Hydraulic tools

Operating instructions

84148/0600-85GB
Hydraulic cylinder 70MPa Issue 09.2006
Replaces 04.2006
EKZ, HLO, HLM, HLZ,
HLOD, HLMD, HLZD
Content page
1 Safety 4

1.1 Safety Instructions (Warning Notices) 4

1.2 Correct use of the device 5

1.3 User Qualifications 5

1.4 Safety Regulations for Operation 6

1.5 Further Safety Regulations 7

2 Intended use 8

3 Function 8

3.1 Function EKZ, HLO, HLM, HLZ 8

3.2 Function HLOD, HLMD, HLZD 8

4 Cylinder identification 9

5 Connecting to a pump 9

5.1 Single-acting cylinder (EKZ, HLO, HLM, HLZ) 9

5.2 Double acting cylinder (HLOD, HLMD, HLZD) 10

5.3 Couplings 10

6 Initial operation 11

7 Operation 11

7.1 Basic selection of cylinder size 11

7.2 Operation Safety Measures 12

7.3 Extending and retracting the cylinders 13

8 Dismantling the components 14

8.1 Single-acting cylinders 14

8.2 Double-acting cylinders 14

9 Servicing and maintenance 14

2
10 Routine Checks 15

10.1 Visual and mechanical inspection 15

10.2 Hydraulic pressure test 15

11 Troubleshooting 16

12 Technical data 17

12.1 Operating Pressure 17

12.2 Compression Forces and Strokes 17

12.3 Temperature Ranges 17

12.4 Recommended Oil 17

12.5 Connection thread torques 17

13 Declaration of Conformity 18

3
1 Safety
This device has been constructed in accordance with state-of-the-art technical
standards and approved safety regulations. Nevertheless, its use may constitute a
risk to life and limb of the user or of third parties, or cause damage to the device
and other material property.

Therefore, in addition to these operating instructions, please observe:

- the instructions on the device
- appropriate laws and provisions
- the valid accident prevention regulations

Always keep the operating instructions in the vicinity of the device!

1.1 Safety Instructions (Warning Notices)

1.1.1 Hazard Categories

We distinguish between various safety instruction categories. The table

below is an overview of assigned symbols (pictograms) and signal words for
specific dangers and possible consequences.

Pictogram Damage Signal Definition Consequences

to word
Danger! Immediate Death or severe
danger injury
Warning! Potentially Possibly death
Persons

dangerous or severe injury

situation
Caution! Less Light or minor
dangerous injury
situation
Attention! Danger of Damage to the
property and device,
Property

environ- environmental
mental damage,
damage property damage
in the vicinity
Note Usage tips No damage to
and other persons,
important/ environment or
- useful device
information
and
instructions

4
1.1.1 Further Pictograms

Helmet and safety goggles are to be worn

Protective gloves are to be worn

Specialized recycling

Observe environmental protection measures

1.2 Correct use of the device

The device may only be used if in technically perfect condition in accordance
with its designated use. The device must be used safely, with an awareness
of the dangers involved. The operating instructions must be observed!
Malfunctions that may impair safety are to be rectified immediately!

The hydraulic cylinders are only to be used for moving loads (e.g. lifting,
hauling, moving) and for clamping parts.

Using the device for purposes other than those mentioned above is
considered contrary to its designated use. The manufacturer/supplier cannot
be held liable for any damage resulting from such use. The risk of such misuse lies
entirely with the user. Operating the device as designated also involves observing
the operating instructions, as well as service and maintenance conditions.

1.3 User Qualifications

LUKAS devices may only be operated by trained personnel.
Repairs and maintenance may only be carried out by specialists.
A specialist is a person whose training and experience have given him/her
sufficient knowledge of hydraulics, and whose awareness of the
appropriate national protective working provisions and generally approved
technical rules (e.g. national standards) is sufficiently advanced to judge
whether the hydraulic devices are safe enough for use.

5
1.4 Safety Regulations for Operation

- WARNING! Before starting up or setting the device in motion and

during operation of the device, ensure no person is at risk!

- WARNING! Avoid all operations that might present a risk to device

safety or stability. Mere toppling of the device can suffice to cause
injury or damage.

- WARNING! BEWARE, squirting oil can cause injury and burning!

