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Compact hydraulic power pack type HK 4
Assembly instructions
Oil immersed compact hydraulic power pack with built-in
electric motor (3-phase version) and single-circuit or dual-
circuit pump.
For continuous, short-period and intermittent operation and
continuous run with intermittent load (S1, S2, S3, S6).
(Translation of the original instructions)
B 7600
07-2024 -1.2 en
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Table of Contents
Summary of Contents for Have Hydraulics HK 4
- Page 1 Compact hydraulic power pack type HK 4 Assembly instructions Oil immersed compact hydraulic power pack with built-in electric motor (3-phase version) and single-circuit or dual- circuit pump. For continuous, short-period and intermittent operation and continuous run with intermittent load (S1, S2, S3, S6).
- Page 2 © by HAWE Hydraulik SE. The reproduction and distribution of this document, as well as the use and communication of its contents to others without explicit authorization, is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of patent or utility model applications. Brand names, product names and trademarks are not specifically indicated.
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Page 3: Table Of Contents
Table of Contents About these instructions..........................5 Target audience..............................5 Safety instructions and symbols...........................5 Applicable documents............................7 For your safety..............................8 Intended use..............................8 Residual risks..............................9 Duties of the operator............................9 Qualification of the personnel..........................9 Personal protective equipment........................... 10 About this product............................ - Page 4 Annex................................32 10.1 Technical data..............................32 10.1.1 General data..............................32 10.1.2 Pressure and volumetric ow..........................33 10.1.3 Weight................................34 10.1.4 Characteristic lines............................35 10.1.5 Electrical data..............................36 10.1.6 Motor data..............................37 10.1.6.1 Current consumption characteristic lines......................37 10.1.7 Additional options............................38 10.1.7.1 Level switch..............................38 10.1.7.2 Temperature switch............................
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Page 5: About These Instructions
About 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. - Page 6 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 Burn hazard Crushing hazard Electrical voltage Suspended loads No access to persons with pacemakers and defibrillators Mandatory signs...
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Page 7: Applicable Documents
1.3 Applicable documents Documents D 5488/1 Oil recommendations Data sheet D 7600-4 Features and potential applications of this product B 5488 General operating manual for the assembly, initial operation and maintenance of hydraulic components and systems Declaration of incorporation "Enclosed in appendix" (EU) Declaration of incorporation (UKCA) -
Page 8: For Your Safety
For your safety The product has been built according to the state of the art and the established technical safety rules. Nevertheless, there is a risk of personal injury and material damage if the information in this chapter and the safety instructions set out in these instructions are not complied with. 2.1 Intended use The product is a technical work tool and intended for commercial and industrial use only. -
Page 9: Residual Risks
2.2 Residual risks When handling hydraulic uid, observe the corresponding safety data sheet issued by the hydraulic uid manufacturer. WARNING Risk to life due to explosive combustion Hydraulic uid, and its associated mists and vapors, is a re accelerant. Contact with ignition sources will lead to explosive combustion. -
Page 10: Personal Protective Equipment
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. -
Page 11: About This Product
About this product 3.1 Structure The ready-for-connection compact hydraulic power packs type HK and HKF contain an oil immersed motor. The stator is securely attached to the housing (tank). The compact hydraulic power pack is suitable for hydraulic systems with operating mode S1, S2, S3 or S6. A fan, which effectively dissipates the heat from the hydraulic system, is mounted on the housing. - Page 12 People cannot reach into the hazard zone of the product. ■ People cannot burn themselves on the hot surfaces. After installing the product in the machine, mark ■ any hot surfaces that could pose a danger to people. Protect the hydraulic system against vibrations and integrate the hydraulic power pack into the system ■...
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Page 13: Transport And Storage
Transport and storage Observe the following safety instructions in addition to those listed in the For your safety chapter. CAUTION Personal injury through tipping or falling load The product might tip over or fall during transport. This could lead to hands and feet becoming trapped. Adhere to the symbols on the packaging. -
Page 14: Storage
2. Check that the product is complete according to the bill of material/order coding and check for transport damage. Note any transport damage on the transport documents or on the carrier's delivery note. Take photos of any transport damage and show them to the manufacturer. 3. -
Page 15: Assembly And Installation
Assembly and installation Observe the following safety instructions in addition to those listed in the For your safety chapter. WARNING Risk of injury through crushing or cutting Body parts might get trapped or severed between the machine frame and hydraulic system in the event of careless transport, installation and de-installation. -
Page 16: Hydraulic Connection
■ 8. After a week of operating time at the latest, check the ttings. Mounting hole pattern Type HK 2 HK 3 HK 4 200 (h1 HKF 4 > 0) 5.2 Hydraulic connection WARNING Danger of crushing/malfunction from unexpected startup Body parts may be crushed or severed if the system starts up unexpectedly. - Page 17 NOTICE Damage to valves caused by air bubbles The system to be connected must already be lled with hydraulic uid free of air bubbles before the hydraulic power pack is connected. Air bubbles in the hydraulic uid cause damage to valves. Filling with hydraulic uid 1.
