joining (threads, male and female) are still clean
and dry, fit the O-RING and apply the adhesive supplied with the jack on the male
thread.
N.B. : it is very important that the thin layer of adhesive is not polluted by dust or
grease.
7. Lower again slowly the upper ram and join the two parts in the same way of the trial
test. Screw the upper ram until the two parts are nearly completely joined.
8. Screw tightly the two parts. Check that the reference lines on the ram are aligned.
9. If the distance between the two lines is greater then 3 mm, the two parts are not
correctly joined: unscrew slightly the two parts and repeat quickly the tightening
with more strength.
N.B. : After 60 minutes from the joining operation the ram cannot be unscrewed
any more.
N.B. : Wait 24 hours before that the jack working in order to allow that the adhe-
sive is completely drying.
10. There must be no “step” between the two parts (try passing one hand on the contact
line) in that case, use emery cloth n° 320.
11. Take away the tools from the ram and lower it until it seats on the cylinder bottom.
12. Take away the clamp and the spacer from the ram head.

CYLINDER JOINING

Joint with ring

A - Setting of the two parts

1. Degrease and clean with a brush and thinner the thread and the housing for lower cylin-
der.
2. Unscrew the oil collector ring and the O-RING holder from cylinder head, then put
them in a clean place.
3. Tighten the specific tool on the upper cylinder, hang it to the pulley block and lift it.
Unscrew the lower protection using a strong bar as a lever among the projecting screws
and pull away the O-RING that is bonded with a red stripe to the same protection.
Then, take away the sealing O-RING.
N.B. : If the O-RING is not pulled away, the lift operating will be seriously com-
promised so it is very important not to forget this operation.
 HL 07.01-5/7
Rev:D
Date:09-08

Tighten with a
Knurled ring chain wrench

Screw M 10
Screw M 10

Fig. C

4. Degrease and clean with a brush and thinner the thread of the knurled ring, the O-RING
groove and the housing for the joint (FIG. C).
5. Put some grease on the O-RING and settle it into its groove.
6. Put the cylinder on the ram, taking care not to damage it.
7. After lowering the upper cylinder, tighten the specific tool on the lower cylinder, next
to the joint area (Fig. C).

B - Joining of the two parts

1. Slowly lower the upper cylinder until it settles into its housing inside the lower cylin-
der: it is very important to make sure that the two parts are perfectly aligned.
2. Screw the knurled ring on the thread of the lower cylinder by hands until the pieces are
 HL 07.01-6/7
Rev:D
Date:09-08

complitely tighten; using a chain wrench. in order to tighten well the joint.
N.B. : the joining operation must be done at least by two persons in visual contact: the
first must operate the pulley block, the second must turn the ram. In this way it
is possible to avoid unwanted movements that could damage the thread.
3. THE RING IS WELL TIGHTENED WHEN THE LOWER THREAD IS COM-
PLETELY COVERED.
N.B. : Attention! During the operation, the two parts must always remain aligned, oth-
erwise the thread could be damage. If an excessive effort is needed to screw
the ring before it is completely locked, unscrew it, check the thread and
repeat the operation.
4. After the joining of the two parts, lock the ring with the two flat headed safety screws,
screwing tight.
N.B. : Attention! The joint is correctly locked only if the head of the safety screws
fit completely inside the ring thickness: if passing the hand on it a projec-
tion is felt, unscrew the safety screws and screw well the ring until the bot-
tom end (see Fig D).

YES NO!

The screw is flush

The screw protrudes
for about 1,5 mm
and
or
the thread is over-
lapped completely
the thread isn’t over-
lapped completely

Fig. D

5. Take away the tools from the cylinder.

6. Clean well the oil collector and the O-RING holder and mount them in their housing.

Monobloc joint.

