HYCON HRD20RV User manual

Hydraulic Rock Drill
HRD20RV
From serial
number 8763
Revised
03.07.2015
Prior to Operation
We thank you for choosing a
HYCON rock drill.
To ensure smooth operation
and long-lasting performance
of your new tool, 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 rock
drill.
Best regards
HYCON A/S
HYCON A/S
Juelstrupparken 11
DK-9530 Støvring
Denmark
Tel: [phone]
Fax: [phone]
Mail [email protected]
www.hycon.dk

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

2
Safety Precautions
Read the rock drill and power source operating manuals prior to use.
Only use the rock drill in accordance with the local working regulations on allowed
working time
Check the oil flow to the rock drill. The oil flow may not exceed 30 l.p.m./max.
150 bar.
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 rock drill when connected to the powerpack.
Always use correct tool
Make sure that the tool is firmly fastened
Always use approved hoses. Contact your dealer, if necessary.
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 rock drill, but always maintain a good footing and keep
your balance.
The operator must be properly trained in using the rock drill or under supervision
of a qualified instructor.
The operator must always use protective goggles, earplugs, hard hat and shoes
when operating the rock drill.
Never wear loose clothing as it may get entangled in the moving parts of the rock
drill.
Inspection or cleaning of the rock drill, change of tool or disconnection of hoses
may never be done while the rock drill is connected to the powerpack, as
unintentional activation can cause severe damage.
Always connect hoses to the rock drill before starting the powerpack. Be sure that
all couplings are tight.

3
The rock drill may not be operated if the oil temperature is above 80 C°.
Operation at higher temperatures may result in the rock 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 rock drill not in use should always be kept in a safe and dry place.
The rock drill may never be operated without tool, or without being held against
the working surface, as this may result in overload of the rock drill.
Always make sure that the rock 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
rock 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
GTIGT

4
Oil Flow and Pressure
Your new HYCON rock 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 rock 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 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 5 you will find a complete survey of the technical data, and on page 7 there
is a guide to connection to hydraulic power sources and how to ensure that the rock
drill is not overloaded.
Starting Instructions
START
Insert tool.
Connect hoses –clean couplings before connection.
Set the power source on ”ON”.
Check blow frequency and rotation settings (see below)
Get a good footing before you start drilling to avoid stumbling during
operation.
Press the drill end against the material to be drilled, then press the control
lever down towards the handle and the rock drill will start drilling.
STOP
Let go of the trigger lever, and the rock drill will stop working.
Settings
Blows
1/min
Rotations
rpm
0
1500
0
1
1350
200
2
1100
300
3
900
400

5
Technical Data
Weight w/o hoses and tool 20 kg
Dimension Total length: 694 mm
Total width: 410 mm
Oil flow 25-30 l.p.m.
Rotation speed 0-400 1/min
Rotation direction
(seen from the top) Counterclockwise
Rotation torque 15 Nm
Striking energy 50 Joule
Working pressure 115 bar
Max return pressure 10 bar
Pressure relief valve
on power source Max. 150 bar
Max. oil temperature 80° C
Tool chuck size 22x108 mm
Built in compressor air supply Max. 0.08 m³/min. / 2 bar
Drilling performance ø45 - 3 m deep
For drilling holes deeper than 800 mm,
the HRD20RV must be rebuilt for
external air supply
Under water use The HRD20RV must be rebuilt for
external air supply
Blow frequency/rotations 4 settings 0 1 2 3
Blows 1/min 1500 1350 1100 900
Rotations rpm 0 200 300 400
Noise level 1 m LPA 95 dB
Noise level LWA 107 dB
Vibration level 9.5 m/s² (25L/min)

6
Performance Chart
Integrated Air Supply
The drill has integrated air supply for flushing, but please note that it is limited in
performance.
Inadequate air flushing will significantly reduce the drilling performance.
The flushing is usually acceptable to a depth of 80 cm –below it will need additional
air supply.
The rock drill can be modified for external air supply by a kit available.
The kit will, however, replace the integrated air flushing function so that external air
supply must be used at all times.
8
20
25
0
5
10
15
20
25
30
HRD20
3/8" hose diameter
1/2" hose diameter
5/8" hose diameter
HRD20RV Rock Drill
Maximum length of different sizes of hoses
Pressure from power pack: 150 bar., Flow: 28 l.p.m., zero elevation, 2 set couplings per 10 m hose.

7
Connection to Hydraulic Power Sources
The rock drill 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 rock drill the absolute best working conditions.
It is important that the rock drill is not subjected to an oil flow and a working pres-
sure beyond its design capability.
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 adjust-
ment of pressure.
Make sure that:
the oil supply 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 150 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 rock drill 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 rock drill
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.

8
Service and Maintenance
Service/Maintenance
Daily
Weekly
Yearly
Check couplings and clean
carefully
X
Check hoses
X
Check accumulator
X
Clean air filter
X
NB. At service/repair it is important to mount the hoses correctly. The feed line from
the power source must be mounted at the upper inlet and the return line at the
lower outlet.
MAINTENANCE
1) Check hydraulic oil on a regular basis to ensure it is always clean. If the oil sticks
or changes the colour, replace it.
2) Before starting, check if oil volume is sufficient as it decreases by connecting and
disconnecting the hoses.
3) The air filter protects the built-in compressor from sucking in dust. Take out the
element and the filter from the filter housing and clean them daily. The negli-
gence of doing this causes fast wear of the compressor cylinder, piston ring and
valve.
Element
Filter
Filter cover

9
Inspection time
Inspection point
200 hours
or 1 year
400 hours
or 2 years
Over 3
years
Accumulator gas pressure check
O
Replacement of accumulator diaphragm
O
Replacement of U-cup packing
O
Replacement of valve rod o-ring
O
Replacement of compressor piston ring
O
Replacement of gear case grease
O
Replacement of motor shaft o-ring
O
Replacement of every o-ring
O
Oil Types
The HYCON rock 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 +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.

10
EC-Declaration of Conformity
From serial No.
We hereby declare that HRD20RV hydraulic rock drill 8763
(service weight 25 kg)
is manufactured in conformity with the EC Directive 2006/42/EC.
HYCON A/S
Juelstrupparken 11
DK-9530 Støvring
Denmark
Henrik Steen
General Manager
15.04.2004
HYCON A/S
Juelstrupparken 11
DK-9530 Støvring
Denmark
Tel: [phone]
Fax: [phone]
Mail [email protected]
www.hycon.dk

11
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.