HYCON HED User manual

HED
Handheld Earth Drill
HYCON A/S
Juelstrupparken 11
DK-9530 Støvring
Denmark
Tel: [phone]
Fax: [phone]
Mail: [e-mail]
www.hycon.dk

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Contents
Side
Safety Precautions.............................................................................................. 2
Oil Flow and Pressure ......................................................................................... 4
Technical Data ................................................................................................... 5
Service and Maintenance .................................................................................... 6
Oil Types ........................................................................................................... 6
Fault Location ....................................................................................................
Dismounting of Main Components ....................................................................... 8
Mounting of Earth Drill..................................................................................... 10
Tool List ...........................................................................................................18
Spare Parts List .................................................................................................19

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1. Safety Precautions
•The earth drill must always be operated by two operators.
•The operators 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 earth drill, but always maintain a good footing and
keep your balance.
•The operators must always use protective goggles, earplugs, hard hat and shoes
when operating the earth drill.
•The operators must be properly trained in using the earth drill or under
supervision of a qualified instructor.
•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 earth drill, when it is connected to the powerpack.
•Use only original HYCON augers.
•Always use approved hoses. Contact your dealer if necessary. Be careful to mount
the hoses correctly. The earth drill is marked with “P” and “T”, and “P” should be
connected to pressure and “T” to tank.
•Never use the earth drill close to electric cables. Prior to operation, check if there
are hidden or buried cables.
•The earth drill is mounted with a pressure relief valve (torque limiter). It has been
adjusted to 90 bar from the factory and may never be changed as this may cause
severe personal injury.

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•Never wear loose clothing as it may get entangled in the moving parts of the
earth drill.
•Inspection or cleaning of the earth drill, change of auger or disconnection of
hoses may never be done while the earth drill is connected to the powerpack, as
unintentional activation of the earth drill can cause severe damage.
•Always connect hoses to the earth drill before starting the powerpack. Be sure
that all couplings are tight.
•The earth drill may not be operated if the oil temperature is above 0 C°.
Operation at higher temperatures may result in the earth drill getting warmer
than normal and the operators risk 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.
•An earth drill not in use should always be kept in a safe and dry place.
•Do not try to do a job with an earth drill that is too small for the job.
•Always make sure that the labels and warning signs on the earth drill 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
earth drill. If this is not done, there is a risk of damage to the quick release coup-
lings or the hydraulic system getting superheated.
IMPORTANT

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. Oil Flow and Pressure
Your new HYCON earth 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 earth 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.
It is important to check that the earth 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.
On page 5 you will find the technical data.
The earth drill is mounted with a pressure relief valve (torque limiter). This has been
adjusted to 90 bar from the factory and may not be changed, as it can cause severe
personal injury.

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3. Technical Data
Weight 19.6 kg (43.2 lbs)
EHTMA category C/D
Oil flow 20-40 l.p.m. (5-10 g.p.m.)
Working pressure nominal 80 bar (1200 psi)
Built-in torque limiter
(pressure relief valve) 90 bar (1300 psi)
Max. setting of pressure relief
valve on power source 210 bar (3100 psi)
Max. return pressure 5 bar (1100 psi)
Max. torque 250 Nm (180 lbf-ft)
Max. oil temperature 0° C
Vibration level < 2.5 m/s² (128 dB)
Sound pressure level L
PA
1 m 91 dB
Guaranteed sound power level L
WA
100 dB

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4. Service and Maintenance
Service/Maintenance Daily Weekly Yearly
Check couplings and clean carefully X
Check hoses X
NB. At service/repair it is important to mount the quick-release couplings correctly.
Mount the female coupling at “P” and the male at “T”.
Oil Types
The HYCON earth 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. Fault Location
Problem Cause Solution
Pressure relief valve may be
clogged up or defective
Dismount pressure relief valve
and clean with compressed
air, or replace the valve
Earth drill is difficult to hold,
keeps turning
Wrong adjustment of
pressure relief valve
Adjust pressure relief valve
correctly
Hydraulic oil is leaking at
the valve block
Worn seals in the seal
housings on the valve block
Replace worn seals.
See section 8
Earth drill does not start to
drill, even though the
trigger lever is fully
activated
Wrong adjustment of
threaded rod between trigger
lever and trigger
Adjust threaded rod between
trigger lever and trigger.
See section 8
Earth drill does not rotate
forwards/reverse
Wrong adjustment of
threaded rod between trigger
lever and trigger
Adjust threaded rod between
trigger lever and trigger.
See section 8
Dirt in pressure relief valve Dismount pressure relief valve
and clean with compressed
air
Wrong adjustment of
pressure relief valve
Adjust pressure relief valve
correctly
Earth drill does not work
satisfactorily, or
performance is too weak
Power source performance is
too low
Check the power source

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7. Dismounting of Main Components
Dismount the spring pin on the trigger rod. Dismount the screw at the bottom of the driving
shaft. Dismount the three screws at the side of the driving shaft. The driving shaft can now
be removed from the motor shaft. Dismount the two screws that fix the motor to the frame.
Remove the motor from the frame. Dismount the four screws that fix the trigger mechanism
to the valve block. Carefully pull out the trigger unit from the valve block.

