Lukas Hydraulic cylinder User Manual
Operating Instructions - Hydraulic tools
Hydraulic cylinder
(Translation of the original operating instructions)
83145000085 GB
Edition 08.2011
replaces 09.2008
2
Contents Page
1. Hazard classes 4
2. Product safety 5
3. Intended use 8
4. Equipment designation 9
5. Functions and performance 9
5.1 Description 9
5.2 Basic construction of the cylinder 10
5.3 Controlling the operating movements 11
5.4 Hydraulic supply 12
6. Connecting the equipment 13
6.1 Hydraulic connections 13
6.2 Coupling the screwed couplings 13
6.3 Coupling Quick-disconnect Couplings 14
7. Operation 15
7.1 Basic selection of cylinder size 15
7.2 Positioning 15
7.3 Commissioning 18
7.4 Hydraulic control of the cylinder 19
8. Dismantling the equipment / deactivation following operation 20
8.1 Hydraulic cylinder 20
8.2 Hydraulic unit 20
8.3 Hoses 20
9. Care and Maintenance 21
10. Repairs 22
10.1 General information 22
10.2 Preventive maintenance 22
10.3 Repairs 23
11. Troubleshooting 26
12. Technical data 29
12.1 Cylinder data 29
12.2 Hydraulicuidrecommendations 29
13. Notes 30
3
1. Hazard classes
We distinguish between various categories of safety instructions. The chart below provides
an overview, using symbols (pictograms) and signal words, of the specic danger and the
possible consequences.
Pictogram
Wear helmet with face protection
Damage /
injury to
human
device
- NOTE
Key word Denition Consequences
DANGER! Immediate danger
WARNING!
CAUTION!
CAUTION!
Potentially
dangerous
situation
Less dangerous
situation
Danger of damage
to device /
environment
Advice for
application and
other important /
useful information
and advice
Death or major
injury
Potential death or
major injury
Minor or slight
injury
Damage to the
equipment,
damage to the
environment,
damage to
surrounding
materials
No injury /
damage to
persons /
environment /
equipment
Wear protective gloves
Wear safety shoes
Proper recycling
Observe the principles of environmental protection
Read and observe the operating instructions
4
2. Product safety
LUKAS products are developed and manufactured to ensure the best performance and
quality with intended use.
The safety of the operator is the most important consideration in the product design.
Furthermore, the operating instructions are intended to help in using LUKAS products safely.
In addition to the operating instructions, all generally applicable, statutory and other
binding rules for accident prevention and for environmental protection must be heeded and
disseminated.
The device may only be operated by appropriately educated, safety trained persons, since
otherwise there is a risk of injury.
We would like to point out to all users that they should read the operating instructions carefully
before using the equipment and comply with the instructions there without reservation.
We further recommend that a qualied instructor train you in the use of the product.
WARNING / CAUTION!
The operating instructions for the hoses, the accessories and the connected
devices must also be heeded!
Even if you have already received instructions on how to use the equipment, you should still
read the following safety notes again.
WARNING / CAUTION!
Ensure that the accessories and connected equipment used are suitable for
the maximum operating pressure!
Please ensure that no body
parts or clothing are caught
between the visibly moving
parts (e.g. piston protection
plate and cylinder).
Wear protective clothing,
safety helmet with visor,
safety shoes and protective
gloves
The responsible department
must be informed immediately
of any changes (including to
the operating behaviour)! If
necessary, the device must
be deactivated immediately
and secured!
It is prohibited to work under
loads if the load is lifted
exclusively by hydraulic
equipment. If this work
is absolutely imperative,
additional mechanical
supports must be used.
Inspect the equipment before
and after use for visible
defects or damage
Check all lines, hoses and
screwed connections for
leaks and externally visible
damage. Rectify any damage
immediately. Squirting
hydraulic uid can result in
injuries and res.
5
In the event of malfunctions,
immediately deactivate the
device and secure it. The
malfunction must be repaired
immediately.
Do not carry out any changes
(additions or conversions) to
the device without obtaining
the prior approval of LUKAS.
Observe all safety and danger
notes on the equipment and
in the operating instructions.
Any method of operation
which impairs safety and/or
stability of the equipment is
prohibited!
Safety devices must never be
deactivated!
Before the equipment is
switched on/started up, and
during its operation, it must
be ensured that nobody is
endangered by the operation
of the equipment.
When working close to live
components and cables,
suitable measures must
be taken to avoid current
transfers or high-voltage
ashovers to the equipment.
All safety instructions and
hazard warnings on the
device must be kept intact
and in a legible condition.
Comply with all specied
dates or dates specied in
the operating instructions
pertaining to regular checks /
inspections of the equipment.
The maximum permitted
operating pressure noted on
the equipment must not be
exceeded.
Only original LUKAS
accessories and spare parts
may be used for repairs.
Make sure that you do not
get caught in the hose loops
and trip when working with or
transporting the device.
