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HAWE Hydraulik HLU LE-X (M) Series Assembly Instructions Manual

Hydraulic locking unit (hlu)
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Hydraulic locking unit (HLU)
series HLU LE-X (M)
Assembly instructions
Hydraulic locking unit (HLU) for personal restraint systems.
(Translation of the original instructions)
B 6052-21
06-2024   -2.0 en

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Summary of Contents for HAWE Hydraulik HLU LE-X (M) Series

  • Page 1 Hydraulic locking unit (HLU) series HLU LE-X (M) Assembly instructions Hydraulic locking unit (HLU) for personal restraint systems. (Translation of the original instructions) B 6052-21 06-2024   -2.0 en...
  • Page 2 HAWE Hydraulik respects these legal provisions in all cases. HAWE Hydraulik cannot provide individual guarantees that the stated circuits or procedures (including in part) are not subject to the intellectual property rights of third parties.

  • Page 3: Table Of Contents

    Switching on and off............................30 Temporary shutdown............................31 Response in emergency............................. 32 7.3.1 Opening with power supply connected........................ 32 7.3.2 Opening with power supply disconnected......................32 7.3.3 Opening under high static load..........................33 HAWE Hydraulik SE B 6052-21 - 06-2024 - 2.0 en  3/70...
  • Page 4 Function daily low-pressure test......................... 61 Disassembly and disposal..........................62 Troubleshooting..............................64 Annex................................66 11.1 Technical data..............................66 11.1.1 Operating conditions............................66 11.1.2 Weights and measures............................67 11.2 Shipping data..............................68 11.3 System - parts list............................69 4/70 B 6052-21 - 06-2024 - 2.0 en  HAWE Hydraulik SE...

  • Page 5: About These Instructions

    The manual provides relevant information for the machine manufacturer and machine operator as well as for training courses. To request further information about the product, contact HAWE Micro Fluid GmbH. HAWE Hydraulik SE B 6052-21 - 06-2024 - 2.0 en  5/70...

  • Page 6: Safety Instructions And Symbols

    Dragging hazard from moving parts Harmful substances Tripping and falling hazard Fire accelerants Falling loads Burn hazard Crushing hazard Electrical voltage Suspended loads No access to persons with pacemakers and defibrillators 6/70 B 6052-21 - 06-2024 - 2.0 en  HAWE Hydraulik SE...
  • Page 7 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. HAWE Hydraulik SE B 6052-21 - 06-2024 - 2.0 en  7/70...

  • Page 8: Applicable Documents

    Information: HAWE load case denition The documents listed here are available via the HAWE customer portal. Register at: https://customerportal.hawe.com/. If you have any questions regarding use, contact your HAWE Sales Manager. 8/70 B 6052-21 - 06-2024 - 2.0 en  HAWE Hydraulik SE...

  • Page 9: For Your Safety

    Do not convert the product or modify it in any way. ■ Do not paint over elastic sealing parts, bearings of moving parts and hose lines. ■ Do not use this product in potentially explosive atmospheres. ■ HAWE Hydraulik SE B 6052-21 - 06-2024 - 2.0 en  9/70...

  • Page 10: Residual Risks

    Only use qualied personnel. Due to their training and experience, qualied 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. 10/70 B 6052-21 - 06-2024 - 2.0 en  HAWE Hydraulik SE...

  • Page 11: Personal Protective Equipment

    In the instructions, safety instructions with mandatory symbols indicate the wearing of special protective equipment for special activities. The supply of PPE, and instruction in its proper use, is carried out by the operator. HAWE Hydraulik SE B 6052-21 - 06-2024 - 2.0 en  11/70...

  • Page 12: About This Product

    The operating principle of the four standard versions type EX, type RE, type DL (EX), and type DL (RE) is described below. To protect them from environmental effects, the emergency override buttons feature rubber caps. 12/70 B 6052-21 - 06-2024 - 2.0 en  HAWE Hydraulik SE...
  • Page 13 Rod end, bar side, with internal thread V1 2/2-way directional seated valve with Connection block electromagnetically releasing check valve Piston type accumulator Check valves with sealing caps Double-acting cylinder HAWE Hydraulik SE B 6052-21 - 06-2024 - 2.0 en  13/70...

  • Page 14: Functions

    Energising the valve V1 when the ride is running can cause the restraint system to open and cause the death of passengers. Valve V1 must remain deenergized during operation. ■ Please note the switching logic on page (20). ■ 14/70 B 6052-21 - 06-2024 - 2.0 en  HAWE Hydraulik SE...