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Page 18: Electrical Connection
5.3 Electrical connection WARNING Risk of fatal injury from electric shock Touching live components directly or indirectly causes injury or death. Electrical and electronic components must only be replaced and connected by trained specialist personnel. Obey all applicable electrical safety rules. Only connect electric lines to the hydraulic system while the system is de-energized. -
Page 19: Connecting The Motor
NOTICE Ensuring electromagnetic compatibility (EMC) If the product is connected to a system , it will not produce any impermissible interference Tests validating immunity to interference for demonstrating compliance with the standard EN 60034-1 para. 12.1.2.1 or VDE 0530-1 are not required. Any transient electromagnetic elds generated when switching the motor on or off that may cause interference can be attenuated using a suppressor Suppressor coding E, PE... - Page 20 Set the motor protection circuit to the maximum current, but no higher than the motor’s nominal current. The motor protection extends to a possible mechanical motor blockage. ■ The pressure varies depending on the pump type and size. See 7600-4. S6 operation (p <...
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Page 21: Start-Up
Start-up WARNING Risk of injury from pressurised components. Risk of serious injury or death. When releasing lines and components on pressurised systems, hydraulic uid may escape at high pressure and enter the body via your skin or eyes. Check all components for correct installation before charging the hydraulic system to operating pressure. -
Page 22: Switching The Hydraulic System On/Off
The hydraulic power pack has soundproofing in the higher-level machine. The hydraulic power pack has been integrated in the higher-level system such that vibrations are not transferred to personnel. 1. The electric motor must be protected with a motor protection circuit, Setting the motor protection circuit see Chapter 5.3.1, "Connecting the motor", page 19... -
Page 23: Maintenance
Maintenance Maintenance measures consist of inspection, service and repair. Maintenance measures are described here. Maintenance work must only be carried out by qualied personnel. Tasks not described in this chapter may only be carried out by HAWE Service. If faults or damage occur, switch off the hydraulic system immediately. Observe the information in the supplier documentation. -
Page 24: Maintenance Plan
7.1 Maintenance plan Failure of hydraulic systems Hydraulic system failures are often caused by an incorrect choice of hydraulic uid or excessive solid contamination in the hydraulic uid. High solid contamination is due to lack of maintenance of the hydraulic system. Select hydraulic uid according to specifications. -
Page 25: Visual Check: Hydraulics
7.2.1 Visual check: Hydraulics NOTICE When handling hydraulic hoses, observe the applicable standards, regulations and rules: ISO 17165-2: Recommended practices for hydraulic hose lines. ■ DGUV Rule 113-020 (German regulations for occupational insurance schemes) hydraulic hose lines – ■ “Rules for safe use”. DGUV information sheet no. -
Page 26: Checking The Hydraulic Uid Level
3. Then move the consumer(s) back and forth several times to remove any trapped air and to assure movement is smooth. 4. If the consumers have venting points, loosen the locking elements and tighten them only when the escaping hydraulic uid is free of bubbles. Catch the escaping hydraulic uid. 5. -
Page 27: Checking The Motor
The system is pressureless. The system has cooled down. The work environment is clean. ✓ Work can be performed on the hydraulic system. Directional valve is in switching position in which the depressurised circulation of the pump is possible 1. Place a suitable receptacle under the hydraulic power pack. 2. -
Page 28: Replacing The Pressure Lter/Return Line Lter
7.2.7 Replacing the pressure lter/return line lter Checking 1. Check the hydraulic ports for visible signs of damage. 2. If external leakages are found, shut down and repair the system. Replacing Observe the document B 5488 “General operating instructions for assembly, commissioning, and maintenance.”... -
Page 29: Checking Accumulator Systems
