Heavy-Duty Shock Absorbers
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- Baldric Brown
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1 HL Heavy-Duty hock bsorbers HL FETURE pplications ranes, wing bridges Energy absorption Max Nm Deceleration characteristics ustomer spec. oating Housing zinc plated / painted Extended Life ycle Piston rod: hard chrome-plated pecial seals + oils Temperatur range -º - +80º / option: -40º º RoH - conform Directive 02/95/E 102
2 HL 40 RFV ø ø40 ø128 ø60 ø55 ø100 Energy/ max. ounterforce Piston return force max. angular tolerance Weight Nm (in lbs) N min. N (min. lbs) max. N (max. lbs) RFV kg HL HL , HL , HL , HL , HL , HL , HL ,
3 HL 63 RFH FH ø18 ø13 ø60 ø ø90 ø75 ø RFV FV ø90 F 60 ø D E Protection ellow 2 Rear flange recoended only for shock absorbers up to stroke! Energy/ max. ounterforce Piston return force max. angular tolerance Weight Weight D E 2* Nm N min. N (min. lbs) max. N (max. lbs) FV / FH kg F kg HL-63-0 HL HL-63-1 HL-63-0 HL-63-2 HL-63- HL-63-3 HL-63- HL-63-0 HL (1.97) 100 (3.94) 1 (5.91) 0 (7.87) 2 (9.84) (11.81) 3 (13.78) 0 (19.69) 600 (23.62) 70 (66381) 0 (132762) 2 (199143) 00 (265524) 370 (331905) (398286) 5 (464667) (531048) 700 (663810) (796572) 1 ( ) 1 ( ) ( ) ( ) 00 (47.99) 00 (47.99) 00 (47.99) 00 (47.99) 00 (47.99) 00 (47.99) 13,5 (29.76) 14 (30.87) 15,5 (34.17) 17 (37.48) 19,5 (42.99) 22 (48.5) 24 (52.91) 27,5 (60.63) 30 (66.14) 3 (71.65) 15,5 (34.17) 17 (37.48) 18,5 (40.79) (44.09) 22 (48.5) (55.12) 27 (59.53) 30,5 (67.24) 33 (72.75) 35,5 (78.27) 329 (12.95) 440 (17.32) 585 (23.03) 7 (28.35) 865 (34.06) 1000 (39.37) 1145 (45.08) 1280 (.39) 1560 (61.42) 1840 (72.44) 229 (9.02) 290 (11.42) 385 (15.16) 470 (18.5) 565 (22.24) 6 (.59) 745 (29.33) 830 (32.68) 1010 (39.76) 1190 (46.85) 261 (10.28) 322 (12.68) 417 (16.42) 2 (19.76) 597 (23.5) 682 (26.85) 777 (30.59) 862 (33.94) 1042 (41.02) 1222 (48.11) 84 (3.31) 134 (5.28) 184 (7.24) 234 (9.21) 284 (11.18) 334 (13.15) 384 (15.12) 434 (17.09) 534 (21.02) 634 (24.96) 335 (13.19) 466 (18.35) 611 (24.06) 746 (29.37) 891 (35.08) 1081 (42.56) 1226 (48.27) 1361 (53.58) 1641 (64.61) 1921 (75.63) * Version with protection bellow: -! 104
4 HL 70 FH ø18 ø ø90 ø FV ø90 Protection ellow 2 Energy/ max. ounterforce Piston return force max. angular tolerance Weight D E 2* Nm (in lbs) N min. N (min. lbs) max. N (max. lbs) FV / FH kg HL-70-0 HL HL-70-1 HL-70-0 (1.97) 100 (3.94) 1 (5.91) 0 (7.87) (888) 000 (177016) 00 (265524) 0 (354032) 00 (562,) 00 (562,) 00 (562,) 00 (562,) 1 ( ) 1 ( ) ( ) ( ) 13,5 (29.76) 14 (30.87) 15,5 (34.17) 17 (37.48) 329 (12.95) 440 (17.32) 585 (23.03) 7 (28.35) 229 (9.02) 290 (11.42) 385 (15.16) 470 (18.5) 261 (10.28) 322 (12.68) 417 (16.42) 2 (19.76) 84 (3.31) 134 (5.28) 184 (7.24) 234 (9.21) 355 (13.98) 466 (18.35) 611 (24.06) 746 (29.37) * Version with protection bellow: -! 105
