Mar. 10, 2025
Machinery
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Hydraulic systems for lifting, lowering, or pulling can vary according to each individual project. There are many different configurations possible, so choosing the right components for your system should be done carefully to ensure a safe and successful outcome.
Important! For the inexperienced, understanding pressurized hydraulic systems can be complex. Every heavy-lift project has its own unique requirements and using the wrong set-up could be catastrophic. Please consult a suitably qualified and experienced person before you start work.
What follows is a simple introductory overview of how to configure a lifting system for anyone unfamiliar, or unaware of the options available. Weve put together eight examples to get you started, ranging from simple hand pump cylinder sets to complex synchronous lifting systems.
If you need advice on choosing the right hydraulic cylinder please see our Buyers Guide.
This diagram shows a very simple hydraulic system suitable for a single-acting lifting application. Arrangements like this can be used in a wide variety of general-purpose maintenance situations, or in a hydraulic press.
It shows a manual hand pump for controlling the cylinder advance. (Note that this could be substituted for a powered pump). Its worth knowing that a cylinder with a capacity of 25 ton and above may require many hand-pump strokes especially for longer stroke applications.
This shows another basic hydraulic system using a single-acting hydraulic cylinder. This time it includes a cylinder with a longer stroke and an air-powered hydraulic pump.
Note the use of a JBI-Series Cylinder Baseplate which increases both stability and load distribution.
When using any of our powered pumps (air/electric) we always recommend using our glycerine-filled gauges to reduce needle vibration for accurate pressure reading.
When lowering a heavy load it is sometimes important to have controlled retract. When this is a requirement, a system designed for a double-acting cylinder should be used. A double-acting cylinder uses hydraulics to lift or lower the load, unlike single-acting cylinders which rely on a return spring and gravity to retract the plunger. The latter can be time-consuming. (especially on longer stroke cylinders).
Safety Tip Ensure all couplers are connected and working properly a defective or incorrectly attached coupler may block the flow, resulting in potential pressure intensification which would result in excess pressure flowing out the external pressure relief valve on cylinder.
The system above is for applications requiring 2 lift points where a controlled lift is needed. Manifold blocks are used to split both flow directions to the 2 cylinders, with the advance line utilizing flow control valves to enable fine-tuning of the synchronicity of lifting across multiple points. Note that the pressure gauge goes into the advance line.
The above shows another two-point lifting set-up, but this time it is simplified by using single-acting cylinders. A safety holding valve is used with each cylinder for temporary load holding.
The company is the world’s best Multi Stage Hydraulic Cylinder supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.
Further reading:For long-term load holding applications, consider Enerpac hydraulic lock nut cylinders which mechanically lock off the load ensuring safe working in and around the area.
Safety Tip Never work under a hydraulically suspended load. Always mechanically lock the load either by using cribbing blocks or mechanically operated locknut cylinders.
The above shows a common multi-point hydraulic system using single-acting cylinders and control manifolds.
The above picture shows an alternative 4 point set-up that utilizes the new Enerpac Split Flow Manifold (SFM). The SFM works by distributing an even flow rate to all lifting points regardless of the load distribution across the lifting cylinders. SFMs features and benefits are shown below;
Split flow pumps offer many benefits for large-scale multi-point jacking applications. For lifting and lowering applications with multiple points, split flow pumps are a far better alternative than using independently operated pumps.
Depending upon the chosen configuration, they can offer extreme control accuracies of +/-1mm per leading and lagging jacking cylinders. See available options described below,
Standard SFP-Series Split Flow Pumps
When synchronization of 4% maximum is acceptable, Standard SFP Series Split Flow Pumps provide a safe and economical solution.
If you need more than 8 lifting points, they can be upgraded to network with additional split flow pumps increasing the number of jacking locations up to an impressive 32 units!
Programmable Logic Controlled Split Flow Pumps
For extreme accuracy applications, SFP-Series split flow pumps can be upgraded to become PLC-controlled synchronous lifting systems. This increases the SFPs capabilities to become an accurate synchronous lifting/lowering system thats capable of achieving +/-1mm accuracy from the leading/lagging hydraulic cylinder.
This upgrade utilizes external stroke sensors which communicate with the master control box to provide continuous feedback. Similarly, the upgraded SFP-Series Split Flow Pumps can also be networked to achieve an impressive 32 point synchronous lifting system without the need to change any of the standard SFP hardware.
As well as the above impressive capabilities, the SFP systems offer the additional elements shown below,
Application examples requiring synchronous lift systems include:
Bridge deck lifting for bearing maintenance
Stage lifting in construction and shipbuilding
Skidding to move structures and buildings
Levelling of large constructions like wind turbines
For more information, please visit dual hydraulic cylinder.
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