Instruction Sheet

POWERFUL SOLUTIONS. GLOBAL FORCE.

Hydraulic Cylinders
L1608 Rev. I 03/20 EN
Index:
English (EN)................................................... 1-4
Français (FR)................................................. 5-8
Deutsch (DE)............................................... 9-12
Italiano (IT)................................................ 13-16
Español (ES).............................................. 17-20
Nederlands (NL)........................................ 21-24
Português (PT).......................................... 25-28
Suomi (FI).................................................. 29-32
Norsk (NO)................................................ 33-36
Svensk (SV)............................................... 37-40
中文 (ZH)................................................... 41-44
日本語 (JA)................................................ 45-47
Русский (RU)............................................ 48-51
Polski (PL)................................................. 52-55 A DANGER is only used when your action or lack of
Slovenščina (SL)....................................... 56-59 action may cause serious injury or even death.
WARNING: Wear proper personal protective
Repair Parts Sheets for this product are available from gear when operating hydraulic equipment.
the Enerpac web site at www.enerpac.com, or from
your nearest Authorized Enerpac Service Center or
WARNING: Stay clear of loads supported
Enerpac Sales office.
by hydraulics. A cylinder, when used as a
1.0 IMPORTANT RECEIVING INSTRUCTIONS load lifting device, should never be used
as a load holding device. After the load has
Visually inspect all components for shipping damage. been raised or lowered, it must always be blocked
Shipping damage is not covered by warranty. If mechanically.
shipping damage is found, notify carrier at once. The WARNING: USE ONLY RIGID PIECES
carrier is responsible for all repair and replacement TO HOLD LOADS. Carefully select steel
costs resulting from damage in shipment. or wood blocks that are capable of
supporting the load. Never use a hydraulic
SAFETY FIRST
cylinder as a shim or spacer in any lifting or pressing
application.
2.0 SAFETY PRECAUTIONS
DANGER: To avoid personal injury
Read all instructions, warnings
keep hands and feet away from
and cautions carefully. Follow all
cylinder and workpiece during
safety precautions to avoid
operation.
personal injury or property damage during system
operation. Enerpac cannot be responsible for damage WARNING: Do not exceed equipment
or injury resulting from unsafe product use, lack of ratings. Never attempt to lift a load
maintenance or incorrect product and/or system weighing more than the capacity of the
operation. Contact Enerpac when in doubt as to the cylinder. Overloading causes equipment
safety precautions and operations. If you have never failure and possible personal injury. The cylinders are
been trained on high-pressure hydraulic safety, designed for a max. pressure of 10,000 psi [700 bar].
consult your distribution or service center for a free Do not connect a jack or cylinder to a pump with a
Enerpac Hydraulic safety course. higher pressure rating.
Failure to comply with the following cautions and Never set the relief valve to a higher
warnings could cause equipment damage and pressure than the maximum rated pressure
personal injury. of the pump. Higher settings may result in
equipment damage and/or personal injury.
A CAUTION is used to indicate correct operating or
maintenance procedures and practices to prevent WARNING: The system operating pressure
damage to, or destruction of equipment or other must not exceed the pressure rating of the
property. lowest rated component in the system.
Install pressure gauges in the system to
A WARNING indicates a potential danger that
monitor operating pressure. It is your window to what
requires correct procedures or practices to avoid
is happening in the system.
personal injury.

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 CAUTION: Avoid damaging hydraulic IMPORTANT: Hydraulic equipment must
hose. Avoid sharp bends and kinks when only be serviced by a qualified hydraulic
routing hydraulic hoses. Using a bent or technician. For repair service, contact the
kinked hose will cause severe back-pressure. Sharp Authorized ENERPAC Service Center in
bends and kinks will internally damage the hose your area. To protect your warranty, use only
leading to premature hose failure. ENERPAC oil.
Do not drop heavy objects on hose. A WARNING: Immediately replace worn or
sharp impact may cause internal damage damaged parts by genuine ENERPAC parts.
to hose wire strands. Applying pressure to Standard grade parts will break causing
a damaged hose may cause it to rupture. personal injury and property damage.
IMPORTANT: Do not lift hydraulic equipment ENERPAC parts are designed to fit properly and
by the hoses or swivel couplers. Use the withstand high loads.
carrying handle or other means of safe
transport.
3.0 INSTALLATION
CAUTION: Keep hydraulic
equipment away from flames and 1. Make hydraulic connections. For single-acting
heat. Excessive heat will soften cylinders (1) use a pump with a release valve (or
packings and seals, resulting in fluid a 3-way valve) and one hose. For double-acting
leaks. Heat also weakens hose materials and cylinders (2) use a pump with a 4-way valve and
packings. For optimum performance do not expose two hoses.
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: On double-acting cylinders
be certain that hoses are connected at
WARNING: BE SURE SETUP IS STABLE BOTH couplers. Never attempt to
BEFORE LIFTING LOAD. Cylinders should pressurize a double-acting cylinder if only
be placed on a flat surface that can support one hose is connected.
the load. Where applicable, use a cylinder
base for added stability. Do not weld or otherwise 2. Fully hand-tighten all couplers. Loose coupler
modify the cylinder to attach a base or other support. connections will block the flow of oil between the
pump and the cylinder.
Avoid situations where loads are not
3. Remove air from the cylinder:
directly centered on the cylinder plunger.
Off-center loads produce considerable Single-acting cylinders: Position the cylinder so
strain on cylinders and plungers. In that the plunger is pointed down and the cylinder
addition, the load may slip or fall, causing potentially is lower than the pump. Fully extend and retract
dangerous results. the cylinder several times, until operation is
smooth.
Distribute the load evenly across the entire
saddle surface. Always use a saddle to Double-acting cylinders: Lay the cylinder on its
protect the plunger. 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.