5 106 Energy/ max. ounterforce Piston return force max. angular tolerance Weight Weight D E Nm (in lbs) N min. N (min. lbs) max. N (max. lbs) FV / FH kg HL-75-0 (1.97) 0 (132762) 0 (78683,15) (44.09) 26 (57.32) 363 (14.29) 283 (11.14) 153 (6.02) 174 (6.85) 239 (9.41) HL (3.94) 00 (265524) 0 (78683,15) 24 (52.91) 30 (66.14) 493 (19.41) 363 (14.29) 213 (8.39) 4 (10) 319 (12.56) HL (5.91) (398286) 0 (78683,15) 29 (63.94) 35 (77.16) 623 (24.53) 443 (17.44) 273 (10.75) 334 (13.15) 399 (15.71) HL (7.87) (531048) 0 (78683,15) 34 (74.96) 40 (88.19) 838 (32.99) 608 (23.94) 359 (14.13) 474 (18.66) 539 (21.22) HL-75- (11.81) (796572) 0 (78683,15) 44 (97.01) (110.23) 1154 (45.43) 824 (32.44) 577 (22.72) 572 (22.52) 637 (.08) HL (10696) 0 (78683,15) 54 (119.05) 60 (132.28) 1468 (57.8) 1038 (40.87) 677 (26.65) 786 (30.94) 851 (33.5) HL (19.69) 100 (11604) 000 (67442,7) 2 60 (132.28) 66 (145.51) 1719 (67.68) 1189 (46.81) 777 (30.59) 938 (36.93) 1002 (39.45) HL (23.62) 00 (13276) 000 (67442,7) 67 (147.71) 73 (160.94) 1974 (77.72) 1344 (52.91) 877 (34.53) 1092 (42.99) 1157 (45.55) HL (27.56) ( ) 00 (562,) 75 (165.35) 81 (178.58) 2269 (89.33) 1539 (60.59) 977 (38.46) 1288 (.71) 1352 (53.23) HL (31.5) (14636) 00 (562,) 84 (185.19) 90 (198.42) 63 (100.91) 1733 (68.23) 1077 (42.4) 1482 (58.35) 1546 (60.87) HL (39.37) ( ) 200 (51706,07) 96 (211.65) 102 (224.88) 3063 (1.59) 33 (80.04) 1277 (.28) 1781 (70.12) 1846 (72.68) HL (47.24) 0000 ( ) 000 (479,89) 112 (246.92) 118 (260.15) 3634 (143.07) 2404 (94.65) 1477 (58.15) 2152 (84.72) 2217 (87.28) Rear flange recoended only for shock absorbers up to stroke! Protection ellow Ø110 Ø110 Ø75 30 Ø130 Ø130 Ø D E 30 Ø Ø18 Ø Ø17,5 HL 75
6 HL 90 Hub ourse orsa arrera ø1 ø107 ø80 Hub ourse orsa arrera ø1 ø26 Hub ourse orsa arrera ø26 Rear flange recoended only for shock absorbers up to stroke! HL-90-2 HL-90- HL-90- Energy/ max. ounterforce Piston return force max. angular tolerance Weight Weight Nm N min. N max. N 2 (9.84) (11.81) (8880) 1000 (10696) ( ) 0000 ( ) 0000 ( ) 0000 ( ) (22480,9) (26977,08) (35969,44) FV kg 58 (127.87) 62 (136.69) 71 (156.53) FH kg 55 (121.26) 59 (130.07) 68 (149.92) 875 (34.45) 1006 (39.61) 1277 (.28) 478 (18.82) 559 (22.01) 730 (28.74) 527 (.75) 577 (22.72) 677 (26.65) 107
7 HL 100 RFH FH ø23 ø23 ø100 ø ø140 ø115 ø RFV FV ø140 F 90 ø D E Protection ellow 2 HL HL HL HL HL HL-100- HL HL-100- HL HL HL * Version with protection bellow: -! Rear flange recoended only for shock absorbers up to stroke! Energy/ max. ounterforce Piston return force (1.97) 100 (3.94) 1 (5.91) 0 (7.87) 2 (9.84) (11.81) 3 (13.78) 4 (17.72) 0 (19.69) 600 (23.62) Nm (in lbs) ( ) ( ) 500 (486794) ( ) 900 (840826) 10 ( ) 1 ( ) 0 ( ) (14636) ( ) 200 (35684) N min. N (min. lbs) max. N (max. lbs) (10341,21) max. angular tolerance Weight Weight D E 2* 108 FV / FH kg 37,5 (82.67) 40 (88.19) 43 (94.8) 49 (108.03) 56 (123.46) 62 (136.69) 67 (147.71) 74 (163.14) 79 (174.17) 85 (187.4) 9 (3.93) 45 (99.21) 47,5 (104.72),5 (111.34) 56,5 (124.56) 63,5 (140) 69,5 (153.22) 74,5 (164.) 