- WARNING! Working under loads is forbidden if these are supported

by hydraulic cylinders only. If such work is essential, sufficient
mechanical supports are additionally required.

- WARNING! Avoid direct contact with current-bearing parts.

- WARNING! Never work with reduced concentration or when overtired or

intoxicated.

- WARNING! Danger of crushing and shearing between load and

cylinder.

- ATTENTION! In the case of malfunctions, shut down and secure the

device immediately! Malfunctions are to be rectified immediately!

- ATTENTION! Ensure that the entire work space is always within your
field of vision. Ensure that the lighting is adequate.

- ATTENTION! After each use, always check the device for visible signs of
damage or faults! During continuous operation, check for damage and
faults once a day! Report any changes (including changes in the device's
working behavior) to the responsible department/person immediately! If
necessary, shut down and secure the device immediately! Check all
lines, hoses and screw connections for leaks and visible damage. Repair
damage immediately!

- ATTENTION! The device and/or attached parts can be damaged

and/or destroyed by temperature fluctuations. The temperature range
for operation of the device is listed in the “Technical Data” chapter.

6
1.5 Further Safety Regulations

- In addition to the operating instructions, observe and pass on all

other generally applicable legal regulations, as well as further
mandatory regulations relevant to accident prevention and
environmental protection! This applies in particular to the wearing of
protective clothing.

- No alterations, additions or modifications may be made to the device

without the manufacturer’s permission!

- Adhere to prescribed intervals – or those specified in the operating

instructions – for routine checks and inspections!

- Check instruction labels and warning signs (safety instructions)

regularly for completeness and efficiency.

- Only original LUKAS parts and original LUKAS accessories and

system components may be used for repairs!

- Before transporting the device, always check that the accessories

have been safely stowed away!

- The device is filled with hydraulic fluid. Hydraulic fluids can be

harmful to your health if swallowed or if hydraulic fluid vapors are
inhaled. Also avoid direct contact with skin.

- When handling hydraulic fluids, ensure these are not released into
the surroundings unchecked. This can cause damage to the
environment.

Beware of hairline cracks!

• High-pressure oil can cause severe injury if it comes

into contact with the skin.

• In the case of injury contact a doctor immediately!

• Oil should be removed from wounds immediately!

• Do not use your fingers to look for leaks!

• Remove any load from the hydraulic system before
undoing connections!

7
2 Intended use
The cylinders are intended for lifting and hauling work and for use when
carrying out assembly work or repairs. They may only be operated with 70
MPa (700 bar) LUKAS tool hydraulic components. Usage with devices from
other manufacturers is possible. However, this is only possible after
technical examination and approval by LUKAS in each individual case. Only
original 70 MPa LUKAS components may be used as accessories (piston
guard plates, extensions, etc.).

Always position the cylinder in such a way that its function and safety will not
be negatively influenced by extreme external temperature conditions.

The cylinders are not suitable for use in underground mining operations.

3 Function
3.1 Function EKZ, HLO, HLM, HLZ
Force
The cylinders are single-acting lifting
cylinders with spring returns. The piston
in this type is hydraulically extended. Spring
The piston returns completely via a spring
return.
These cylinders have only one coupling
connection at ground level for hydraulically
controlled extension purposes.

Pressuriation

3.2 Function HLOD, HLMD, HLZD

The piston is hydraulically extended and Force
retracted on these models (with two
coupling connections). It is possible to work Retract
in both directions of travel. A safety valve in pressurization
the head area of the cylinder protects it
from damage through maloperation. If the
specified maximum pressure is exceeded, the
safety valve opens automatically and oil is
released.

Extend pressurization

8
4 Cylinder identification
HLMD 55 - 2 / 200 M

Cylinder model Compressive Tractive force Stroke Connection

range force in t (daN) in t (daN) thread
(only for couplings
double-acting
cylinders)

Cylinder model range:

HL M D
D = Double-acting
M = Metric thread on the cylinder head
Z = Imperial thread on the cylinder head
O = No thread on the cylinder head
Cylinder type HL

Connection thread couplings:

M : Metric thread

Z : Imperial thread

5 Connecting to a Pump
5.1 Single-acting cylinders (EKZ, HLO, HLM, HLZ)
The hydraulic cylinders are connected to the pressure generator via
couplings (see illustration).
Observe all additional instructions and regulations contained in the separate
operating instructions for the pump.