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Dismount the flat-face couplings from the fittings. Dismount the two fittings. Dismount the
pressure relief valve. Dismount the two banjo bolts that fix the valve block to the motor. The
valve block can now be removed from the motor.
Earth Drill Main Components

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8. Mounting of Earth Drill
Add Loctite 542 to the two threads. Mount the two pipe plugs. Turn around the valve block,
and add Loctite 542 to the thread as shown on the picture, and mount the pipe plug. Mount
the threaded plug with seal. Mount the two banjo bolts through the valve block, and mount
seal rings on the bolts from the opposite side of the valve block. Mount the valve block on
the motor, and tighten the two banjo bolts with a torque of 130 Nm. Mount the fittings with
seal rings on the valve block.

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Mount seal rings at the other side of the fittings. Mount the flat-face couplings on the fittings.
Mount the male coupling at T and the female coupling at P on the valve block. Mount the
aluminium washer at the bottom of the hole for the pressure relief valve. Tighten the
pressure relief valve with a torque of 30 Nm. Grease the seal housing on the inside and in
the groove on the outside with silicone. Place the seal at the bottom of the seal housing.
Press or strike in the seal by means of HYCON special tool No. 9991664. Place the rod wiper
at the outside of the seal housing. Press or strike in the rod wiper by means of HYCON
special tool No. 9991664.

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Mount the O-ring in the groove on the seal housing. Do the same on the other seal housing.
Mount a spring ring on the trigger rod. Mount the spool on the trigger rod. Mount another
spring ring at the other side of the spool. Mount the lock for spring ring on the trigger rod.
Mount the spring and the spring retainer on the trigger rod. Finally mount the seal housing
on the trigger rod. Mount the trigger unit through the valve block.

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Add Loctite 243 to the two threads, and mount the trigger plate with the two screws. Tighten
the screws with a torque of 25 Nm. Mount the lock for spring ring, spring, spring retainer and
seal housing on the trigger rod. Add Loctite 243 to the two threads, and mount the trigger
plate. Tighten the two screws very carefully. When the seal housing is almost in place,
tighten each screw by a half turn only and by turns. This is done to prevent damage of the
O-ring. Finally tighten the two screws with a torque of 25 Nm.

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Mount the threaded plug with seal. Mount the motor on the frame. Mount the two bolts,
washers and lock nuts that fix the motor to the frame. Add Loctite 638 to the two threads on
the trigger bracket. Mount the two trigger levers in the trigger bracket. Mount the complete
trigger handle on the frame with screw, washer and lock nut.

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Mount the O-ring in the eye for trigger lever. Mount the retaining ring on the trigger lever,
and then mount the eye on the lever. Mount the other retaining ring at the other side of the
eye. Mount the nuts at both ends of the threaded rod. Add Loctite 243 to the thread on the
eye for trigger lever. Mount the threaded rod on the eye.

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Mount the nut on the trigger rod. Add Loctite 243 to the thread on the joint piece for fork
head. Mount the joint piece on the threaded rod. Add Loctite 243 to the thread on the fork
head and mount it on the threaded rod. Mount the spring pin through fork head and joint
piece. Press down the spring over the fork head. Assemble the two frame parts, and tighten
the four set screws that keep the frame parts together.

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Add Loctite 243 to the three threads in the driving shaft and tighten the three screws
slightly. Mount the driving shaft down over the motor shaft, and tighten the three screws
with a torque of 25 Nm. Place the screw through the washer and add Loctite 243 to the
screw. Mount the washer and the screw at the bottom of the driving shaft. Tighten the screw
with a torque of 30 Nm. Mount the split pin through the driving shaft.

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9. Tool List
a
b
c
d
e
f
g
h
i
j
a. Hex head wrenches, sizes 5, 6, 10 mm
b. Hex head socket drivers 1/2”, sizes 3/16”, 5, 6 mm + 6 mm long
c. Torque wrenches 1/2", sizes 5-50 Nm, 10-100 Nm, 20-200 Nm
d. Reversible ratchet 1/2”
e. Sockets 1/2", sizes 24, 30 mm
f. Combination spanners, sizes 10, 13, 19, 24, 2 , 30 mm
g. External circlip plier
h. HYCON special tool No. 9991664
i. Silicone
j. Loctite Nr. 234, 542, 638