8 (179.68) 86,5 (190.7) 9 (3.93) 100 (2.47) 405 (15.94) 5 (19.88) 605 (23.82) 740 (29.13) 875 (34.45) 1010 (39.76) 1145 (45.08) 1280 (.39) 1415 (55.71) 15 (61.02) 18 (71.65) 305 (12.01) 355 (13.98) 405 (15.94) 490 (19.29) 575 (22.64) 660 (.98) 745 (29.33) 830 (32.68) 915 (36.02) 1000 (39.37) 1170 (46.06) 355 (13.98) 405 (15.94) 455 (17.91) 540 (21.26) 6 (24.61) 710 (27.95) 795 (31.3) 880 (34.65) 965 (37.99) 10 (41.34) 12 (48.03) 75 (2.95) 1 (4.92) 175 (6.89) 2 (8.86) 275 (10.83) 3 (12.8) 375 (14.76) 4 (16.73) 475 (18.7) 5 (.67) 6 (24.61) 432 (17.01) 532 (.94) 632 (24.88) 767 (30.2) 902 (35.51) 1092 (42.99) 1227 (48.31) 1362 (53.62) 1497 (58.94) 1632 (64.) 1902 (74.88)
8 Ø1 HL 110 Ø115 FV Ø1 Ø115 Ø26 Ø115 FH Ø1 Ø26 Ø115 Ø26 Protection ellow Ø130 Ø1 2 Ø115 2 Rear flange recoended only for shock absorbers up to stroke! Energy/ max. ounterforce Piston return force max. angular tolerance Weight 2 2 Nm (in lbs) N min. N (min. lbs) max. N (max. lbs) FV / FH kg HL HL-110- HL HL (4.49) 0 (19.69) 600 (23.62) (796572) 2000 ( ) ( ) 3 (29618) (2328.1) ( ) ( ) ( ) 0 (232,81) 0 (49457,98) 0 (62946,52) (75311,02) (1.5) (1.5) (1.5) 45 (99.21) 80 (176.37) 90 (198.42) 97 (213.85) 529 (.83) 1280 (.39) 365 (14.37) 830 (32.68) 15 (61.02) 1000 (39.37) 18 Ø (71.65) (46.06) 235 (9.) 728 (28.66) 828 (32.6) 928 (36.54) 556 (21.89) 1362 (53.62) 1632 (64.) 1902 (74.88) 262 (10.31) 810 (31.89) 910 (35.83) 1010 (39.76) 109
9 HL 160 Ø3 Hub 52 Ø27 RFH Ø0 Ø0 Ø Hub 52 FH 215 Ø0 Ø0 Ø Hub 52 FV 215 Ø0 Ø32 40 Rear flange recoended only for shock absorbers up to stroke! Energy/ max. ounterforce Piston return force max. angular tolerance Weight Nm N min. N max. N FV / FH kg HL HL-160- HL HL (7.87) 600 (23.62) 800 (31.5) 1600 ( ) 32 ( ) ( ) ( ) 9000 ( ) 9000 ( ) 9000 ( ) 9000 ( ) 0 ( ) 0 ( ) 0 ( ) 0 ( ) (36419,06) (72838,12) ( ) ( ) (319.68) 5 (451.96) 265 (584.23) 3 (716.51) 800 (31.5) 1 (55.12) 00 (78.74) 2600 (102.36) 548 (21.57) 948 (37.32) 1348 (53.07) 1748 (68.82) 600 (23.62) 800 (31.5) 1000 (39.37) 110
10 LD / HL urface protection LD / HL FETURE 1) Indoor applications (without humidity) Piston rod: chrome plated, hardened (LD) Piston rod: chrome plated (HL) Housing: zinc plated eal bushing from high strength aluminium 2) Outdoor Piston rod: nickel (30 µm) and hardchrome ( µm) plated Housing and seal bushing painted conforming to DIN IO L leaning agents! efore using cleaning agents please consult Weforma Packaging Wooden boxes; depending on national regulations according to IPM 15 INTRUTION FOR UE ND EMLY LD / HL HL and LD series shock absorbers are delivered ready for installation fter receiving the shock absorbers, check for transport damage. This applies particularly for damage to the chrome finish on the piston rod. efore using, ensure that the part number in the order confirmation and on the shipping documents coincides with the number on the shock absorber. Use the shock absorbers only as specified in the technical data, based on the design. lways observe the following installation instructions: - Ensure that shock absorbers are installed rigidly and vibration-free. - Ensure that the stop surfaces are perpendicular to the stop cap and mounting flange - Ensure that the mass