HYCON HH35 User manual

Hydraulic Breakers
HH35
Revised 01.02.2015
Prior to Operation
We thank you for choosing a
HYCON breaker.
To ensure smooth operation
and long-lasting performance
of your new breaker, we re-
commend you to study this
operating manual carefully and
pay special attention to the
chapters about
Safety and Service
Precautions
and
Oil Flow and Pressure
We hope you will be satisfied
with your new HYCON
breaker.
Best regards
HYCON A/S
HYCON A/S
Juelstrupparken 11
DK-9530 Støvring
Denmark
Tel: [phone]
Fax: [phone]
Mail [email protected]
www.hycon.dk
From Serial No. 12263

1
Contents
Page
Safety Precautions.............................................................................................. 2
Oil Flow and Pressure ......................................................................................... 4
Vibration Level ................................................................................................... 4
Starting Instructions ........................................................................................... 5
Technical Data ................................................................................................... 6
Performance Chart ............................................................................................. 7
Connection to Hydraulic Power Sources ............................................................... 8
Service and Maintenance .................................................................................... 8
Trouble Shooting................................................................................................ 9
Oil Types ..........................................................................................................10
EC-Declaration of Conformity ............................................................................ 11
Warranty Terms ............................................................................................... 12
Spare Parts List ................................................................................................ 13

2
Safety Precautions
Only use the breaker in accordance with the local working regulations on allowed
working time based on breaker vibration level. Working with the breaker longer
than prescribed may damage the operator. Please refer to the chapter about vi-
brations, page 4.
All HYCON breakers are supplied with safety trigger. The safety trigger may not
be dismounted. Always make sure that it is in order.
In case of horizontal breaking or breaking above the head, always be aware of
material falling down.
A fine jet of oil at pressure can penetrate the skin. It is therefore important never
to use your fingers to check for oil leaks and never to hold your face close to su-
spected leaks –use a piece of cardboard instead. If oil has penetrated the skin,
you should get medical treatment immediately.
Never leave the breaker when connected to the powerpack.
Always use correct tool
Before connecting the breaker to the power source, always check that the latch is
in order to prevent the tool from falling out of the nose part.
Always use approved hoses. Contact your dealer, if necessary. Mount the hoses
correctly –the valve housing is marked with ”P” and ”T”.
The operator must make sure that there are no persons nearby when he starts
breaking. Flying pieces of broken material can cause severe injury.
The operator must pay extra attention and show caution when working in difficult
working areas, such as slopes and other dangerous nature of the ground. Do not
reach too far with the breaker, but always maintain a good footing and keep your
balance.
The operator must be properly trained in using the breaker or under supervision
of a qualified instructor.
The operator must always use protective goggles, earplugs, hard hat and shoes
when operating the breaker.
Never use the breaker close to electric cables. Prior to operation, check whether
there are hidden or buried cables in the ground.
Never wear loose clothing as it may get entangled in the moving parts of the
breaker.

3
Inspection or cleaning of the breaker, change of tool or disconnection of hoses
may never be done while the breaker is connected to the powerpack, as uninten-
tional activation of the breaker can cause severe damage.
Always connect hoses to the breaker before starting the powerpack. Be sure that
all couplings are tight.
The breaker may not be operated if the oil temperature is above 70 C°. Operation
at higher temperatures may result in the breaker getting warmer than normal and
the operator risks getting burnt on it.
To avoid all personal injury and damage to material, all repair, maintenance and
service work must be carried out by authorized or properly trained persons only.
A breaker not in use should always be kept in a safe and dry place.
Try not to do a job with a breaker which is too small for the job.
Keep the tool sharp for maximum breaker performance. Make sure that the tool is
sharp-pointed and not round.
The breaker may never be operated without tool, or without being held against
the working surface, as this may result in overload of the breaker.
Always make sure that the breaker labels and warning signs are legible.
Always use hoses, couplings and spares as such recommend by HYCON A/S.
Repairs may only be carried out by experienced personnel.
Make sure that all couplings are cleaned before connection.
Always disconnect the hydraulic circuit before connecting or disconnecting the
breaker. If this is not done, there is a risk of damage to the quick release coup-
lings or the hydraulic system getting superheated.
IMPORTANT
GTIGT

