HYCON Hydraulic Post Driver User manual

HPD
Hydraulic
Post Driver
From serial No. 13110
Revised 03.04.2019
Prior to Operation
We thank you for choosing a
HYCON Post Driver.
To ensure smooth operation
and long-lasting performance
of your new post driver, we
recommend 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 post
driver.
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
Vibration Level .............................................................................................................4
Starting Instructions .....................................................................................................5
Technical Data .............................................................................................................7
Performance Chart .......................................................................................................8
Connection to Hydraulic Power Sources..........................................................................9
Service and Maintenance ..............................................................................................9
Trouble Shooting........................................................................................................ 10
Oil Types ................................................................................................................... 11
EC-Declaration of Conformity....................................................................................... 12
Warranty Terms ........................................................................................................ 13
Spare Parts List......................................................................................................... 14

2
Safety Precautions
Only use the post driver in accordance with the local working regulations on allowed
working time based on post driver vibration level. Working with the post driver longer than
prescribed may damage the operator. Please refer to the chapter about vibrations, page 4.
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 suspected leaks –use
a piece of cardboard instead. If oil has penetrated the skin, you should get medical
treatment immediately.
Never leave the post driver when connected to the powerpack.
Always use correct adaptor when ramming a post into ground.
Before connecting the post driver to the power source, always check that the adaptor is
firmly secured in order to prevent damaging post and injure operator.
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 using the
post driver.
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 post driver, but always maintain a good footing and keep your balance.
The operator must be properly trained in using the post driver or under supervision of a
qualified instructor.
The operator must always use protective goggles, earplugs, hard hat and shoes when
operating the post driver.
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 post driver.
Inspection or cleaning of the post driver, change of adaptor or disconnection of hoses may
never be done while the post driver is connected to the powerpack, as unintentional
activation of the post driver can cause severe damage.
Always connect hoses to the post driver before starting the powerpack. Be sure that all
couplings are tight.
The post driver may not be operated if the oil temperature is above 70 C°. Operation at
higher temperatures may result in the post driver 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.

3
A post driver not in use should always be kept in a safe and dry place.
Try not to do a job with a post driver which is too small for the job.
Keep the adaptor in good condition for maximum driving performance.
The post driver may never be operated without adaptor, or without being held against the
pole end, as this may result in overload of the post driver.
Always make sure that the post driver 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 post driver. If
this is not done, there is a risk of damage to the quick release couplings or the hydraulic
system getting overheated.
IMPORTANT
GTIGT

4
Oil Flow and Pressure
Your new HYCON post driver 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 post driver,
meaning that the lifetime of your new HYCON post driver will not be as expected, and that your
service and repair costs will be too high.
It is important to check that the post driver 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 7 you will find a complete survey of the technical data, and on page 9 there is a guide
to connection to hydraulic power sources and how to ensure that the post driver is not
overloaded.
Vibration Level
There are many examinations about the risk of contracting the so-called “white fingers” disease
as a consequence of the use of tools with high vibration level.
To reduce the risk of injury, a number of guidelines for maximum daily use have been laid
down. The risk is minimized if you stay below maximum of daily use.
It is therefore important to manufacturers of handheld post drivers that they offer post drivers
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.
If you wish to obtain further information about the guidelines for maximum daily use, please
contact us.

5
Starting Instructions
START –NO REMOTE
Mount adaptor designed for the post
Connect hoses –clean couplings before connection
Set the power source on ”ON”
Press the trigger lever towards the handle
Always hold the post driver at right angle towards the post
START –WITH REMOTE
Mount adaptor designed for the post
Connect hoses –clean couplings before connection
Set the power source on ”ON”
Slide the post into the driver as shown in fig. 1

6
Lift the post and driver to a vertical position as shown in fig. 2
To start the post driver move the control valve to the ON-position. Fig 3
STOP
Let go of the trigger lever or move the control valve to OFF-position
Turn off the hydraulic oil flow before disconnecting the post driver

7
Technical Data
Post Driver
30 l.p.m.
Weight Post Driver kg
28
Service weight incl.
adaptor and hoses kg
30
EHTMA category
D
Oil flow l.p.m. (g.p.m.)
30 (8)
Working pressure Bar (psi)
120 (1750)
Max. setting
pressure relief valve Bar (psi)
160 (2300)
Max. return pressure Bar (psi)
15 (220)
Blow frequency 1/min.
1380
Blow energy Joule
95
Max. oil temperature C°
70
Accumulator
charging pressure Bar (psi)
50 (730)
Cooling capacity needed kW
3
Vibration level 3 axis (ISO 20643) m/s² (dB)
Uncertainty (K) m/s² (dB)
9.4 (139)
1.4 (123)
Sound pressure level (LPA) 1 m dB
Sound power level (LWA) guaranteed dB
96
108
Adaptor size mm
Depending on post
Adaptors available (Part no.)
Round
4012575
Ø60 mm
4012585
Ø80 mm
4012837
Ø105 mm
4012838
Ø130 mm
Square
4012570
65 mm x 65 mm
4012836
110 mm x 110 mm

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

9
Connection to Hydraulic Power Sources
The post driver can be connected to various hydraulic power sources, such as excavators,
trucks, loaders, tractors etc., and of course HYCON powerpacks, the design of which ensures
your new HYCON post driver the absolute best working conditions.
It is important that the post driver is not subjected to an oil flow and a working pressure
beyond its design capability. Please refer to the ID-tag on the post driver 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 post driver 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 post driver
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.

10
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
Post driver 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.
Post driver 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
Adaptor cannot get a grip
around the post during
operation
Adaptor is damaged
Replace parts.
Wrong adaptor size
Replace adaptor to right size.
Post driver works irregularly
Impurities in hydraulic oil
Replace oil and oil filter
Oil level in power source too
low
Add hydraulic oil
Wrong adaptor size or worn out
anvil
Check
Bad performance
Internal leak
Dismount valve housing and
replace O-rings.
Oil flow from the power source
is not correct for the post driver
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

11
Oil Types
The HYCON post driver 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.

12
EC-Declaration of Conformity
We hereby declare that
HPD post driver, from serial No. 13110
is manufactured in conformity with the EC Directive 2006/42/EC.
HYCON A/S
Juelstrupparken 11
DK-9530 Støvring
Denmark
Lars Melgaard
Production Manager
15.02.2016
HYCON A/S
Juelstrupparken 11
DK-9530 Støvring
Denmark
Tel: [phone]
Fax: [phone]
Mail [email protected]
www.hycon.dk

13
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.