Enerpac L1608 User manual

POWERFUL SOLUTIONS. GLOBAL FORCE.
Instruction Sheet
Hydraulic Cylinders
L1608 Rev. H 08/16
Index:
English ......................................................... 1-4
Français........................................................ 5-8
Deutsch...................................................... 9-12
Italiano ..................................................... 13-16
Español.................................................... 17-20
Nederlands............................................... 21-24
Português................................................. 25-28
Suomi....................................................... 29-32
Norsk ....................................................... 33-36
Svensk ..................................................... 37-40
中文.......................................................... 41-44
日本語 .................................................... 45-47
Русский ................................................... 48-51
Polish ...................................................... 52-55
Repair Parts Sheets for this product are available from
the Enerpac web site at www.enerpac.com, or from
your nearest Authorized Enerpac Service Center or
Enerpac Sales oce.
1.0 IMPORTANT RECEIVING INSTRUCTIONS
Visually inspect all components for shipping damage.
Shipping damage is not covered by warranty. If
shipping damage is found, notify carrier at once. The
carrier is responsible for all repair and replacement
costs resulting from damage in shipment.
SAFETY FIRST
2.0 SAFETY PRECAUTIONS
Read all instructions, warnings
and cautions carefully. Follow all
safety precautions to avoid
personal injury or property damage during system
operation. Enerpac cannot be responsible for damage
or injury resulting from unsafe product use, lack of
maintenance or incorrect product and/or system
operation. Contact Enerpac when in doubt as to the
safety precautions and operations. If you have never
been trained on high-pressure hydraulic safety,
consult your distribution or service center for a free
Enerpac Hydraulic safety course.
Failure to comply with the following cautions and
warnings could cause equipment damage and
personal injury.
A CAUTION is used to indicate correct operating or
maintenance procedures and practices to prevent
damage to, or destruction of equipment or other
property.
A WARNING indicates a potential danger that
requires correct procedures or practices to avoid
personal injury.
A DANGER is only used when your action or lack of
action may cause serious injury or even death.
WARNING: Wear proper personal protective
gear when operating hydraulic equipment.
WARNING: Stay clear of loads supported
by hydraulics. A cylinder, when used as a
load lifting device, should never be used
as a load holding device. After the load has
been raised or lowered, it must always be blocked
mechanically.
WARNING: USE ONLY RIGID PIECES
TO HOLD LOADS. Carefully select steel
or wood blocks that are capable of
supporting the load. Never use a hydraulic
cylinder as a shim or spacer in any lifting or pressing
application.
DANGER: To avoid personal injury
keep hands and feet away from
cylinder and workpiece during
operation.
WARNING: Do not exceed equipment
ratings. Never attempt to lift a load
weighing more than the capacity of the
cylinder. Overloading causes equipment
failure and possible personal injury. The cylinders are
designed for a max. pressure of 10,000 psi [700 bar].
Do not connect a jack or cylinder to a pump with a
higher pressure rating.
Never set the relief valve to a higher
pressure than the maximum rated pressure
of the pump. Higher settings may result in
equipment damage and/or personal injury.
WARNING: The system operating pressure
must not exceed the pressure rating of the
lowest rated component in the system.
Install pressure gauges in the system to
monitor operating pressure. It is your window to what
is happening in the system.
CAUTION: Avoid damaging hydraulic
hose. Avoid sharp bends and kinks when
routing hydraulic hoses. Using a bent or
kinked hose will cause severe back-pressure. Sharp
bends and kinks will internally damage the hose
leading to premature hose failure.
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Do not drop heavy objects on hose. A
sharp impact may cause internal damage
to hose wire strands. Applying pressure to
a damaged hose may cause it to rupture.
IMPORTANT: Do not lift hydraulic equipment
by the hoses or swivel couplers. Use the
carrying handle or other means of safe
transport.
CAUTION: Keep hydraulic
equipment away from flames and
heat. Excessive heat will soften
packings and seals, resulting in fluid
leaks. Heat also weakens hose materials and
packings. For optimum performance do not expose
equipment to temperatures of 65°C [150°F] or higher.
Protect hoses and cylinders from weld spatter.
DANGER: DO NOT HANDLE
PRESSURIZED HOSES. Escaping oil
under pressure can penetrate the skin,
causing serious injury. If oil is injected under the skin,
see a doctor immediately.
WARNING: Only use hydraulic cylinders in a
coupled system. Never use a cylinder with
unconnected couplers. If the cylinder becomes
extremely overloaded, components can fail
catastrophically causing severe personal injury.
WARNING: BE SURE SETUP IS STABLE
BEFORE LIFTING LOAD. Cylinders should
be placed on a flat surface that can support
the load. Where applicable, use a cylinder
base for added stability. Do not weld or otherwise
modify the cylinder to attach a base or other support.
Avoid situations where loads are not
directly centered on the cylinder plunger.
O-center loads produce considerable
strain on cylinders and plungers. In
addition, the load may slip or fall, causing potentially
dangerous results.
Distribute the load evenly across the entire
saddle surface. Always use a saddle to
protect the plunger.
IMPORTANT: Hydraulic equipment must
only be serviced by a qualified hydraulic
technician. For repair service, contact the
Authorized ENERPAC Service Center in
your area. To protect your warranty, use only
ENERPAC oil.
WARNING: Immediately replace worn or
damaged parts by genuine ENERPAC parts.
Standard grade parts will break causing
personal injury and property damage.
ENERPAC parts are designed to fit properly and
withstand high loads.