A - Setting of the two parts

1. Degrease and clean with a brush and thinner the thread and the housing for lower cylin-
der.
 HL 07.01-7/7
Rev:D
Date:09-08

2. Unscrew the head of the cylinder, then put it in a clean place.

3. Tighten the specific tool on the upper cylinder, hang it to the pulley block and lift it.
Unscrew the lower protection and pull away the rubber protection that is bonded
with a red stripe to the same protection.
4. If the rubber protection is not pulled away, the lift operating will be seriously com-
promised so it is very important not to forget this operation.
5. Degrease and clean thread of the cylinder.
6. Put the cylinder on the ram, taking care not to damage it.

B - Joining of the two parts

1. Lowering down slowly the upper cylinder and start to screw the two part: during the
assemby of the two cylinders use the same attention you taked for the joining of the ram
to avoid damage of the thread.
2. Take away the tools from the cylinder.
3. Clean well the head of the cylinder then screw it.

IMPORTANT

1. If the jack is not connected to the power unit for some time, fill carefully the hose attach
(with clean wipers) and cover the jack head from dust and dirt.
2. After connecting the jack to the power unit, install the pulley on ram head and make the
jack extend until it’s close to the upper stop; then proceed at creeping speed until it
reaches the upper stop.
Adjusting the pressure switch, give the system a pressure of 50 Kg/cm2 and wait for
some minutes.
In this way it is possible to check if there are oil leakages from the jack head or cylin-
der.

SCRAPER
GUIDE RING
SEAL

GUIDE RING

O-RING
 HL 07.02
Rev: A
Data: 11-98

FUNCTION DESCRIPTION

Pilot valve 12:N

Pilot valve 12:H

HYDRONIC 300

Pilot valve 12:N

Pilot valve 12:H

Pilot valve 12:S

HYDRONIC 300S

Pilot valve 12:S for service drive is compulsory for elevators

with speed over 0,63 m/s.
When using service drive, the pilot valve 12:H is not energized.
 HL 07.03
Rev: B
Data: 09.01

Principal diagram for HYDRONIC 300

M Motor SoV Shut-off valve

P Pump PCV Pressure compensator valve
T Tank DTV Down travel valve
C Cylinder RV Relief valve
MC Manometer PV Pressure valve (indirect drive)
ML Manual lowering valve CV1-6 Check valve
HP Hand pump DV1-2 Pressure difference vallve
PC Pressure switch HDV Hydraulic delay valve
SV Start valve J1-12 Jets
MSV Main speed valve F1-4 Filters
LSV Levelling speed valve 12:H Pilot valve for nominal speed
TCJ Temp. controlled needle valve 12:N Pilot valve for down travel
(for HYDRONIC300 as an option) 12:NN Emercgency pilot valve for down travel
ARV Automatic rupture valve
 HL 07.04
Rev: B
Data: 09.01

Principal diagram HYDRONIC 300S

M Motor SoV Shut-off valve

P Pump PCV Pressure compensator valve
T Tank DTV Down travel valve
C Cylinder RV Relief valve
MC Manometer PV Pressure valve (indirect drive)
ML Manual lowering valve CV1-6 Check valve
HP Hand pump DV1-2 Pressure difference valve
PC Pressure switch HDV Hydraulic delay valve
SV Start valve J1-12 Jets
MSV Main speed valve F1-4 Filters
LSV Levelling speed valve 12:H Pilot valve for nominal speed
TCJ Temp. controlled needle valve 12:N Pilot valve for down travel
SSV Service speed valve 12:S Pilot valve for service speed
12:NN Emergency pilot valve for down travel
ARV Automatic rupture valve
 HL 07.05-1/3
Rev: A
Data: 11-98

FUNCTION DESCRIPTION VALVE HYDRONIC 300

THE ELEVATOR STANDS AT FLOOR LEVEL

All the spools and pilot valves are in the ideal position when the elevator stands at floor level.
The components, which are tight against leakage and keep the elevator car at floor level, are:

check valve 1 CV1

down travel valve DTV
pressure difference valve 1 DV1
manual lowering valve ML
pilot valve for nominal speed 12:H
pilot valve for down travel 12:N
pilot valve for service speed 12:S

and of course all the static seals must be in order.