  • Page 15: Type Ex: Blocking Against Extension

    An additional system (such as a gas spring or leg spring) is therefore required to drive the opening motion and keep the restraint system (such as the bar) open. HAWE Hydraulik SE B 6052-21 - 06-2024 - 2.0 en  15/70...

  • Page 16: Type Dl (Ex): Blocking Against Extension With Comfort Lock

    The hydraulic locking unit acts as a bar drive. The piston rod (9) is extended by extension force as soon Secondary function: as V1 (5) is energised, which opens it. Hydraulic pressure is relieved and the bar of the restraint system Opening the restraint system opens actively. 16/70 B 6052-21 - 06-2024 - 2.0 en  HAWE Hydraulik SE...

  • Page 17: Type Dl (Re): Blocking Against Retraction With Comfort Lock

    An additional system (such as a gas spring or leg spring) is therefore required to drive the opening motion and keep the restraint system open. HAWE Hydraulik SE B 6052-21 - 06-2024 - 2.0 en  17/70...

  • Page 18: Instructions For The Ride Manufacturer

    The control system must prevent the valve V1 (5) from being energised and opening during ride ■ operation. Please note the switching logic on page (20). ■ – V2 with type DL (RE and EX) is only intended for comfort locking. 18/70 B 6052-21 - 06-2024 - 2.0 en  HAWE Hydraulik SE...
  • Page 19 2/2-way directional valve (= emergency actuation). The accessories listed below are listed on the technical data sheet (see "D 6052-21/-31", page Type EX/RE Type DL (EX and RE) Remote unlocking set HAWE Hydraulik SE B 6052-21 - 06-2024 - 2.0 en  19/70...
  • Page 20 Extend piston rod, piston rod movable in both directions Opening the restraint system Restraint system locked - for ride - for entry and exit assist when using the comfort function *for commissioning and service 20/70 B 6052-21 - 06-2024 - 2.0 en  HAWE Hydraulik SE...

  • Page 21: Markings

    The data matrix code is located on the side of the cylinder. The following information is encrypted in the (2) Data matrix code data matrix code: Item number ■ Order number ■ Serial number ■ Date of production ■ Pressure P2 in bar ■ HAWE Hydraulik SE B 6052-21 - 06-2024 - 2.0 en  21/70...

  • Page 22: Transport And Storage

    ■ Not included Aid for assembling the rod ends on the base side ■ Tool to actuate the emergency release ■ Fastening pins and bushings ■ Electrical cables ■ 22/70 B 6052-21 - 06-2024 - 2.0 en  HAWE Hydraulik SE...

  • Page 23: Storage

    Protect from sunlight (UV radiation) and corrosion (such as very salty water). ■ Protect from mechanical damage and damp. ■ Do not store near ignition and heat sources. ■ Note all additional specifications by the ride manufacturer. ■ HAWE Hydraulik SE B 6052-21 - 06-2024 - 2.0 en  23/70...

  • Page 24: Assembly And Installation

    Use suitable aids when lling or bleeding. Check all connecting elements that convey oil for leaks before switching on the motor in the parent system. Wipe up leaked hydraulic uid with suitable aids. 24/70 B 6052-21 - 06-2024 - 2.0 en  HAWE Hydraulik SE...

  • Page 25: Set-Up - Positioning - Attachment

    Property damage from incorrectly installed hydraulic system Assembly by trained specialists only. Ensure all labels and markings of the hydraulic system are easily visible and legible after assembly. Check installation space/connection points for damage. HAWE Hydraulik SE B 6052-21 - 06-2024 - 2.0 en  25/70...
  • Page 26 6. Check the tilt angle setting in the following operating states: Restraint system open Restraint system closed Restraint system in mid-way position 7. Fasten the locking unit to the restraint system via the ball joint (1) using pins (2). 26/70 B 6052-21 - 06-2024 - 2.0 en  HAWE Hydraulik SE...

  • Page 27: Electrical Connection

    Use only cables designed for the specic application type (xed, exible or highly exible; outdoor). Follow the cable manufacturer's instructions for selecting the cable type. Include all metal components of the ride in the equipotential bonding plan. HAWE Hydraulik SE B 6052-21 - 06-2024 - 2.0 en  27/70...
  • Page 28 3. Check whether the HLU has any more solenoid valves that require connecting and connect them as instructed in step 2. 4. Check electrical connection after one week of operation. 28/70 B 6052-21 - 06-2024 - 2.0 en  HAWE Hydraulik SE...

