HYCON HCD25-100 Instruction manual

Hydrauli
c
Core Drill
HCD25-100 • HCD50-200
HYCON A/S
Juelstrupparken 11
DK-9530 Støvring
Denmark
Tel: [phone]
Fax: [phone]
Mail: [e-mail]
www.hycon.dk

1
Con en s
Page
1. Safety Precautions ...................................................................................... 2
2. Oil Flow, Pressure and Testing ..................................................................... 4
3. Technical Data ............................................................................................ 5
4. Dimensions ................................................................................................. 6
5. Service and Maintenance .............................................................................
6. Fault Location ............................................................................................. 8
. Dismounting and Mounting of Main Components .......................................... 9
8. Repair of Bearing Housing .......................................................................... 19
9. Repair of Valve Housing ............................................................................. 24
10. Tool List ....................................................................................................26
11. Spare Parts Lists ........................................................................................2

2
1. Safe y Precau ions
•Read the core drill and power source operating manuals prior to use.
•Only use the core drill in accordance with the local working regulations on al-
lowed working time.
•Check the oil flow to the core drill. The oil flow may not exceed 20 l.p.m./max.
1 0 bar. Please refer to page 4.
•Make sure that the core bit is firmly fastened.
•For handheld drilling, always use core bits approved for this purpose.
•The HYCON core drill is supplied with a trigger lock. This may only be used when
drilling in a rig.
•The core drill has an automatic integrated security that makes the core drill stop
if the core bit jams. However, in case of jamming, always loosen the core bit from
the material, before you start drilling again. The integrated security is set from
the factory and may not be disturbed.
•Start the core drill just before you start drilling, and stop it once the drilling is
done. Do not let the core drill run freely in the air.
•In case of horizontal drilling or drilling 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 core drill when connected to the powerpack.
•Always use approved hoses. Contact your dealer, if necessary. Mount the hoses
correctly so that the core drill rotates in the right direction (clockwise).
•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 core drill, but always maintain a good footing and keep
your balance.
•The operator must be properly trained in using the core drill or under supervision
of a qualified instructor.
•The operator must always use protective goggles, earplugs, hard hat and shoes
when operating the core drill.

3
•Never use the core drill close to electric cables. Prior to operation, check whether
there are hidden or buried cables.
•Never wear loose clothing as it may get entangled in the moving parts of the core
drill.
•Inspection or cleaning of the core drill, change of core bit or disconnection of
hoses may never be done while the core drill is connected to the powerpack, as
unintentional activation of the core drill can cause severe damage.
•Always connect hoses to the core drill before starting the powerpack. Be sure that
all couplings are tight.
•The core drill may not be operated if the oil temperature is above 0 C°.
Operation at higher temperatures may result in the core drill 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 core drill not in use should always be kept in a safe and dry place.
•Always make sure that the core drill 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
core drill. If this is not done, there is a risk of damage to the quick release coup-
lings or the hydraulic system getting overheated.
IMPORTANT

4
2. Oil Flow, Pressure and Tes ing
Your new HYCON core drill 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 core drill, meaning that the lifetime of your new HYCON tool will not be as
expected, and that your service and repair costs will be too high.
The core drill should be tested before and after servicing – before servicing to check
if there are certain problems related to the core drill, and after servicing to ensure
that the core drill works satisfactorily. Efficient testing can only be done by means of
test equipment that includes a flow and pressure gauge.
It is important to check that the core drill 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. The table below shows the pressure range of the core
drills.
Working Pressure
HCD25-100/HCD50-200
Free Air
(without drilling) Drilling
20 l.p.m. 40-60 bar 120–150 bar

5
3. Technical Da a
HCD25
-
100
HCD50
-
200
Weigh w/o hoses,
core bi and adap or
.6 kg
.6 kg
Oil
flow
20 l.p.m.
20 l.p.m.
Working pressure nominal
100 bar
100 bar
Pressure rel
ief valve in
power source
Max. 1 0 bar
Max. 1 0 bar
Max. re urn pressure
40 bar
40 bar
Max. oil empera ure
0° C
0° C
Ro ary speed a 20 l.p.m.
1500 r.p.m.
600 r.p.m.
Sound pressure level 1 m L
PA
85 dB
84 dB
Vibra ion level
‹ 2.5 m/s²
‹ 2.5 m/s²
Core bi size
ø25
-
ø100 mm
ø50
-
ø200 mm
Up to ø350 mm for
the experienced user
Thread:
External G ½” or
internal 1 ¼” – UNC
Thread:
External G ½” or
internal 1 ¼” – UNC
Necessary cooling capaci y
on power source
1 kW
1 kW

6
4. Dimensions

7
5. Service and Main enance
Service/Main enance Daily Weekly Yearly
Check couplings and clean carefully
X
Check hoses X
Check bearing for clearance X
NB. At service/repair it is important to mount the hoses correctly.
Oil Types
The HYCON core drill uses 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
+ 0° 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.

