HAWE Hydraulik HICON Bedienungsanleitung
Compact hydraulic power pack type HICON
Original assembly instructions
B 8543
10-2021-1.0en
Operating pressure pmax:
Geometric displacement volume:
Usable volume (tank) Vuse max:
170 bar
0.5 cm3/rev
0.6 l
© by HAWE Hydraulik SE.
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HAWE Hydraulik respects these legal provisions in all cases.
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intellectual property rights of third parties.
Printing date / document generated on: 20.10.2021
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Table of Contents
1 About these instructions.................................................................................................................................. 4
1.1 Target audience................................................................................................................................................. 4
1.2 Safety instructions and symbols...........................................................................................................................4
1.3 Applicable documents......................................................................................................................................... 5
2 For your safety................................................................................................................................................ 7
2.1 Intended use.....................................................................................................................................................7
2.2 Misuse.............................................................................................................................................................. 7
2.3 Residual risks.................................................................................................................................................... 7
2.4 Duties of the operator........................................................................................................................................8
2.5 Qualification of the personnel............................................................................................................................. 8
2.6 Personal protective equipment.............................................................................................................................9
3 About this product......................................................................................................................................... 10
3.1 Structure......................................................................................................................................................... 10
3.2 Functions........................................................................................................................................................ 10
3.3 Control............................................................................................................................................................11
4 Transport and storage..................................................................................................................................... 12
4.1 Scope of delivery............................................................................................................................................. 12
4.2 Checking the delivery........................................................................................................................................12
4.3 Storage........................................................................................................................................................... 13
5 Assembly and installation...............................................................................................................................14
5.1 Mechanical connection......................................................................................................................................14
5.2 Hydraulic connection........................................................................................................................................ 14
5.3 Electrical connection........................................................................................................................................ 15
6 Start-up......................................................................................................................................................... 18
6.1 Switching the hydraulic system on/off................................................................................................................ 18
7 Maintenance...................................................................................................................................................19
7.1 Maintenance plan............................................................................................................................................. 19
7.2 Service............................................................................................................................................................19
7.2.1 Vent the hydraulic system................................................................................................................................. 19
7.2.2 Checking the hydraulic uid level.......................................................................................................................20
7.2.3 Replacing the hydraulic uid............................................................................................................................. 20
8 Disassembly and disposal................................................................................................................................22
9 Troubleshooting..............................................................................................................................................23
10 Appendix........................................................................................................................................................24
10.1 Technical data..................................................................................................................................................24
10.1.1 Weight............................................................................................................................................................ 24
10.1.2 General data....................................................................................................................................................24
10.1.2.1 Tank size.........................................................................................................................................................25
10.1.3 Electrical data..................................................................................................................................................25
10.2 Circuit diagram................................................................................................................................................ 26
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1About these instructions
This manual is part of the product and describes the safe and proper use in all operating phases.
All photos and drawings in this manual show an available product variant. For precise details concerning
the variant you have purchased, please refer to the type plate attached to the product.
Read instructions before use.
Make the manual accessible to operating and maintenance personnel at all times.
Keep this manual for the lifetime of the product.
Only pass on the product to third parties together with this manual.
1.1 Target audience
The target audience of this manual is trained and qualied personnel who are familiar with the installa-
tion, operation and maintenance of machines.
The manual provides relevant information for the machine manufacturer and machine operator as well as
for training courses.
1.2 Safety instructions and symbols
Safety indication In these instructions, the following warning and safety notes are used:
Symbol Meaning
DANGER
Draws your attention to a hazardous situation that can lead directly to serious injury
or death if not avoided.
WARNING
Draws your attention to a hazardous situation that can indirectly lead to serious
injury or death if not avoided.
CAUTION
Draws your attention to a hazardous situation that can indirectly lead to light to
moderate injury if not avoided.
Notice to prevent environmental and material damage.
Information to ensure the correct use of the product.
Safety symbols General safety symbol
Draws your attention to additional safety information.
Slipping hazard Dragging hazard from moving parts
Harmful substances Tripping and falling hazard
Fire accelerants Falling loads
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Burn hazard Crushing hazard
Electrical voltage Suspended loads
No access to persons with pacemakers
and defibrillators
Mandatory signs Protective equipment
Safety boots
Wear appropriate safety boots to protect your feet against mechanical hazards
Work gloves
Wear suitable work gloves to protect your hands against chemical and mechanical
hazards.
Safety goggles
Wear safety goggles to protect your eyes against chemical and mechanical hazards.
Protective clothing
►Wear tted clothing without protruding parts.
►Follow the safety data sheet of the hydraulic uid.