4
Oil Flow and Pressure
Your new HYCON breaker is designed for a certain oil flow, working pressure and
maximum pressure. A too high oil flow and/or a too high pressure results in overload
of the breaker, meaning that the lifetime of your new HYCON breaker will not be as
expected, and that your service and repair costs will be too high.
It is important to check that the breaker is not supplied with an oil flow beyond its
design capacity, that the working pressure is correct and that the maximum allowed
pressure is not exceeded.
On page 6 you will find a complete survey of the technical data, and on page 8 there
is a guide to connection to hydraulic power sources and how to ensure that the brea-
ker is not overloaded.
The HYCON breakers are available both as 20 l.p.m. and 30 l.p.m. models. The
individual types are stated on the ID-tag.
Vibration Level
There are many examinations about the risk of contracting the so-called “white fin-
gers” disease as a consequence of the use of tools with high vibration level. Hand-
held electric, pneumatic and hydraulic breakers belong to this category.
To reduce the risk of injury, a number of guidelines for maximum daily use have
been laid down. The risk is minimized if you keep the times of maximum daily use.
It is therefore important to manufacturers of handheld breakers that they offer brea-
kers with a low vibration level.
At HYCON, we attach great importance to the protection of our customers in the
form of a very low vibration level.
Therefore, your new HYCON breaker is equipped with a handle designed for the
lowest possible vibration level, even though the breaker has high performance. On all
HYCON breakers we mount our best vibration-dampened handle as standard to pro-
tect you as user.
If you wish to obtain further information about the guidelines for maximum daily use,
please contact us.

5
Starting Instructions
START
Insert tool
Connect hoses –clean couplings before connection
Set the power source on ”ON”
Release the safety trigger
Press the trigger lever down towards the handle
Always work at right angles to the material, and only break pieces of a size
that makes the material break quickly. If it does not break quickly, either the
breaker is too small for the job, or you try to break too large pieces.
STOP
Let go of the trigger lever
The safety trigger automatically re-locks the trigger lever.

6
Technical Data
HH35
30 l.p.m.
Weight breaker lbs (kg)
64 (29)
Service weight incl. moil point and hoses lbs (kg)
72 (33)
EHTMA category
II
Oil flow g.p.m. (l.p.m.)
8-10 (38)
Working pressure psi (bar)
1900 (130)
Max. setting pressure relief valve psi (bar)
2300 (160)
Max. return pressure psi (bar)
220 (15)
Blow frequency bpm
1100
Blow energy ft-lb (Joule)
100 (120)
Max. oil temperature °F (°C)
155 (70)
Accumulator charging pressure psi (bar)
870 (60)
Cooling capacity needed Hp (kW)
5 (3)
Vibration level 3 axis (ISO 20643) dB (m/s²)
141 (10.7)
Uncertainty (K) dB (m/s²)
124 (1.6)
Sound pressure level (LPA) 1 m dB
107
Sound power level (LWA) guaranteed dB
110
Tool size standard inches (mm)
1¼” x 6”
(32x152)
1⅛” x 6¼”
(28x160)
Tool size on request inches (mm)
1¼” x 6¼”
(32x160)
1⅛” x 6”
(28x152)

7
Performance Chart
All HYCON breakers
Maximum length of different sizes of hoses
0
5
10
15
20
25
30
20 l.p.m.
30 l.p.m.
3/8" hose diameter
1/2" hose diameter
5/8" hose diameter
Pressure from power pack: 150 bar., Flow: 20 l.p.m., zero elevation, 2 set couplings per 10 m hose.