  • Page 29: Start-Up

    ("Instructions for the ride manufacturer", page 18). 7. Check the locking and opening function ("Functional test", page 58 onwards) 8. Check bolt connections after one week of operation at the latest. HAWE Hydraulik SE B 6052-21 - 06-2024 - 2.0 en  29/70...

  • Page 30: Operation

    1. Check mechanical connections according to the maintenance plan. starting rides 2. Check locking, opening and holding function as well as the drift as per "Functional test", page 58 and maintenance plan. 30/70 B 6052-21 - 06-2024 - 2.0 en  HAWE Hydraulik SE...

  • Page 31: Temporary Shutdown

    1. Make sure the piston rod is in the correct position. 2. Switch off the hydraulic locking unit in the ride control system. 3. Secure the unit against use by unauthorized persons. 4. Ensure correct storage, page HAWE Hydraulik SE B 6052-21 - 06-2024 - 2.0 en  31/70...

  • Page 32: Response In Emergency

    1. Make sure that all ride passengers are secured against falling before unlocking. 2. Make sure there is no one within the opening radius of the restraint bar. 3. Open the locking unit: 32/70 B 6052-21 - 06-2024 - 2.0 en  HAWE Hydraulik SE...

  • Page 33: Opening Under High Static Load

    3. Make sure that all ride passengers can disembark safely. 4. Check locking, opening and holding function according to chapters "Functional test", page 58 sqq. 5. If the restraint system does not open, proceed with action 2. HAWE Hydraulik SE B 6052-21 - 06-2024 - 2.0 en  33/70...
  • Page 34 Check all connecting elements that convey oil for leaks before switching on the motor in the parent system. Wipe up leaked hydraulic uid with suitable aids. Aids, tools, materials M8 hex key ■ M10 hex key ■ 34/70 B 6052-21 - 06-2024 - 2.0 en  HAWE Hydraulik SE...
  • Page 35 5. Replace the hydraulic locking unit. Get in touch with HAWE Micro Fluid GmbH. 6. Dispose of hydraulic uid, the hydraulic uid container and any cleaning cloths contaminated with hydraulic uid in the correct manner. HAWE Hydraulik SE B 6052-21 - 06-2024 - 2.0 en  35/70...

  • Page 36: Maintenance

    Depressurize the hydraulic system including the pressure tank. Secure the hydraulic system against unintentional restart. Check components for correct assembly before pressure is applied. Observe maximum pressure load for ttings and lines. 36/70 B 6052-21 - 06-2024 - 2.0 en  HAWE Hydraulik SE...
  • Page 37 Use suitable aids when lling or bleeding. Check all connecting elements that convey oil for leaks before switching on the motor in the parent system. Wipe up leaked hydraulic uid with suitable aids. HAWE Hydraulik SE B 6052-21 - 06-2024 - 2.0 en  37/70...

  • Page 38: Maintenance Plan

    Functional check 'holding and weekly drifting' Load distribution on the locking systems Note the effects of the mutual check on the load distribution of the locking units, see "Functional test", page 38/70 B 6052-21 - 06-2024 - 2.0 en  HAWE Hydraulik SE...

  • Page 39: Cleaning And Visual Inspection For Damage

    (Art. # 616715) Degreaser to clean the pivot mount threads LOCTITE 7063; Dupont Prepclean 3608S Other Threadlocking adhesive LOCTITE 243 Threadlocker Standard commercial products Hydraulic uid AVIA Fluid RSL 22 HAWE Hydraulik SE B 6052-21 - 06-2024 - 2.0 en  39/70...

  • Page 40: Locking Unit

    4. Clean the area around the emergency override button with brake cleaner. Stubborn stains can be removed with a cloth soaked in universal thinner. 5. After waiting about two minutes for the cleaner to act, press the emergency override button again ve times. 40/70 B 6052-21 - 06-2024 - 2.0 en  HAWE Hydraulik SE...

  • Page 41: Piston Rod

    2. If there is any corrosion, use the care products listed below to protect the locking unit. 3. The locking unit must be replaced if damaged. Get in touch with HAWE Micro Fluid GmbH. HAWE Hydraulik SE B 6052-21 - 06-2024 - 2.0 en ...

  • Page 42: Check Valves With Cover

    2. In the event of corrosion, use listed care agents to protect the hydraulic locking unit. 3. In the event of damage or leakage of hydraulic uid on one of the covers, the hydraulic locking unit must be replaced. Contact HAWE Micro Fluid GmbH. 42/70 B 6052-21 - 06-2024 - 2.0 en  HAWE Hydraulik SE...