is applied parallel to the damping direction and in the center of the stop cap/piston rod (see angle deviation in our catalog) - The mounting bolts should not be more than 2 smaller than the intended mounting holes. - Ensure that the shock absorbers are never subjected to direct or indirect distortion, because this would prevent the piston rod from moving. - Protect the piston rod against damage - From 800 stroke the shock absorber has to be mounted with foot mounting or with flanges at each side We recoend to use a front flang mounting from stroke. For the LD series is recoended for an easy maintaince to mount the damper so that the filling valve is at the top. Heavy duty shock absorbers versions FVFH (2 flanges) and F (foot mounting): In these versions, the rear flange and the rear foot mounting are not glued in (status: ). The shock absorber must be mounted free of tension. This is possible by twisting the rear flange if necessary. ontrol: the shock absorber can be removed without tools after loosening the fastening screws. For safety reasons we recoend the use of a security chain when the installation height of the LD / HL heavy-duty shock absorber is 2 m or above. The customer decides on the use. In creep gear (maximum shock absorber compression rate 0.5 m/s) the shock absorber should not be compressed more than 70% of its maximum stroke. Operating temperature (standard version): - to max. +80 ; ontinuous operation (standard version): -10 to max. +70 ; Operating temperature (LT version): -32 to max. + ; ontinuous operation (LT version): -32 to max. + ; When used at low temperatures down to -32 we recoend stationary installation; mobile mounting can result in leakage of the shock absorbers due to transfer of vibration! Do not weld shock absorbers or subject to aggressive liquids. If shock absorbers are painted, ensure that the piston rod and the area where the piston rod enters the housing remain paintfree. If it is not possible to maintain the above conditions, obtain written approval from Weforma Dämpfungstechnik GmbH before using. If the piston rod does not extend by itself, the gas bladder can be filled through the pressure valve similar to a passenger car tire. Filling pressure: 6 bars/85 psi, Medium: Nitrogen, compressed air also possible. The filling valve for gas is labelled IR. In the HL series, it is located in the stop cap; in the LD series in the front flange mounting; in older versions it is situated in the base of the housing. The filling screw for oil is located in the front flange mounting in the LD series and in the base section in the HL. The filling screw for oil must not be opened by the customer without consulting Weforma. efore refueling the filling valve needs to point vertically upward, as it can otherwise lead to a loss of oil. fter an accident be sure to check the shock absorber for proper function and leakage. Otherwise perform this test once a year. Design: ompression of piston rod in creep gear; after the load is relieved the piston rod should return to the original position. aution: The shock absorber is charged with gas at a pressure of 6 bars and should never be opened by customers. Risk of injury! The current versions of our operating and installation instructions apply. These can be downloaded under menu point Login/ervice. We reserve the right to make changes without further notice! 111