3.0 INSTALLATION
1. Make hydraulic connections. For single-acting
cylinders (1) use a pump with a release valve (or
a 3-way valve) and one hose. For double-acting
cylinders (2) use a pump with a 4-way valve and
two hoses.
WARNING: On double-acting cylinders
be certain that hoses are connected at
BOTH couplers. Never attempt to
pressurize a double-acting cylinder if only
one hose is connected.
2. Fully hand-tighten all couplers. Loose coupler
connections will block the flow of oil between the
pump and the cylinder.
3. Remove air from the cylinder:
Single-acting cylinders: Position the cylinder so
that the plunger is pointed down and the cylinder
is lower than the pump. Fully extend and retract
the cylinder several times, until operation is
smooth.
Double-acting cylinders: Lay the cylinder on its
side so that the couplers are facing up. Fully
extend and retract the cylinder several times, until
operation is smooth.
4. Install adaptors and attachments as required.
NOTES:
• During adaptor installation, extend the plunger
and apply approximately 1500 to 2000 psi
[103 to 138 bar] of hydraulic pressure. This will
help keep the plunger from turning inside the
cylinder base.
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• Do not allow the plunger to rotate during
adaptor installation. Plunger rotation may
damage the internal seals and/or the plunger
return spring (if equipped).
• Hand-tighten adapters and attachments until
full thread engagement occurs and the item
can no longer be turned by hand. Do not use
tools.
• Always check for full thread engagement.
Thread damage may occur if cylinder is
loaded and threads are not fully engaged.
• Note that the plunger threads on single-acting
cylinders are not rated for the full cylinder
load.Forces must betransferreddirectly from
theadapteror attachment to the face of the
plunger, and not through the threads.For this
reason, it is very important to verify that the
adapter or attachment is fully installed on the
plunger.
• Use care when installing adaptors and
attachments. Be careful not to nick or mar the
plunger rod surface.
• Collar threads are rated for the full capacity of
the cylinder when fully engaged in attachments.
WARNING: Some cylinder attachments
require that the cylinder be used at no
more than 50% of its rated capacity. Refer
to the accessory instruction sheet for
additional information.
4.0 OPERATION
Operate the hydraulic pump to advance and retract
the cylinder. Some single-acting cylinders are spring-
return, others are load-return. The speed of retraction
is aected by the length of the hose and other
restrictions in the line. Double-acting cylinders are
powered in both directions by the pump.
The cylinder stop ring is designed to take the full load.
However, to reduce cylinder wear, use less than full
stroke and pressure when possible.
5.0 RELIEVING TRAPPED PRESSURE
Pressure can sometimes become trapped in a
hydraulic cylinder if a hose is disconnected before
pressure is completely relieved.
If a trapped pressure condition occurs, always use the
Enerpac model CT-604 coupler bleed tool (available
from your Authorized Enerpac Distributor) to safely
relieve the remaining pressure.
DANGER: Never attempt to relieve hydraulic
pressure by loosening a coupler. Trapped
hydraulic pressure can cause a loosened
coupler to dislodge unexpectedly with great force.
Serious personal injury or death will result if the
coupler becomes a projectile and strikes persons
working in the area.
WARNING: Loosening a coupler may
result in an escape of high pressure oil
that can penetrate the skin. Serious
personal injury or death could result.
WARNING: Never use a hammer and
punch (or other similar method) to unseat
a coupler check ball that is under
pressure. Serious personal injury or death
could result due to the sudden and uncontrolled
escape of high pressure oil.
6.0 MAINTENANCE
1. Use only Enerpac oil with the cylinder. The use of
any other oil may invalidate your warranty.
2. Use dust cap(s) when cylinder is disconnected
from the hose(s). Keep the entire cylinder clean to
prolong its life.
3. Store cylinders upright to prevent seal distortion.
4. Single-acting cylinders only: Before long term
storage, fully extend and retract the plunger once.
Then, store the cylinder upside-down. This will
help protect the cylinder from corrosion and seal
distortion.
7.0 TROUBLESHOOTING
Refer to the troubleshooting chart for a list of
typical cylinder problems and possible causes. The
troubleshooting chart is not all-inclusive, and should
be considered only as an aid to help diagnose the
most common problems.
The cylinder should be repaired only by trained and
experienced hydraulic technicians.
WARNING: Single-acting cylinders are
spring-loaded and require special
disassembly techniques to prevent
personal injury.

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PROBLEM
Cylinder will not advance.
Cylinder advances part way.
Cylinder advances in spurts.
Cylinder advances slower than normal.
Cylinder advances but will not hold.
Cylinder leaks oil.
Cylinder will not retract or retracts
slower than normal.
Oil leaking from external relief valve.
POSSIBLE CAUSE
Pump release valve open.
Coupler not fully tightened.
Oil level in pump is low.
Pump malfunctioning.
Load is too heavy for cylinder.
Cylinder seals leaking.
Oil level in pump is low.
Coupler not fully tightened.
Cylinder plunger binding.
Air in hydraulic system.
Cylinder plunger binding.
Leaking connection.
Coupler not fully tightened.
Pump malfunctioning.
Pump malfunctioning.
Leaking connection.
Incorrect system set-up.
Cylinder seals leaking.
Worn or damaged seals.
Internal cylinder damage.
Loose connection.
Pump release valve is closed.
Coupler not fully tightened.
Pump reservoir over-filled.
Narrow hose restricting flow.
Broken or weak retraction spring (if equipped).
Cylinder damaged internally.
Coupler not fully tightened.
Restriction in return line.
TROUBLESHOOTING CHART