Single-acting cylinder

Pump unit

9
5.2 Double-acting cylinders (HLOD, HLMD, HLZD)
The hydraulic cylinders are connected to the pressure generator via
couplings (see illustration). Connect line B first, followed by line A. Then
check the connections.
Impermissible pressure transmission is relieved via a safety valve.
Observe all additional instructions and regulations contained in the separate
operating instructions for the pump!

Double-acting cylinder
B A

Pump unit

Attention!
Oil is released when the safety valve is activated!
Keep a safe distance from the cylinder before operating the
hydraulic pump!

5.3 Couplings
5.3.1 Plug-In Couplings
The device is unmistakably connected to the hydraulic pump via two plug-in
coupling halves (plug and socket).

X
Y

Before coupling, remove the dust protection caps and turn the socket to position X
by means of the rotating ring. This unlocks the socket. Pull back and hold the
locking sleeve of the socket. Connect the plug into the socket and release the
locking sleeve. Finally, turn the locking sleeve to position Y.
The connection is now complete and secured. Decoupling is done in the reverse order.
Coupling the devices is only possible when the hoses are not under pressure.
The dust protection caps are supplied for purposes of dust protection.

10
5.3.2 Screw Couplings
- Remove dust protection caps,
- Connect the SKN2 plug on the hose to the SKM1 socket on the cylinder.
- Screw the tapped bush of the socket to the exterior thread of the plug and
tighten by hand.

6 Initial operation
Before venting the cylinder as described below, connect it to the pump as
described in Chapter 5.
Extend the piston halfway and set the
cylinder down as illustrated on the right.
The highest point of the cylinder must be
below the pump and the connections
must be pointing upwards. Extend and
retract the piston fully, so that any air can
be released from the system via the oil
tank of the pump.

Note
The oil filler cap on the pump must be open during venting.
The retracting piston presses the air back into the oil tank via
the high-pressure hose and can escape via the oil filler cap.
After venting, ensure that the oil filler cap is securely closed
again.

7 Operation
7.1 Basic selection of cylinder size
Before operation, ensure that the lifting power of the deployed cylinder(s) is
at least 25 % higher than the maximum load expected in the worse case.

The load should never exceed the maximum lifting power

of the cylinder!

We recommend selecting a stroke with approx. 10 % reserve lift. This

increases stability in borderline cases.

11
7.2 Operation Safety Measures
The cylinder should always stand on a stable, level, anti-slip surface; the
entire cylinder base should be in contact with the ground. If unsure of the
load-bearing capacity of the ground surface, use suitable wood or metal
underlays to increase the supporting surface.

correct incorrect

Position the cylinder under the center-of-gravity of the load so that it cannot
topple when lifted thus causing possible injury to operating personnel or
damage to the cylinder itself. The load should always be applied to the
middle of the piston surface. Lateral loads should be avoided!

Weight of the load Weight of the load

correct incorrect

If several cylinders are used simultaneously, the load should be spread as

evenly as possible over all cylinders.

force 1 force 2
force1 force 2

force 1 = force 2 force1 < force 2

correct incorrect

12
 During lifting, ensure that no operating personnel is
under the load!

Never work in the direct vicinity of a load that is only

supported hydraulically!

Use support blocks or other safety measures for mechanical

support.
7.3 Extending and retracting the cylinders
7.3.1 Single-Acting Cylinders

In the case of single-acting cylinders, the piston is pressurized via the pump
via the sole connection. The cylinder extends, thus tensioning the spring
return.
To retract the piston, pressurization is stopped and the spring return brings
the piston back to its original position.
Note that load stabilizing valves are necessary to hold the piston in the
extended position.

7.3.2 Double-Acting Cylinders

In the case of double-acting cylinders, the piston is also pressurized via a

pump. These cylinders have two connections. Both must be connected to
the pump. Pressure is applied to one of the connections, depending on the
direction of movement. If the cylinder is to be extended, pressure must be
applied to the lower connection (1) as illustrated below. To retract the
cylinder, pressure must be applied to the upper connection (2). The pressure
is diverted via a valve positioned between the cylinder and the pump. This
valve is usually an integral part of the pump. Be sure to observe the
operating instructions of the pump being used.
After use, retract the cylinder back to 5 mm.