 HL 07.05-2/3
Rev: A
Data: 11-98

UP TRAVEL
Start
Pump motor and pilot valve 12:H are activated.
Oil flow from the pump pushes the start valve SV open and goes back to the tank. The motor
reaches the nominal speed “compressing” the oil to by pass pressure (SV is wide open).
After a short time delay, which depends on J12, HDV closes.
This delay enables the star/delta motor starting and eliminates the need of a specific pilot valve.
Pilot valve 12:H is activated and the main speed valve MSV starts to open.
The start valve SV closes with constant speed determinated by the spring and the jet J1 increas-
ing the pressure inside the chamber in front of CV1.

Acceleration
When it is higher than the load pressure, the pressure pushes CV1 and the compensator valve
PCV, to the open position. The elevator begins to accelerate due to oil flow through the check
valve, the main speed valve and PCV to the cylinder line.

Nominal speed
When SV is completely closed, the whole flow from the pump goes to the cylinder and the ele-
vator drives up at the nominal speed.
The still activated 12:H pilot valve keeps MSV wide open.

Deceleration
When the elevator arrives at the deceleration vane, the pilot valve 12:H drops, SV gradually
closes, thanks to J1, DV1, J9, J4 while deceleration is actuated by the gradual closing of MSV
valve.

Levelling speed
After MSV has closed completely, a little portion of the flow reaches the jack through levelling
valve LSV while the bigger part will come back to the tank through SV, and the car will climb
at levelling speed.

Stop
When the elevator car arrives at the floor level vane, the motor is switched off.
Inertia of the motor and the flywheel makes the elevator stop smoothly.
While the pump retards, SV, CV1 and PCV close to the position they had before start up.
the route through CV3 and J10 is provided for speeding up the closing of PCV after the elevator
has stopped.
 HL 07.05-3/3
Rev: A
Data: 11-98

DOWN TRAVEL
Start
The pilot valves, 12:H e 12:N are activated, this causes the opening of the down travel valve
DTV, MSV and PCV.

Acceleration
MSV, slowed by jets J4 and J5, opens gradually until it’s wide open and the car accelerates until
it reaches the max speed.

Nominal speed
MSV is wide open, PCV regulates the oil flow and therefore the car speed, thanks to the pressure
balance created by J6, J7, DV2 (last one is adjustable)

Deceleration
When the car reaches the slowing vane, 12:H is deactivated, MSV start closing, slowed by J4,
and the car decelerates.
Again PCV keeps the pressure drop over MSV constant and the elevator decelerates to the lev-
elling speed as MSV closes.

Levelling speed
MSV is fully closed, oil flows just through LSV, and the car goes down slowly. PCV regulates
oil flow according to car load.

Stop
Finally 12:N is de-energized. the down travel valve DTV start closing and the elevator stops
smoothly. The pressure compensator valve PCV closes too and the elevator is ready for the next
travel.
 HL 07.06
Rev. F
Data: 10-11

INSTRUCTION FOR ADJUSTMENT

Elevator movement Change Procedure Remarks

Slower Screw 2
Acceleration
Faster Screw 2

Elevator speed Not adjustable

Deceleration up and down Softer Screw 4 1/6 turn at time

UP

Increased Screw 5
Common for up and down.
Levelling speed
Normally c:a 0,05 m/sec
Decreased Screw 5

Adjusted with
Stop Levelling Vane ~ 30 mm from floor level
shaft vane

Acceleration Not adjustable

Increased Screw 6
Normally equal with speed in up
Elevator speed
Decreased Screw 6 direction

Deceleration up and down Softer Screw 4 1/6 turn at time

DOWN

Increased Screw 5 Common for up and down.