7.2.9 Checking accumulator systems NOTICE Damage to accumulator systems Accumulators should be lled using designated equipment in accordance with the pressure specifications of the hydraulic schematic. The relevant operating instructions must be followed. Checking and lling Observe the document B 5488 “General operating instructions for assembly, commissioning, and maintenance.”... -
Page 30: Disassembly And Disposal
Disassembly and disposal Observe the following safety instructions in addition to those listed in the For your safety chapter. WARNING Sudden movement of the hydraulic drives when disassembled incorrectly Risk of serious injury or death Depressurise the hydraulic system. Perform safety measures in preparation for maintenance. CAUTION Burn hazard from hot surfaces and hydraulic uid A burn hazard results from directly or indirectly coming into contact with hot hydraulic uid and hot... -
Page 31: Troubleshooting
Troubleshooting The following table lists possible faults and measures to eliminate these. Contact the manufacturer in case of faults that cannot be remedied by following the descriptions here. Fault Possible cause Check Remedy Consumer does not move Power supply disrupted Measure the voltage. -
Page 32: Annex
Annex Further documentation, such as technical data sheets, circuit diagrams, bills of material, installa- tion drawings, as well as optional documents (e.g. works test certificate) form part of the technical documents and are delivered separately upon request. The attached product information from third-party manufacturers is not necessarily the most current version. -
Page 33: Pressure And Volumetric Ow
Temperatures Environment: approx. -40 to +60 °C, hydraulic uid: -25 to +80 °C, pay attention to the viscosity range. Environment: approx. -25 to +60 °C, hydraulic uid: -25 ... +80°C, ensure the correct viscosity range. Start temperature: down to -40 °C is permissible (take account of the start viscosi- ties!), as long as the steady-state temperature is at least 20 K higher during subsequent operation. -
Page 34: Weight
(without oil lling) power pack Type H - Z HH - Z Z - Z H - H HH - H HK 4.5, HKF 4.5 29.8 kg 26.3 kg 27.6 kg 29.3 kg HK 4.9, HKF 4.9 34.4 kg 30.9 kg 33.9 kg... -
Page 35: Characteristic Lines
10.1.4 Characteristic lines HAWE Hydraulik SE B 7600 - 07-2024 - 1.2 en 35/45... -
Page 36: Electrical Data
10.1.5 Electrical data The drive motor forms an enclosed, non-separable unit with the tank and pump. Data applies to radial piston pumps and gear pumps. Connection Version with HARTING connector: housing with female insert HARTING HAN 1 CE or comparable, cable cross-section 1.5 mm Version with terminal box: cable tting M20x1.5 –... -
Page 37: Motor Data
10.1.6 Motor data 10.1.6.1 Current consumption characteristic lines HAWE Hydraulik SE B 7600 - 07-2024 - 1.2 en 37/45... -
Page 38: Additional Options
10.1.7 Additional options 10.1.7.1 Level switch Coding A, D, S Max. switching AC/DC: 3010 VA capacity NOTICE The specied max. switching capacity must not be exceeded by the combination of switching voltage and switching current. Max. current AC/DC: 0.5 A (cos 9 = 0.95) Max. -
Page 39: Temperature Switch
10.1.7.2 Temperature switch Technical data: Bimetallic-element switch ■ Coding T, T60, T55, T65, T55T65, W, W60 Signal indication 80°C * 5K (coding T, W) ■ 60°C * 5K (coding T60, W60) ■ 55°C or 65°C (coding T55, T65) ■ Max. switching AC/DC: 10 VA capacity Nominal current... - Page 40 40/45 B 7600 - 07-2024 - 1.2 en HAWE Hydraulik SE...
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Page 41: Documents
10.2 Documents 10.2.1 Declaration of incorporation HAWE Hydraulik SE B 7600 - 07-2024 - 1.2 en 41/45... -
Page 42: Einbauerklärung_Hk(F)3(4)_Ukca_Signed_2024-07-24
Declaration of incorporation of partly completed machinery – original according to Supply of Machinery (Safety) Regulations 2008, 2008 No. 1597, annex II B Einbauerklärung einer unvollständigen Maschine - Original nach Supply of Machinery (Safety) Regulations 2008, 2008 No. 1597, Anhang II B Manufacturer: HAWE Hydraulik SE Hersteller:... -
Page 43: Declaration Of Conformity
10.2.3 Declaration of conformity HAWE Hydraulik SE B 7600 - 07-2024 - 1.2 en 43/45... - Page 44 44/45 B 7600 - 07-2024 - 1.2 en HAWE Hydraulik SE...
- Page 45 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. Electronic components, ideally matched to hydraulic components, complement modular systems and facilitate control, signal evaluation and error detection.
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