  • Page 43: Mechanism

    4. Trip emergency override and check whether the piston rod extends/retracts. If the piston rod fails to move, work through the troubleshooting catalog. If it works, recommission hydraulic locking unit in the system, see "Start-up", page HAWE Hydraulik SE B 6052-21 - 06-2024 - 2.0 en  43/70...

  • Page 44: Check Rod End Bolt Connection

    4. If the paint marking is damaged or rod ends/nuts should become loosened: immediately shut down hydraulic locking unit. Then perform the steps mentioned in chapter ("Rod-side rod end", page or chapter ("Base-side rod end", page 50). 44/70 B 6052-21 - 06-2024 - 2.0 en  HAWE Hydraulik SE...

  • Page 45: Check Pivot Bearing Clearance

    3. Replace the rod end (3) if gap between the ball joint (1) and the bearing case (2) exceeds 0.2 mm. ✓ HAWE-approved pivot mount used. ✓ Rod end replaced in accordance with "Replace pivot mounts", page HAWE Hydraulik SE B 6052-21 - 06-2024 - 2.0 en  45/70...

  • Page 46: Replace Pivot Mounts

    2. Remove the hydraulic locking unit from the ride. 3. Clamp the hydraulic locking unit in a vise so that the rod end is easily accessible. Use jaw caps. Be careful not to damage the connection block. 46/70 B 6052-21 - 06-2024 - 2.0 en  HAWE Hydraulik SE...
  • Page 47 6. Heat the marked area (1) of the rod end to 200°C with a hot air gun (2). The threadlocker loses its adhesive properties. 7. Open the heated rod end using the wrenches. Wrench size 22 (1); wrench size 24 (2) HAWE Hydraulik SE B 6052-21 - 06-2024 - 2.0 en  47/70...
  • Page 48 10. Apply threadlocking adhesive to the new rod end’s internal thread. Spread a visible amount of the adhesive onto the rst thread turns. Fill at least one turn of the internal thread with adhesive. 48/70 B 6052-21 - 06-2024 - 2.0 en  HAWE Hydraulik SE...
  • Page 49 13. After tightening to torque, mark the nut and rod eye with threadlocker paint. 14. After 24 hours of curing time, the hydraulic locking unit can be used again and recommissioned in the system, see "Start- up", page HAWE Hydraulik SE B 6052-21 - 06-2024 - 2.0 en  49/70...

  • Page 50: Base-Side Rod End

    3. Clamp the hydraulic locking unit in a vise so that the rod end is easily accessible. Use jaw caps. Be careful not to damage the connection block. 4. Open the rod end using a size 24 open-end wrench. 50/70 B 6052-21 - 06-2024 - 2.0 en  HAWE Hydraulik SE...
  • Page 51 7. Blow off the cylinder base’s thread with compressed air. 8. The gradation in the nut thread faces toward the piston rod on the rod-side rod end toward the base on the base-side rod end HAWE Hydraulik SE B 6052-21 - 06-2024 - 2.0 en  51/70...
  • Page 52 11. Apply threadlocking adhesive to the rod end’s thread. Spread on an easily visible amount of adhesive 3 mm from the base. Fill at least one turn of the thread with adhesive. 52/70 B 6052-21 - 06-2024 - 2.0 en  HAWE Hydraulik SE...

  • Page 53: Electrics

    1. Shut down hydraulic locking unit and secure it against inadvertent restarting. 2. Remove component coverings. 3. Disconnect the cables from the solenoid valve coils. 4. Measure the resistances on the coils one after the other with the multimeter. HAWE Hydraulik SE B 6052-21 - 06-2024 - 2.0 en  53/70...
  • Page 54 9. Place the assembly aid (1) on the solenoid housing (2) and carefully x the solenoid housing in place by lightly tapping the assembly aid with the plastic hammer. 54/70 B 6052-21 - 06-2024 - 2.0 en  HAWE Hydraulik SE...

  • Page 55: Filling The Hydraulic Accumulator

    ■ Preparation 1. Switch off the hydraulic locking unit and secure it from being unintentionally switched on again. 2. Remove any component coverings preventing checks. 3. Extend piston rod: HAWE Hydraulik SE B 6052-21 - 06-2024 - 2.0 en  55/70...
  • Page 56 4. Set the nitrogen controller to the pressure P1 of your hydraulic locking unit according to the technical data sheet. 5. Monitor the pressure on the pressure gauge (3) of the nitrogen controller. 56/70 B 6052-21 - 06-2024 - 2.0 en  HAWE Hydraulik SE...
  • Page 57 Make sure the O-ring is present on the lling device. Lay the O-ring into the guide groove (1). Screw the union nut (2) of the lling device onto the adapter by hand. HAWE Hydraulik SE B 6052-21 - 06-2024 - 2.0 en  57/70...