Levelling speed
Decreased Screw 5 Normally c:a 0,05 m/sec

Adjusted with
Stop Levelling Vane ~ 30 mm from floor level
shaft vane

Higher pressure Screw 1

Adjusted to 140% max. static
Over pressure
pressure
Lower pressure Screw 1

5 1. Adjustment screw for over pressure

2. Adjustment screw for acceleration up
3. Adjustment screw for by-pass pressure
4. Adjustment screw for deceleration up and
down (for HYDRONIC 300 as an option)
1 5. Adjustment screw for levelling speed up
and down
6 6. Adjustment screw for elevator speed down
4
7. Adjustment screw for hand pump pressure
8. Adjustment for service speed (only for
3 8 HYDRONIC 300S)
2 7
 HL 07.07-1/13
Rev. C
Data: 09-09

INSTRUCTION FOR HYDRONIC 300 ADJUSTMENT

NOTE: open the manometershut off valve only during the adjustment of the Hydronic valve. During the
normal lift work the manometer shut off valve must be closed.

By-pass pressure

The by-pass pressure is adjusted at the factory. It is readjusted only if start delay time needs adjustment.
The by-pass flow pressure must be equal or slightly less than empty car static pressure. Too low by-pass
pressure causes extra delay during up start or a little car sink before up start.
manometer
manometer shut off

Close Stroke control screw SCS

Open

Relief valve RV
Shut-off valve
Tools:
- socket head wrench 5 and 6 mm
- spanner 10 mm 13 mm 19 mm

Adjustment of by-pass pressure:

– Close the shut-off valve.
– Open the relief valve (RV) so much that there is no spring force.
– Start the elevator for up travel.
– Adjust the stroke control screw (SCS) until the manometer indicates about the min
static pressure with empty car. (turning the screw clockwise increases the by-pass pres-
sure)
– secure the adjustment with the lock nut.
– Adjust the over pressure.
 HL 07.07-2/13
Rev. B
Data: 05-01

Over pressure

The over pressure (140% of the max static pressure) is adjusted at the factory. It is readjusted only, if
the relief valve (RV) has been repaired or if its adjustment has been altered for some reason.
Max. working pressure = car with full load, travelling up (dynamic pressure).

Hand pump

manual lowering
valve

Close

Open
Adjustment screw for hand
pump pressure

Tools:
Shut-off valve
- socket head wrench 6 and 8 mm
- spanner 19 mm Relief valve RV
- spanner 24 mm

Adjustment of over pressure:

Relief valve RV
– Close the shut-off valve.
– Start the elevator for up travel.
– Turn the adjustment screw of the relief valve (RV) until the manometer shows the cor-
rect pressure (140% of the max. static pressure).
– Lock the adjustment with lock nut.

Hand pump
– Close the shut-off valve.
– Pump up the pressure with the hand pump and read the value from the manometer.
– Adjust the hand pump pressure screw if the value is less than the over pressure (the
value must not exceed 2.3 times the full load static pressure).
– Lock the adjustment with lock nut.
 HL 07.07-3/13
Rev. B
Data: 05-01

Acceleration up

The start valve (SV) spring force must be adjusted so that the elevator has a comfortable acceleration.

Stroke control screw SCS

Start valve SV
Tools:
- spanner 5 mm, 10 mm, 13 mm, 19 mm

Adjustment of acceleration up:

– Measure the length L of the stroke control screw (SCS) (see picture).
– Start the elevator to up-direction and observe the acceleration.
– Turn the black adjusting screw of the start valve (SV) anti-clockwise, if the accelera-
tion is too hard, or clockwise if the acceleration is too slow.
– Lock the adjustment with lock nut.
– Re-adjust the stroke control screw (SCS) to the measured length L.
– Listen and make sure that the by-pass flow is completely stopped within 2.5....3 sec-
onds.
(If not, increase the acceleration up. Also check the by-pass pressure)
 HL 07.07-4/13
Rev. B
Data: 05-01

Deceleration up and down

Deceleration is controlled with TCJ, which with J4 forms a needle valve.