8
Connection to Hydraulic Power Sources
The breaker can be connected to various hydraulic power sources, such as excava-
tors, trucks, loaders, tractors etc., and of course HYCON powerpacks, the design of
which ensures your new HYCON breaker the absolute best working conditions.
It is important that the breaker is not subjected to an oil flow and a working pressure
beyond its design capability. Please refer to the ID-tag on the breaker in case of
doubt. Check the oil flow and the working pressure by means of test equipment. The
test equipment should comprise a pressure gauge, a flow meter and a valve for
adjustment of the pressure.
Make sure that:
the oil flow is not too high
the working pressure is not too high
the return pressure is not too high
the pressure relief valve is not set higher than 160 bar
the internal diameter of the hoses is sufficient (min. ½”)
all couplings are clean
the power source is equipped with an oil filter of min. 25 Micron
Hoses with too small internal diameter and/or defect couplings cause the breaker to
work with incorrect working pressure. Your dealer can help you check this.
If the output of the power source is too high:
the power source must be adjusted to correct output
or you can choose to mount a HYCON oil flow divider to protect the breaker
against overload
or you can choose one of our HYCON powerpacks. Your dealer can guide you
in choosing the right powerpack.
In case of doubt, please contact your dealer or HYCON A/S.
Service and Maintenance
Service/Maintenance
Daily
Weekly
Yearly
Check couplings and clean carefully
X
Check hoses
X
Check accumulator
X
NB. At service/repair it is important to mount the hoses correctly. The feed line from the power source
must be mounted at “P” and the return line at “T”. “P” and “T” are marked on the valve housing.

9
Trouble Shooting
Before you start locating faults, check that the oil flow from the power source is
correct and that the pressure relief valve is set correctly. Follow the instructions in
the workshop manual of the power source.
Problem
Cause
Solution
Breaker does not start, there
is no pressure in P-hose
Trigger mechanism does not
actuate trigger piston
correctly
Dismount top cover, and
check and adjust functioning.
Breaker does not start, there
is pressure in P-hose
Striking piston is stuck in
cylinder
Nose part is tightened too
hard.
Seizing between cylinder and
striking piston. Polish or
replace components.
Defective Q.R. coupling
Check Q.R. coupling
Oil supply is made to T-
connection
Switch pump and tank line
Chisel falls out during
operation
Latch and pin are worn
Replace parts.
Chisel bushing is worn
Replace parts.
Wrong chisel size
Check
Breaker works irregularly
Impurities in hydraulic oil
Replace oil and oil filter
Oil level in power source too
low
Add hydraulic oil
Wrong chisel size or worn
chisel bushing
Check
Bad performance
Internal leak
Dismount valve housing and
replace O-rings.
Oil flow from the power
source is not correct for the
breaker
Check oil flow
Accumulator pressure too
low
Charge with Nitrogen.
Defective diaphragm
Replace diaphragm
Defective Q.R. coupling
Check Q.R. coupling
Return pressure too high
Check power source/hoses
Hose diameter too small
Check hoses

10
Oil Types
The HYCON breakers use standard hydraulic oil, i.e. all types of mineral oil and
biodegradable oil, which comply with the following values:
Recommended viscosity
20-40 cSt
Permitted viscosity
15-1000 cSt
Viscosity index
Min. 100
Temperature area
-20° to +70° C
If using biodegradable oil, we recommend the use of oil based on rape. Other types
of oil can be aggressive towards the seals. If you are in doubt, please ask your
dealer.

11
EC-Declaration of Conformity
We hereby declare that
From Serial No.
HH35 hydraulic breaker (service weight 31 kg) 12263
are manufactured in conformity with the EC Directives 2006/42/EC and 2000/14/EC.
Notified Body 1585:
AkustikNet A/S
Frederikssundsvej 179 B
DK-2700 Brønshøj
Denmark
HH35
Measured sound power level: 107 dB
Guaranteed sound power level: 110 dB
HYCON A/S
Juelstrupparken 11
DK-9530 Støvring
Denmark
Henrik Steen
General Manager
01.02.2015
HYCON A/S
Juelstrupparken 11
DK-9530 Støvring
Denmark
Tel: [phone]
Fax: [phone]
Mail [email protected]
www.hycon.dk

12
Warranty Terms
We grant 12 months warranty from the first date of operation –however, not more
than 18 months from the date of delivery.
The warranty applies to faults that can be related to construction and production
errors.
Faults caused by incorrect operation, incorrect handling, lack of maintenance or the
like, will not be accepted as warranty.
The warranty covers the parts necessary for repair and the suggested average time
needed for repair.
For further warranty details, please contact your local dealer.