  • Page 58: Functional Test

    Note unequal load distribution when planning and calculating the load. 8.6.1 Locking function Daily Interval Aids, tools, materials Distance measuring systems (e.g. caliper gage, etc.) ■ Tool to remove any component covering ■ 58/70 B 6052-21 - 06-2024 - 2.0 en  HAWE Hydraulik SE...

  • Page 59: Opening Function

    Never perform any maintenance on the hydraulic accumulator yourself. Daily Interval Aids, tools, materials None ■ Do not carry out checks in an extreme temperature range (see technical data sheet). HAWE Hydraulik SE B 6052-21 - 06-2024 - 2.0 en  59/70...

  • Page 60: Hold And Drift Function

    4. Pay attention to the position of the piston rod before and after applying the load. Remove any component coverings that obstruct checking. Take into account any permissible play in the restraint system mechanism. 60/70 B 6052-21 - 06-2024 - 2.0 en  HAWE Hydraulik SE...

  • Page 61: Function Daily Low-Pressure Test

    At a bar ratio of, for example, 1:6, the bar may open by no more than 90 mm. The displacement of the bar can then be compared to the permitted displacement. HAWE Hydraulik SE B 6052-21 - 06-2024 - 2.0 en ...

  • Page 62: Disassembly And Disposal

    Arrange the access to the hydraulic system in such a way that hot surfaces are not accessible to the user. Wait until the hydraulic system has cooled down before servicing or disassembling. 62/70 B 6052-21 - 06-2024 - 2.0 en  HAWE Hydraulik SE...
  • Page 63 uid according to the regional waste disposal requirements. Dispose of the electronic components at approved collection points or with approved disposal companies according to local regulations. Dispose of metal with approved specialist disposal companies. HAWE Hydraulik SE B 6052-21 - 06-2024 - 2.0 en  63/70...

  • Page 64: Troubleshooting

    Using non-approved aids to heat the hydraulic system will damage seals and cause leaks in the hydraulic system. Never use heaters, gas burners or other similar heating devices to heat the system. Operate the hydraulic locking unit within the permissible operating temperatures. 64/70 B 6052-21 - 06-2024 - 2.0 en  HAWE Hydraulik SE...
  • Page 65 HAWE.) Piston rod can be moved Permanently trapped air in the Hydraulic locking unit must be permanently in locking direction hydraulic locking unit. replaced. Contact HAWE. (permanent loosening). HAWE Hydraulik SE B 6052-21 - 06-2024 - 2.0 en  65/70...

  • Page 66: Annex

    Maximum 10 years or 1 million cycles (depending on which comes rst, starting with the date of delivery). 1 cycle: one extension and retraction of the piston ■ rod. 66/70 B 6052-21 - 06-2024 - 2.0 en  HAWE Hydraulik SE...

  • Page 67: Weights And Measures

    Note the following exceptions: IMDG code (Chapter 2.2 in 2.2.2.5 Class 2.2) IATA/DGR (Section 3 in 3.2.2.4 Division 2.2), exemption in ADR regulations (in 1.1.3.2). Note: The Material Safety Data Sheet (MSDS) is available on request. HAWE Hydraulik SE B 6052-21 - 06-2024 - 2.0 en  67/70...

  • Page 68: Shipping Data

    Air Transport Association Dangerous Goods Regulations (IATA-DGR): A114. Not restricted as per special provision IATA-DGR: A114. Class None Danger label number None Packaging group None Packaging specification None 68/70 B 6052-21 - 06-2024 - 2.0 en  HAWE Hydraulik SE...

  • Page 69: System - Parts List

    11.3 System - parts list Only use genuine HAWE spare parts. For detailed ordering instructions refer to the accompanying external documentation, the technical data sheet. Contact details Headquarters Manufacturer HAWE Hydraulik SE HAWE Micro Fluid GmbH Einsteinring 17 Borsigstraße 11 85605 Aschheim 93092 Barbing...
  • Page 70 Further information HAWE Hydraulik SE is a responsible development partner with application expertise and experience in more than 70 areas of mechanical and plant engineering. The product range includes hydraulic power packs, constant and variable pumps, valves, sensors and accessories.

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