1.3 Applicable documents
Standard Designation
2006/42/EC Directive 2006/42/EC of the European Parliament and of the Council of
17 May 2006 on machinery, and amending Directive 95/16/EC
2014/30/EU Directive 2014/30/EU of the European Parliament and of the Council
of 26 February 2014 on the harmonisation of the laws of the Member
States relating to electromagnetic compatibility
2011/65/EU, RoHS Directive 2011/65/EU of the European Parliament and of the Council
of 8 June 2011 on the restriction of the use of certain hazardous
substances in electrical and electronic equipment
Regulation (EC) No 1907/2006 Regulation (EC) No 1907/2006 of the European Parliament and of the
Council of 18 December 2006 concerning the Registration, Evaluation,
Authorisation and Restriction of Chemicals (REACH), establish-
ing a European Chemicals Agency, amending Directive 1999/45/EC
and repealing Council Regulation (EEC) No 793/93 and Commission
Regulation (EC) No 1488/94 as well as Council Directive 76/769/EEC
and Commission Directives 91/155/EEC, 93/67/EEC, 93/105/EEC and
2000/21/EC
ISO 4406 Hydraulic uid power. Fluids. Method for coding the level of contamina-
tion by solid particles
IEC 60529 Protection classes provided by housings (IP code) (IEC 60529:1989 +
A1:1999 + A2:2013)
DIN EN ISO 12100 Safety of machinery - General principles for design - Risk assessment
and risk reduction
EN 626-1:1994+A1:2008 Safety of machinery — Reduction of risks to health from hazardous
substances emitted by machinery — Part 1: Principles and specifica-
tions for machinery manufacturers
DIN EN 894-3 Safety of machinery - Ergonomics requirements for the design of
displays and control actuators - Part 3: Control actuators
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Standard Designation
DIN EN 894-4 Safety of machinery - Ergonomics requirements for the design of
displays and control actuators - Part 4: Location and arrangement of
displays and control actuators
EN 953:1997+A1:2009 Safety of machinery — Guards — General requirements for the design
and construction of xed and movable guards
DIN EN 1005-2 Safety of machinery - Human physical performance - Part 2: Manual
handling of machinery and component parts of machinery
DIN EN 1005-4 Safety of machinery - Human physical performance - Part 4: Evaluation
of working postures and movements in relation to machinery
EN 1037:1995+A1:2008 Safety of machinery — Prevention of unexpected start-up
DIN EN ISO 4413 Hydraulic uid power - General rules and safety requirements for
systems and their components
EN 13478:2001+A1:2008 Safety of machinery — Fire prevention and protection
DIN EN ISO 13732-1 Ergonomics of the thermal environment - Methods for the assessment
of human responses to contact with surfaces - Part 1: Hot surfaces
DIN EN ISO 13849-1 Safety of machinery - Safety-related parts of control systems - Part 1:
General principles for design
DIN EN ISO 13849-2 Safety of machinery - Safety-related parts of control systems - Part 2:
Validation
DIN EN ISO 19353 Safety of machinery - Fire prevention and re protection
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2For your safety
The product is built according to the state of the art and recognized safety regulations.
Nevertheless, there is a risk of personal injury and damage to property if this chapter and the safety
instructions in this manual are not observed.
2.1 Intended use
■The product is a technical work tool and intended for commercial and industrial use only.
■The product may only be operated in accordance with the technical data, operating conditions and
performance limits specied in this manual.
■Only use original accessories and original spare parts approved by the manufacturer.
■The product may be used to control single and double-acting consumers. The size of the consumers is
limited by the minimum and maximum ll volume of the tank.
Partly completed machinery
The product is a partly completed machine according to the EC Machinery Directive 2006/42/EC and
is intended exclusively for installation in a machine or system. The product is controlled via the
manufacturer's machine / plant control.
►Comply with the manufacturer’s operating instructions.
2.2 Misuse
■Use in other operating modes than specied in the intended use
■Using the product beyond the specied performance limits
■Do not use the product in potentially explosive areas.
■Do not paint over seals and hose lines.
2.3 Residual risks
When handling hydraulic uid, comply with the safety data sheet of the manufacturer of the
hydraulic uid.
DANGER
Risk to life due to explosive combustion
Hydraulic uid and its associated mists and vapours are oxidizing. Contact with ignition sources will
lead to explosive combustion. Risk of serious injury or death.
►Avoid re and open light and do not smoke anywhere near the product.
►Immediately dispose of any ammable materials moistened with hydraulic uid as hazardous waste.
►Do not use any ammable or corrosive cleaning agents.