Temperature controlled
needle valve TCJ
(for HYDRONIC 300 as an option)
Jet J4

Locking screw:
DO NOT
UNSCREW!

Tools:
- Spanner 13 mm e 19 mm Reference dimension L: 40 mm

Adjustment of deceleration:
– Drive the elevator in up-direction and observe the deceleration and charge-over to the
levelling speed.
– Turn the adjustment screw of TCJ clockwise to get a smoother deceleration and anti-
clockwise for harder deceleration.
(Attention: turn only 1/6 of a turn at a time; screwing the needle valve too far inwards
can destroy the valve).
– Lock the adjustment with lock nut.
 HL 07.07-5/13
Rev. B
Data: 05-01

Nominal speed down

The adjustment of the pressure difference (DV2) for nominal speed in down-direction must be always.
(Normally, the elevator speed has to be equal in both up and down direction).

Tools:
- Socket head wrench 6 mm
- Spanner 19 mm

Pressure difference valve DV2

Adjustment of nominal speed down:

– Drive the elevator in up-direction and measure the elevator speed with a tachometer or
a clock (stop-watch).
– Drive the elevator in down-direction and measure the speed as in up-direction. Com-
pare the results.
– Turn the adjustment screw of the pressure difference valve clockwise for speed increase
or anti-clockwise for speed decrease.
– Lock the adjustment with the lock nut.
 HL 07.07-6/13
Rev. B
Data: 05-01

Levelling speed

The levelling speed valve (LSV), which is common for the levelling speeds in both up- and down-direc-
tion, is pre-adjusted at the factory. therefore, only a fine-adjustment is carried out at the site.
The levelling speed must be adjusted so that the final stop is comfortable. As too low levelling speed
can cause vibrations (stick-slip effect).

Levelling speed valve LSV

Tools:
- Socket head wrench 4 mm
- Spanner 13 mm

Adjustment of levelling speed:

– Turn the adjusting screw of the levelling speed valve anti-clockwise in order to gain a
higher speed or clockwise for a lower speed.
– Check the levelling or clockwise for a lower speed.
– Lock the adjustment with the lock nut.
 HL 07.07-7/13
Rev. B
Data: 05-01

Service speed (only valid for HYDRONIC 300S)

The service speed valve (SSV), which is common for the service speeds in both up- and down-direction,
is preadjusted in factory.
the service speed must not exceed 0,63 m/s.

Service speed valve SSV

Tools:
- Socket head wrench 5 mm
- Spanner 13 mm

Adjustment of service speed:

– Turn the adjustment screw of the service speed valve (SSV) anti-clockwise in order to
gain a higher speed or clockwise to reduce the speed.
– Check the service speed in both directions.
– Secure the adjustment with the lock nut.

N.B. : Service speed is obtained only activating 12:S pilot valve

 HL 07.07-8/13
Rev. B
Data: 05-01

Adjustment of minimal pressure PV valve

The minimal pressure PV valve keeps a minimum amoount of pressure in the hydraulic system, even
when there is no load on the ram. This is achieved to avoid the ropes to get slack and come out of the
pulley if the parachute devices on the car sling are activated or if the car lies on the shaft bottom springs.
The PV valve is adjusted in the factory for a minimal pressure of about 10 bar.
If the hydraulic system is operated with a static pressure below the min. static pressure in operative con-
ditions (i.e. during the assembly of the elevator), a tuning of the PV adjustment could be necessary to
perform down travel.

Follow the procedure here below to modify the PV adjustment:

– Close the shut off valve and relief the static pressure with the manual lowering lever.
– Take away the sealing cap over the PV valve with a socket head wrench.
– Use a screwdriver to turn the adjustment grain: screw in for an higher min. pressure,
screw out for a lower min. pressure.
– If the min. pressure is still too high, unscrew completely the adjustment grain and take
away the spring below it.
– Put again the sealing cap in its original position, taking care that the rubber sealing is in
contact with the valve body.
– Open the shut off valve and perform a trial car run.