11 HL Operating Principle HL teel ap Filling Valve Nitrogen Piston rod OPERTING PRINIPLE HL models have two chambers filled with hydraulic oil and nitrogen. The piston rod is used as an accumulator. Under impact the piston rod is pushed into the cylinder displacing the oil through the orifices into the pressure tube, moving the seperator piston towards the steel cap and compressing the nitrogen. When the mass is released the pressure of the nitrogen sets back the piston rod. eparation Piston eal ushing Piston Throttle orifices Pressure Tube Oil Housing 87
12 election FLLING M m Example Formula & alculation election H m = 1000 kg H = m = 0,4 m X = 1/h n = 1 = m g H = Nm W = m g = Nm = + W = Nm /h = X = Nm/h LD-40--XXXX LOD GINT OLID TOP Example Formula & alculation election F m v m = kg v = m/s F = N = 0,2 m X = 5/h n = 2 = m v 2 2 = Nm with propelling force W = F = 1.0 Nm = ( + W ) : n = Nm /h = X = Nm/h v e = v HL XXXX J LOD GINT OLID TOP WITH HOK ORER Example Formula & alculation election F m m = kg v = 2,6 m/s F = N X = 10/h = 0,4 m = m v 2 2 : 2 = Nm with propelling force W = F = Nm = + W = 18.0 Nm LD-40--XXXX v /h = X = Nm/h v e = v / 2 = 1,3 m/s K LOD GINT LOD WITH ONE HOK ORER Example Formula & alculation election F m 1 m 2 m1 = kg v1 = 1,6 m/s m2 = kg v2 = 2,0 m/s X = 6/h = 0,5 m = (m1 m2) (v1 + v2)2 2 (m1 + m2) = Nm with propelling force W = F =? Nm = + W =? Nm LD-32-0-XXXX v 1 v 2 /h = X = Nm/h v e = v 1 + v2 = 3,6 m/s 84
13 election L LOD GINT LOD WITH HOK ORER Example Formula & alculation election F m 1 m 2 m1 = kg v1 = 1,9 m/s m2 = kg v2 = 1,8 m/s X = 12/h = 0,4 m = (m1 m2) (v1 + v2)2 4 (m1 + m2) = Nm with propelling force W = F = = + W = LD---XXXX v 1 v 2 /h = X = Nm/h v e = (v 1 + v2) / 2 = 1,85 m/s F LOD ON INLINE Example Formula & alculation election α m H m g F m = kg H = 0,5 m α = 22 = 0,6 X = 1/h = m g H = Nm W = m g sin α = Nm = + W = Nm /h = X = Nm/h v = v e = 2 g H HL XXXX! For a utilizaltion per stroke >80 % the approval of Weforma is necessary! at 1/h: number of strokes per year required Formula OUNTERFORE DEELERTION TIME DEELERTION RTE * F G = t = 2 v e 1,2* v 2 a = 2 1,2* v 2 = 1,2* 2 a *alculation for optimum setting. llow a safety margin! LEGEND (Nm) Kinetic energy W (Nm) Propelling force energy (Nm) Total energy / + W /h (Nm/h) Total energy per hour m (kg) Mass me (kg) Effective mass v (m/s) Impact speed v e (m/s) Effective speed (m) F (N) Propelling force H (m) Height g (m/s 2 ) ccerelation due to gravity (9.81 m/s 2 ) α ( ) ngle a (m/s 2 ) cceleration/deceleration t (s) Deceleration time F G (N) ounter force X (1/h) Number of strokes per hour 85
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