Air

Air

A B

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NOTES: DANGER: Never attempt to relieve hydraulic
• During adaptor installation, extend the plunger pressure by loosening a coupler. Trapped
and apply approximately 1500 to 2000 psi hydraulic pressure can cause a loosened
[103 to 138 bar] of hydraulic pressure. This will coupler to dislodge unexpectedly with great force.
help keep the plunger from turning inside the Serious personal injury or death will result if the
cylinder base. coupler becomes a projectile and strikes persons
working in the area.
•  Do not allow the plunger to rotate during
adaptor installation. Plunger rotation may WARNING: Loosening a coupler may
damage the internal seals and/or the plunger result in an escape of high pressure oil
return spring (if equipped). that can penetrate the skin. Serious
• Hand-tighten adapters and attachments until personal injury or death could result.
full thread engagement occurs and the item WARNING: Never use a hammer and
can no longer be turned by hand. Do not use punch (or other similar method) to unseat
tools. a coupler check ball that is under
• Always check for full thread engagement. pressure. Serious personal injury or death
Thread damage may occur if cylinder is could result due to the sudden and uncontrolled
loaded and threads are not fully engaged. escape of high pressure oil.
• Note that the plunger threads on single-acting
6.0 MAINTENANCE
cylinders are not rated for the full cylinder
load. Forces must be transferred directly from 1. Use only Enerpac oil with the cylinder. The use of
the adapter or attachment to the face of the any other oil may invalidate your warranty.
plunger, and not through the threads. For this 2. Use dust cap(s) when cylinder is disconnected
reason, it is very important to verify that the from the hose(s). Keep the entire cylinder clean to
adapter or attachment is fully installed on the prolong its life.
plunger. 3. Store cylinders upright to prevent seal distortion.
• Use care when installing adaptors and 4. Single-acting cylinders only: Before long term
attachments. Be careful not to nick or mar the storage, fully extend and retract the plunger once.
plunger rod surface. Then, store the cylinder upside-down. This will
• Collar threads are rated for the full capacity of help protect the cylinder from corrosion and seal
the cylinder when fully engaged in attachments. distortion.
WARNING: Some cylinder attachments
require that the cylinder be used at no
more than 50% of its rated capacity. Refer 7.0 TROUBLESHOOTING
to the accessory instruction sheet for
additional information. 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
4.0 OPERATION
most common problems.
Operate the hydraulic pump to advance and retract
The cylinder should be repaired only by trained and
the cylinder. Some single-acting cylinders are spring-
experienced hydraulic technicians.
return, others are load-return. The speed of retraction
is affected by the length of the hose and other WARNING: Single-acting cylinders are
restrictions in the line. Double-acting cylinders are spring-loaded and require special
powered in both directions by the pump. disassembly techniques to prevent
personal injury.
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.

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 TROUBLESHOOTING CHART
PROBLEM POSSIBLE CAUSE

Cylinder will not advance. 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.

Cylinder advances part way. Oil level in pump is low.

Coupler not fully tightened.
Cylinder plunger binding.

Cylinder advances in spurts. Air in hydraulic system.

Cylinder plunger binding.

Cylinder advances slower than normal. Leaking connection.

Coupler not fully tightened.
Pump malfunctioning.

Cylinder advances but will not hold. Pump malfunctioning.

Leaking connection.
Incorrect system set-up.
Cylinder seals leaking.

Cylinder leaks oil. Worn or damaged seals.

Internal cylinder damage.
Loose connection.

Cylinder will not retract or retracts Pump release valve is closed.

slower than normal. Coupler not fully tightened.
Pump reservoir over-filled.
Narrow hose restricting flow.
Broken or weak retraction spring (if equipped).
Cylinder damaged internally.

Oil leaking from external relief valve. Coupler not fully tightened.
Restriction in return line.

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