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WARNING
Electrical and magnetic elds
Electrical and magnetic elds impair the functionality of cardiac pacemakers and implanted
defibrillators.
►People with pacemakers or implanted defibrillators must maintain a sufcient distance from
magnets.
►Advise people with pacemakers or implanted defibrillators against approaching magnets.
►Cordon off the area around the drive system and afx suitable warning signs to the barriers.
WARNING
Risk of injury through crushing or cutting
Body parts might get trapped or cut off between the machine frame and hydraulic system in the event of
careless transport, installation and de-installation.
►Never reach between the hydraulic system and the machine frame.
►Ensure that other people cannot enter the danger area.
►Wear gloves and work shoes.
2.4 Duties of the operator
Observe and comply with regulations:
►Do not put the product into operation until the complete machine or system complies with the
country-specic regulations, safety regulations and standards of the application.
►Observe and apply regulations for accident prevention and environmental protection.
Operate product safely:
►Despite safety devices, the product still poses residual risks. Observe the safety instructions in this
manual to reduce health hazards and avoid dangerous situations.
►The operator must ensure that the operating conditions (see general, hydraulic and electrical data)
are within the operating limits of the product.
►Keep all instructions / signs on the product in legible condition and observe them.
Instruct personnel:
►Regularly train the personnel in all points of these instructions and ensure that they are observed.
►Ensure the terms of the industrial safety and operating instructions are observed.
►Only use qualied personnel. Due to their training and experience, the qualied personnel must be
able to recognize risks and avoid possible hazards.
2.5 Qualification of the personnel
The activities described in these instructions require basic knowledge of mechanics, hydraulics and
electrics.
For the transport and handling of heavy loads, additional knowledge in handling hoists and slings is
required.
►The activities may only be carried out by an appropriate specialist or an instructed person under the
supervision of a specialist.
►Activities other than those described in these instructions may only be performed by HAWE or
authorized specialist companies.
►The personnel must have read and understood these instructions.
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Trained personnel Personnel instructed comprehensively, by skilled staff on behalf of the owner, in how to perform its
appointed tasks and in how to use the product safely.
Specialist personnel Due to their technical training, knowledge and experience, specialists are able to assess and carry out the
assigned work and can independently recognize possible dangers.
Qualied electrician A person with appropriate professional training, knowledge and experience, so that he/she can recognize
and avoid dangers that can be caused by electricity.
Auditor Persons of a technical inspection body who are authorized to perform testing and monitoring tasks for
pressure equipment and electrical systems.
2.6 Personal protective equipment
Personal protective equipment is designed to prevent and reduce hazards.
In the instructions, safety instructions with mandatory symbols indicate the wearing of special
protective equipment for special activities.
Instruction and supply is carried out by the operator.
HAWE Hydraulik SE B 8543 - 10-2021 - 1.0 9/27
3About this product
3.1 Structure
The hydraulic power pack consists of a fully enclosed metal housing containing a tank, a brushless
electric drive, and a gear pump.
The bell housing contains the following:
■hydraulically actuated shuttle valve
■two congurable pressure-limiting valves for safeguarding the system pressure
■two check valves for stop function that can be activated hydraulically
■two overpressure valves for safeguarding maximum pressure in the event of heating
■emergency manual valve
3.2 Functions
Further information see "Circuit diagram".
Motor Check valve 1 Check valve 2
Pressure at connection A ON
(anti-clockwise
rotation direction)
OPEN OPEN
Consumer hydraulically held in
place OFF CLOSED CLOSED
Pressure at connection B ON
(clockwise
rotation direction)
OPEN OPEN
Pressure at connection A Energize the electric drive so there is pressure at connecting line A. The motor and pump deliver a ow
rate. The ow rate ows via the open check valves to consumer port A.
Stop function The electric drive is not energized. The closed check valves ensure the consumer remains hydraulically
held in place.
Pressure at connection B Energize the electric drive so there is pressure at connecting line B. The pump and motor deliver a ow
rate. The ow rate ows via the open check valves to consumer port B.
Manual override The system can be switched to a pressureless state using the emergency manual valve.
CAUTION
Injuries due to cylinders dropping down in the event of a strong pressure drop
In the event of a strong pressure drop, connected cylinders may drop down very quickly, causing damage
or injuries.
►Secure connected cylinders before opening the emergency manual valve.
Opening the emergency manual valve:
1. Unscrew the screw attached to the side of the connection block anti-clockwise by 3 to a maximum of
5 revolutions.
✓Port A is connected to the tank.
✓A line to Port B is opened if turned by a further revolution.
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