Prevent electrostatic
discharge, which has the
possible consequence of
spark generation, when
handling the device.
6
The device is lled with
hydraulic uid. These
hydraulic uids can be
harmful to your health if
swallowed or if their vapours
are inhaled. Direct contact
with the skin must be avoided
for the same reason. Please
note also that hydraulic uids
can have an adverse effect on
biological systems.
Ensure adequate lighting
when you are working.
When working with or storing
the equipment, ensure
that the function and the
safety of the equipment
are not impaired by the
effects of extreme external
temperatures and that the
equipment is not damaged in
any way. Please note that the
device can also heat up over
a long period of use.
Before transporting the
equipment, always ensure
that the accessories are
positioned such that they
cannot cause an accident.
Always keep these operating
instructions easily accessible
at the location where the
device is used.
The generally applicable, legal and other binding national and international regulations
pertaining to the prevention of accidents and protection of the environment apply and
must be implemented in addition to the operating instructions.
Make sure you dispose of
all parts removed, oil and
uid residues and packaging
materials in a proper manner!
WARNING / CAUTION!
The equipment is to be used exclusively for the purpose stated in the operating
instructions (see chapter “Intended use”). Any other or further use is not considered
Intended use. The manufacturer / supplier is not liable for any damages resulting from not
intended use. The user bears sole responsibility for such.
Observance of the operating instructions and compliance with the inspection and maintenance
conditions are part of the Intended use.
Never work when you are overtired or intoxicated!
7
3. Intended use
LUKAS hydraulic cylinders are designed specially for use in lifting and displacing work, use
in assembly and in service work.
In general, LUKAS hydraulic cylinders can be used to lift, push or relocate objects.
WARNING / CAUTION!
All objects which are to be moved must be secured using stable supports or
substructures. In addition, you have to make sure that the hydraulic cylinders
cannot slip.
CAUTION!
Pay strict attention to leaks in order to prevent threats to the environment.
Every time you use the equipment, make sure that the necessary accessories, such as the
piston protection plate etc., are used.
WARNING / CAUTION!
The following may not be crushed or damaged:
- live cables
- hardened parts such as steering columns and rollers
- Explosive objects, such as air bag cartridges and pressurised gas
cylinders
NEVER operate the hydraulic cylinders at a higher operating pressure than
shown on the identication plate. A higher setting may cause damage to property
and/or injuries.
Genuine spare parts, accessories for the equipment and suitable hydraulic uids can be
ordered from your authorised LUKAS dealer!
8
4. Equipment designation
single-acting
cylinders:
double-acting
cylinders:
LFO 55 / 200 Z
HLMD 55 - 25 / 200 M
Cylinder range Cylinder type Stroke Connection
thread for
couplings
Coupling connection thread:
M = metric thread
Z = inch thread
5. Functions and performance
5.1 Description
LUKAS hydraulic cylinders can be either single or double acting. This can be seen in the
designation of the cylinder.
The movement of the piston when extending is carried out hydraulically for both cylinder
types. When retracting, only the double acting cylinders move under hydraulic force. On
single acting cylinders it takes place mechanically, e.g. by a release spring. Single acting
cylinders can also be equipped without release springs, and the retraction is actuated by the
lifted load which acts on the piston of the cylinder when the pressure is removed.
WARNING / CAUTION!
Please take care that single acting cylinders can move unexpectedly if the
pressure is removed and the line to the cylinder is not closed off!
The direction of movement is controlled by the application of pressure to the rod side of
the piston (only on double acting cylinders) or to the cylinder base side. The control of
the pressurisation must be effected by an external control unit (e.g. a control valve) and
a hydraulic aggregate connected to it. The use of a hand pump instead of the hydraulic
aggregate is also possible.
In general, all LUKAS double acting cylinders are equipped with an integrated safety valve on
the piston rod side. These safety valves protect the cylinder from damage caused by pressure
transmission. If the specied maximum pressure is exceed, the safety valves automatically
open and hydraulic oil (shielded) is ejected into the open air.
9
LUKAS offers hydraulic cylinders in a wide variety of designs.
Depending on the type, the cylinders are made of different materials such as aluminium alloy, steel or stainless steel. The types of cylinder also vary by method of construction. They
are available as normal lifting cylinders, heavy duty, short stroke, locking and at cylinders.
Depending on the version, they can be used in a wide range of different applications.
If you have any doubts as to whether the cylinder you have selected is suitable for the
application in question, please consult LUKAS directly or one of the authorised LUKAS
dealers.
5.2 Basic construction of the cylinder
2
3
6
3
8
5
3
4
1
8
2
1 Cylinder body
2 Piston
3 Guiding ring
4 Piston return
5 Wiper
6 Piston protection plate
7 Thread protection ring
8 Connection coupling
1
(plug or screw coupling)
5
7
2
1
8
10
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