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6. Faul Loca ion
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
Solu ion
Core drill does not start,
there is no pressure in P-
hose
Trigger
mechanism does not
actuate trigger piston
correctly
Replace worn parts in handle
(nylon distance piece)
Trigger mechanism is stuck
in valve block
Dismount trigger piston from
valve block, and clean or
replace parts
Core drill does not start,
there is pressure in P-hose
Defective Q.R. coupling
Check Q.R. coupling
Oil supply is made to T
-
connection
Switch pump and tank line
Trigger lock is too slack
Spring is too slack
Replace spring
Core drill works irregularly
Impurities in hydraulic oil
Replace oi
l and oil filter
(see workshop manual of
power source)
Oil level in power source too
low
Add hydraulic oil
Bad performance
Intern
al leak because of dirt
in pressure relief valve
Clean valve
Oil flow from the power
source is not correct for the
core drill
Check oil flow
Core drill stops too easily
Adjust pressure relief valve
Hose diameter too small
Check hoses
Defective Q.R. coupling
Check Q.R. coupling
Retur
n pressure too high
Check power source/hoses
Trigger piston nut fully
activated
Repl
ace worn parts in handle
(nylon distance piece)

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7. Dismoun ing and Moun ing of Main Componen s
Dismount the front adaptor and the water hose. Dismount the handle ring for the
supporting handle, and remove supporting handle. Mount HYCON service tool No. 1
(special screw) and No. 2 (tightening cup). The bearing housing can now be
removed from the motor adaptor.
ATTENTION!
The hread be ween bearing housing and mo or adap or is lef -handed

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Loosen the three screws, and remove the motor adaptor. Dismount the two screws
at the back of the handle, and remove the handle. Dismount the distance piece.
Then dismount the tail-hoses. Wait a while to let the hydraulic oil run out. The valve
block with motor can now be pulled out of the plastic cover. Dismount the two seal
rings.

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Dismount the two banjo bolts, and remove the valve block from the motor.
Core Drill Main Componen s

12
Moun ing
Place the two O-rings on the motor, and mount the valve housing over the motor. It
is important that the O-rings are placed precisely in the grooves on motor and valve
block. Mount the seal rings on the banjo bolts, and mount the banjo bolts through
the valve block into the motor. Tighten the bolts with a torque of 55 Nm. Place the
ball in the banjo bolt, and strike a blow on the ball with a hammer and a drift punch.
Place the compression spring in the hole, and mount the threaded plug with seal.

13
Mount the pressure relief valve, and tighten with a torque of 30 Nm. Mount the
trigger piston, and add Loctite 243 to the two threads. Mount the mounting plate and
the two screws. Tighten the screws with a torque of 30 Nm. Mount the four cylinder
pins. Mount the seal rings in the valve block before pushing motor and valve block
into the plastic cover.

14
Push motor and valve block into the plastic cover. Mount the two fittings and tighten
with a torque of 0 Nm. Mount the tail-hoses. Mount the hose with male coupling at
”T”, and the hose with female coupling at ”P”. Clean the three threads on the motor
with Loctite 063, and add Loctite 243 to the threads. Mount the motor adaptor with
the three screws. Tighten the screws with a torque of 20 Nm.

15
Mount the complete bearing housing on the motor adaptor (beware of left-handed
thread). Then use HYCON service tools No. 1 and 2 (special screw and tightening
cup). Tighten the bearing housing with a torque of 130 Nm. Set the pressure relief
valve by loosening the nut and turning the set screw with a hex head wrench.
Setting of the pressure relief valve can be done as follows: Connect the core drill to
the powerpack, and insert the test equipment in between (HYCON test equipment
No. 4040062). Fasten the core drill in a vice, and activate the trigger lever.
CAUTION:
Hold on igh ly o he core drill before ac iva ing he rigger lever
Hold on to the core drill so that it does not revolve, and read the pressure on the
pressure gauge. Normal setting is 115 bar for the HCD50-200 and 125 bar for the
HCD25-100. If the pressure deviates too much, adjust the set screw a little in or out.

16
Moun ing of Handle
Place the trigger lever in the handle, and mount the pin through all three holes.
Mount a retaining ring on each side. Mount the trigger lock on the handle.

17
Add Loctite 243 to the two threads, and mount the handle on the valve block. Always
mount the distance piece between trigger rod and handle (check distance piece for
wear. Replace it, if too worn). Tighten the two screws with a torque of 25 Nm.
Mount the handle ring for the supporting handle. Then mount the spring ring for the
supporting handle. Mount the nipple and the water hose. Fix the hose clamp with an
end cutter.

18
Mount the supporting handle. Grease the thread on the front adaptor with copper
paste, and mount it on the shaft.

19
8. Repair of Bearing Housing
Dismoun ing
Dismount the retaining ring, and remove the distance ring and the compression
rings. Use a drift punch and a hammer to remove the shaft from the bearing
housing. Then use HYCON service tool No. 3 to remove the bearing and the seal
housing at the other end of the bearing housing. Replace all seals and O-rings on
both the inside and the outside of the seal housing.