Minimal pressure
PV valve
 HL 07.07-9/13
Rev. B
Data: 05-01

Valve details
Levelling speed valve
LSV
Check valve CV6

Check valve
Check valve CV2
CV4

Check valve CV3

Jet J10

Jet J6
Jet J2

Pressure difference valve DV2

Jet J2 0,8 mm for all pump sizes. Placed under the plug

Jet J6 0,6 mm for all pump sizes. Placed under the plug

Jet J10 0,8 for all pump sizes. Placed under the plug

Check valve CV2 Placed under the plug

Check valve CV3 Placed under the Jet J10

Check valve CV4 Placed under the plug

Check valve CV6 Placed under the plug

Pressure difference valve DV2 Adjustment screw for elevator speed down

Levelling speed valve LSV Adjustment screw for levelling speed

 HL 07.07-10/13
Rev. C
Data: 09-09

Start valve SV

Jet J5

Stroke control screw

SCS Pressure difference valve
DV1

Check valve CV5 Jet J12

Jet J9 Jet J1

0,8 mm for pump size 70 a 145 l., 0,7 mm for larger pumps. Placed
Jet J1
under the plug.

0,8 mm for all pump size. Placed under the plug.

Jet J5
Only when reduction of acceleration downwards is required.

Jet J9 1,0 mm for all pump sizes. Placed under the plug

Jet J12 0,8 mm for all pump sizes. Placed under the plug

Check valve CV5 Placed under the Jet J9

For adjusting of the by-pass pressure.

Stroke control screw SCS
preadjusted at the factory.

Acceleration upwards is adjusted by means of the adjusting screw.

Start valve SV
Carried out the site.

Pressure difference valve DV1 Placed under the plug

 HL 07.07-11/13
Rev. B
Data: 05-01

(for HYDRONIC 300 as an option)

Pressure valve PV Jet J4

Temperature controlled needle valve

TCJ

Main speed valve

MSV

Jet J3

Manual
lowering valve

Pressure compensator valve

PCV (ref. measure: 25,7 mm)

Jet J7 Filter F4
Relief valve RV

Jet J3 0.8 mm for all pump sizes. Placed under the plug.

1,0 mm for all pump size. Placed under TCJ.

Jet J4 0,8 mm for pump sizes up to 145 l/min, 0,7 for 172 up to 270 l/min
without TCJ. Placed under the plug.

Jet J7 0,8 mm for all pump size. Placed under the plug.

The valve spring has to be removed when unloaded cylinder is low-

Pressure valve PV
ered. Placed under the plug.

Adjusting screw for acceleration down and deceleration up and

Temperature controlled needle valve TCJ
down. To be adjusted at site.

The screw is adjusted to the correct value at the factory and should
Main speed valve MSV
not required any adjustment at site.

The screw is adjusted to the correct pressure. at the factory and

Relief valve RV
should not normally required any adjustment at site

For testing the rupture valve. The screw is adjusted to the correct
Pressure compensator valve PCV
value at the factory and should not require any adjustment at site.
 HL 07.07-12/13
Rev. C
Data: 09-09

HYDRONIC 300 Manometer Pilot valve 12:N

Inspector’s manometer
Shut-off valve for manometer
Connections for
pressure switches

Hand Pump

Pilot valve 12:H

Adjustment screw for hand
pump pressure

HYDRONIC 300 S

Service speed
valve SSV

Pilot valve 12:S

Pilot valve 12:H Pilot valve for speed in up and down travel

Pilot valve 12:N Pilot valve for down travel

Pilot valve 12:S Pilot valve for service drive

Service speed valve SSV Adjusting screw for service speed in up and down travel
 HL 07.07-13/13
Rev. B
Data: 05-01

MSV and PCV spool valves setup

The setup of these valves is done by the manufacturer during the power unit test; they don’t require any
further regulation. The following instructions are given only to check out and correct unwanted manip-
ulations.