Connection (2) Connection (1)

Note:
When operating the cylinder, be sure to observe the operating
instructions of the pump being used.

13
8 Dismantling the components
8.1 Single-acting cylinders
In the following order, ensure that:
- the load is in a stable, immovable position.
- the cylinder piston is completely retracted.
- the drive motor of the hydraulic power package has been shut
down.
- the hoses are not under pressure.
The components may now be separated from each other.

8.2 Double-acting cylinders

In the following order, ensure that:
- the load is in a stable, immovable position.
- the cylinder piston is retracted back to 5 mm.
- the drive motor of the hydraulic aggregate has been shut down.
- the hoses are not under pressure.
The components may now be separated from each other. To this end, first
close the pressure hose and then the return hose.

Note: When dismantling the cylinders, ensure that any leaking

hydraulic oil is completely collected and does not leak into the
ground. Ensure that it is correctly disposed of!

9 Servicing and maintenance

We recommend having servicing and maintenance carried out by an
authorized dealer or directly by LUKAS.

Suitable tools and workshop equipment are to be used for servicing and
maintenance purposes.

Work on the hydraulic system must be carried out by specialist hydraulic

personnel only! (See also Chapter 1.3.)

14
10 Routine Checks
In addition to servicing and maintenance, regular checks of the cylinders are
to be carried out, as described in the following 2 sub-chapters.
10.1 Visual and mechanical inspection
The device should be inspected after each application (once a day, if in
permanent operation), as follows (if dirty, clean first):
- Are all the pistons of single-acting cylinders fully retracted? Are all
the pistons of double-acting cylinders retracted back to approx. 5
mm? If this is not the case, check the individual cylinder pistons for
smooth retraction. Are the cylinders and pistons in order?
- Check to ensure that all hydraulic screw connections on the
cylinders and hose connections are still tight (tighten if necessary!).
(See the Technical Data chapter for torques)
- Is there any visible damage to mechanical parts, e.g. abrasional
wear?
- Check whether the cylinder is losing oil, especially around the seals.
- Check if all accessories such as foot plates, head plates, etc. are in
order.
- Check whether all safety equipments (e.g. hoop guards, etc.) are in
place and in working order.
- Are all labels, such as warning notices, operating symbols and other
identification, in place and legible?

10.2 Hydraulic pressure test

A hydraulic pressure test must be carried out at least once a year. This test
should be carried out more often if operation safety is in doubt.
A manometer (available from the LUKAS accessory program) is necessary to
carry out the hydraulic pressure test.

Connect the manometer between the pump and the cylinder, as illustrated
above. Now apply the nominal pressure to the cylinder and extend the
cylinder piston to the internal stop point. Monitor the value on the manometer
and check the cylinder for leakages.

In case of damage, contact LUKAS or an authorized dealer.

15
11 Troubleshooting
Fault Cause Remedy
Cylinder does not Not enough oil in the Fill up with oil according to the
extend, extends pump tank operating instructions of the pump.
too slowly or Escape valve on the Close the escape valve on the pump.
fitfully. pump is open
Hydraulic coupling is Check whether the coupling is tight, if
loose not, tighten it.
Load too heavy Remove the load.
Note: Never attempt to lift loads that
exceed the nominal load!
Air locked in the Release the air according to the
system instructions in Chapter 6.
Cylinder piston stuck Check the cylinder for damage and
have any damage repaired by an
authorized dealer or directly by LUKAS.
Load off-center Center the load.
The cylinder Leaky connection Check whether all of the connections
extends, but fails are tight and sealed, if not, tighten
to maintain the them.
correct pressure. Leaky seals Find the leaks and/or have them
serviced by an authorized dealer or
directly by LUKAS.
Inner cylinder leakage Have the cylinder serviced by a
specialist, an authorized dealer or
directly by LUKAS.
Inner pump leakage Observe the instructions in the
operating instructions of the pump.
The cylinder Escape valve on the Open the escape valve on the pump.
does not retract, pump is closed
retracts only Hydraulic coupling is Check whether all of the couplings are
partially or loose tight, if not, tighten them.
retracts slower Air locked in the Release the air according to the
than normal. system instructions in Chapter 6.
Hose is too long Replace the hydraulic hose with a
shorter hose.
Incorrect oil viscosity Change the oil in the cylinder and in
the pump. Observe the “Temperature
Ranges” in the “Technical Data”
chapter.
The spring return on Have the cylinder serviced by an
the cylinder is broken authorized dealer or directly by LUKAS.
or otherwise
damaged.
Load off-center Remove or center the load.
16
If the faults cannot be rectified, contact an authorized dealer or the LUKAS service
department.
LUKAS service department address:
LUKAS Hydraulik GmbH, Weinstrasse 39, 91058 Erlangen
P.O. Box 2560, 91013 Erlangen
Telephone: (+49) 9131 / 698 - 348
Fax: (+49) 9131 / 698 - 353