Spool valve PCV

The setup for this spool valve is the same for all the power unit: the reference measure is 25.7 mm from
H300 body. PCV vlve must be tuned only for the ruppture valve operative test; after the test, ad-
just the valve to the original position.

Spool valve MSV

This spool valve is regulated as follows:

Take away the locking nut and screw the regulation screw inward until it stops (it stands out from the
H300 body for about 8 mm) then unscrew it out for the measure indicated in table 1. which is function
of power unit oil flow.
The final dimension L is the sum of the (about) 8 mm, plus the measure indicated in table 1. Lock
the screw with the locking nut: be careful not to rotate the screw while tightening the nut! Check again
the dimension L after tightening the locking nut.
Table 1

Pump flow (L/min) Measure

50 Hz (60 Hz) (mm)

50 (70) 7.5 (9)

70 (96) 9 (11)

96 (115) 11 (12)

115 (125) 12 (13)

125 (145) 13 (15)

145 (172) 15 (10,5)

172 (210) 10,5 (12)

210 (270) 12 (15)

270 (only 50 Hz for

15 (-)
H300)
 HL 07.08-1/2
Rev: B
Data:09/08

PROCEDURE FOR THE SUBSTITUTION OF THE SEAL OF THE JACKS

Warning: The following procedure gives useful informations for the substitution of the
sealings inside the head of jacks.
The following operations must be executed according to current safety rules..

THREE PIECES JACK HEAD

Scraper
Guide ring
Seal

Guide ring

O-Ring

MONOBLOC HEAD

Scraper

Seal
Guide ringa

O-Ring

- Lower the car until the ram stands out from the cylinder head for about 50 mm.
 HL 07.08-2/2
Rev: B
Data:09/08

- Block the car with the safety devices and add a second safety block to have a further protection. For
indirect acting lifts, also the top pulley sling must be blocked about 50 cm over cylinder head.
- Clean well the jack head from dirt and dust.
THIS OPERATION IS VERY IMPORTANT: dirt fallen inside jack head could damage quickly the
sealings and the ram!
- Unscrew the screws that keep the sling (or the pulley sling) in order to free the ram head.
Lower the ram using the manual lowering valve, until it stops on the cylinder bottom. From this moment
there is no more pressure in the hydraulic circuit and the jack head can be dismounted. Unscrew all the
screws that keep the top part of the head and put them away carefully.

Three pieces jack head

Pull away the top part of the jack head, which contains the scraper. Pull away the main pressure sealing,
eventually using a screwdriver.
Warning! never touch the ram with the screwdriver! The ram could be scratched and the whole jack
would be seriously damaged! Fit the screwdriver between the sealing and the cylinder.
- Clean the seal set with brush and thinner and let dry, then put some grease on the seal and the set and
fit the sealing using a no metallic tool. Caution: the white ring of the sealing must be on the upper
side! If necessary, change also the scrapert.
- Fit the upper part of the cylinder head and lock it with the screws.
Caution! Do not use for this operations metallic or sharp tools to avoid damages to the ram and sealings!

Monobloc head
- Unscrew the cylinder head using a hook spanner.
- Pull away the main pressure sealing, eventually using a screwdriver.
- Clean the seal set with brush and thinner and let dry, fit the sealing into the seal set; Caution: the white
ring of the sealing must be on the upper side! If necessary, change also the scrapert and the guide
rings.
- Change the O-Ring of the cylinder head, lubricate the ram and the seals then screw the hean on the
cylinder using a hook spanner.