12 Technical Data
12.1 Operating pressure
The cylinders are designed for a maximum operating pressure of 70 MPa
(700 bar).

12.2 Compression forces and strokes

The data for compression forces and strokes at an operating pressure of 70
MPa is listed in the cylinder identification (see Chapter 4).

12.3 Temperature ranges

Operating temperature -20 …. +55°C
Ambient temperature (device in operation) -24 …. +45°C
Storage temperature (device not in operation) -30 …. +60°C

12.4 Recommended oil

DIN 51524 mineral oil should be used for Lukas hydraulic cylinders. More
detailed information can be found in the following table.
Oil temperature range Viscosity rating Note
A -24 … +30 °C HL 5
B -18 … +50 °C HLP 10
C -8 … +75 °C HLP22
D +5 … +80 °C HLP32
E -8 … +70 °C HF_E 15 Biodegradable

12.5 Connection thread torques

Connection threads Torque
M 18 x 1.5 80 +10 Nm
3/8 - 18 NPTF 40 +10 Nm
G 1/4 80 +10 Nm

17
13 Declaration of Conformity

18
Notes

19
Notes

20
Notes

21
Notes

22
 Ensure that all packaging materials and dismantled parts are
correctly disposed of.

LUKAS Hydraulik GmbH

A Unit of IDEX Corporation
Weinstraße 39, 91058 Erlangen, Germany
subject to revision

Postfach 2560, 91013 Erlangen, Germany

Telefon +49(0)9131/698-0 • Telefax +49(0)9131/698-394
E-Mail: info@lukas.de

EKZ_HLx_HLxD_Zylinder_BA_GB_841480600_0906.pub © Copyright 2005 LUKAS Hydraulik GmbH

 Betriebsanleitung
Operating Instructions
Werkzeughydraulik
Hydraulic Tools

Hydraulikzylinder /
84148/0734-85 D
Hydraulic cylinder Ausgabe 04.2007
EKZ 20/200
EKZ 40/200
EKZ 65/200

Änderungen vorbehalten • subject to revision

LUKAS Hydraulik GmbH

A Unit of IDEX Corporation
Weinstraße 39, D-91058 Erlangen
Postfach 2560, D-91013 Erlangen • Germany
Telefon +49 (0) 91 31/6 98-0 • Telefax +49 (0) 91 31/69 83 94 Ergänzung zur Betriebsanleitung 84148/0600-85
E-mail: lukas.info@idexcorp.com Supplement to operating instructions 84148/0600-85

Ergänzung_EKZ_Sonderzyl_BA_DRUCK_841480734_0407.p65 © Copyright 2007 LUKAS Hydraulik GmbH

1 Sicherheit / Safety 12 Technische Daten / Technical Data
Zylinder dürfen niemals mit einem ande- Cylinders must never been connected
Typ
ren Zylinder so zusammengeschlossen with an other cylinder in such way, that the EKZ 20/200 EKZ 40/200 EKZ 65/200
werden, dass sich die Ausfahrlängen der extension length of the cylinder pistons type
Zylinderkolben summieren können. (sie- could be sum up. (see figures below!) Artikelnummer
84148/0434 84148/0634 84148/0734
he Abbildungen unten!) ref. no.
Abmessungen eingefahren
(D x H)
[mm] 90 x 400 130 x 435 165 x 406
Dimensions retracted
(dia. x h)
Hubkraft
[kN] 207 443 649
lifting capacity
max. Druck
[Mpa]* 62,5
max. pressure
Hub Kolben
[mm] 200
stroke piston
Ölbedarf
[l] 0,66 1,42 2,08
oil requirement
Masse
[kg] 16 32 51
weight

2 3