- Join the ram to the sling (pulley sling for indirect lift). Use the hand pump to lift the ram.
- After joining the ram to the sling, free the car and make some runs with the air escape screw slightly
untightened, until some oil starts coming out from the hole, then re-tighten the screw. make another
complete run and stop the car near the upper floor. Proceed at creeping speed until it reaches the upper
stop.
- Adjusting the pressure switch, give the system a pressure of 50 bar and wait for some minutes. In this
way it is possible to check if there are oil leakages from the jack head or cylinder.
 HL 07.09-1/3
Rev: A
Date: 06/99

PERIODIC MANTEINANCE OF THE HYDRAULIC LIFT

FREQUENCY OF THE PERIODIC CHECKS AFTER LIFT INSTALLATION

Table 1:

1
5 - 10
PERIODIC CHECK installation month 1 year
years
(*)

1 Oil level check X X

2 Oil condition check X X

3 Jack sealing check X X

4 Pressure check X X

5 H 300 valve check X X

6 Hand pump check X X

7 Manual lowering valve check X X

8 Relevelling check X X

9 Rupture valve check X X

10 Motor thermal protection check X X

11 Overall check of the fittings and hoses X X

12 Labels and schemes check X X

13 Overall check X

(*) Optionally: every scheduled periodic maintenance.

X = Suggested check
 HL 07.09-2/3
Rev: B
Data: 09-09

PERIODIC CHECKS
NOTE: open the manometershut off valve only during the adjustment of the Hydronic valve. During the
normal lift work the manometer shut off valve must be closed.

1 Oil level check

When the car is in the upper position, oil level must be over the min. admitted level: the motor-pump
group must be completely submerged in the oil.

2 Oil condition check

Be sure that the oil is not alterated by the presence of dirt or water (oil colour becomes matt yellow).

3 Jack sealings check

Jack head must be clean from dust or any other abrasive material that could damage the sealings. The
quantity of gathered oil between two scheduled checkups must be nearly constant, and must not exceed
anyway 1-2 liters each month. In case of grater oil escape the sealings must be changed.

4 Pressure check

Check lift pressure: during car travel, it must not exceed max admitted pressure. When the car rests for
a long time, pressure must be constant.

5 H 300 valve check

Be sure that the valve regulations haven’t been changed; try making some travels with different car loads
(if possible) and check speed profile (start, slowing down, creeping speed, max speed, stopping preci-
sion at floors).

6 Hand pump check

Drive the car to a low floor, Close the shut-off valve (red lever besides the H300 valve) and operate
the hand pump with the apposite bar. The manometer must indicate a pressure increase.

7 Manual lowering check

Drive the car to an high floor, then switch off the power and pull the manual lowering valve red lever.
Be sure that the car comes down even when empty.

8 Relevelling check

For each floor stop, lower the car with manual lowering valve in order to check the efficiency of elec-
tronic relevelling control.
 HL 07.09-3/3
Rev: A
Data: 06/99

9 Rupture valve check

Check that the rupture valve activates before max admitted speed. If necessary, set the valve according
to the procedure.

10 Motor thermal protection check

Check the efficiency of electric circuit to avoid dangerous oil over heating. Use a tester to check wiring
integrity.

11 Overall check up of hoses and fittings

Check hoses conditions where possible ; look for any oil escape in the rubber flex hoses. Look for any
leakage from threaded fittings. Test the tightening of the fittings and eventually change the bonded seals.

12 Label and schemes check

Inside the machine room must always be the following items: electric scheme, hydraulic scheme with
the indications of the installed hoses type, emergency acting instructions. Labels on the power unit must
be always clean and readable.

13 Overall check up of the lift

It is recommended to do an overall check up of the lift every 5-10 years (depending on working condi-
tions) all the damaged or worn parts; the recommended operations are the following:
– Tank drying, cleaning from water and dirt, check of the condition of the motor, pump,
filter and submerged cables.
– Filtering or changing of the hydraulic oil.
– Check of the hoses and fittings, test of the tightening of the fittings, and eventual substi-
tution of the bonded seals.
– Disassembling ofthe jack head and check of the sealings (eventually: substitution).
– Check of the H300 and rupture valve regulations; if necessary repeat the setup and reg-
ulation procedure.