HYCON HH10 Instruction manual

Hydraulic Breaker
HH10 • HH10RV
HYCON A/S
Juelstrupparken 11
DK-9530 Støvring
Denmark
Tel: [phone]
Fax: [phone]
Mail [email protected]k
www.hycon.dk

1
Content
Page
1. Generally ..................................................................................................... 2
2. Safety Precautions ........................................................................................ 2
3. Dimensions .................................................................................................. 4
4. Technical Data ............................................................................................. 5
5. Maintenance ................................................................................................ 6
6. Testing ........................................................................................................ 6
. Fault Location ..............................................................................................
8. Mounting and Dismounting of Main Components ............................................ 8
9. Repair of Cylinder ........................................................................................ 14
10. Repair of Valve Housing and Trigger Piston .................................................. 15
11. Charging of Accumulator .............................................................................. 19
12. Handle Check .............................................................................................. 21
13. Tool List ..................................................................................................... 22
14. Spare Part Drawings/Lists ............................................................................ 23

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1. Generally
HYCON demolition breakers are designed for long-term operation under difficult
working conditions. All vital components are made of first-class material and have
undergone tempering processes to ensure maximum life. A hydraulic breaker is
produced with small tolerances to obtain an efficient tool with high performance.
However, this makes heavy demands on the manufacture of the tool, and also
requires great care at repair and service work. Be careful not to damage the surface
of the inner components and to keep the hydraulic components clean. It is important
always to observe the tightening torques stated in the repair section.
2. Safety Precaution
•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.
•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 chisel.
•Before connecting the breaker to the power source, always check that the chisel
retainer is in order to prevent the chisel from falling out of the nose part.
•Always use approved hoses. Contact your dealer, if necessary. Mount the hoses
correctly – the plastic cover 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.

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•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.
•Inspection or cleaning of the breaker, change of chisel 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 0 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.

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3. Dimen ion

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4. Technical Data
Weight breaker 9.9 kg
Service weight incl.
moil point and ho e 12. kg
EHTMA category C
Oil flow 20 l.p.m. (5.3 g.p.m.)
Working pre ure nominal 100 bar (1450 psi)
Max. etting
pre ure relief valve 160 bar (2320 psi)
Max. return pre ure 15 bar (220 psi)
Blow frequency 2100 1/min.
Blow energy 22 Joule
Max. oil temperature 0° C
Accumulator charging pre ure 40 bar (580 psi)
Cooling capacity needed 2 kW
Vibration level 3 axi (ISO 20643) 9.6 m/s² (140 dB)
Uncertainty (K) 1.4 m/s² (123 dB)
Sound pre ure level L
PA
1 m 93 dB
Sound power level L
WA
guaranteed 105 dB
Tool ize tandard 19x50 mm

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5. Maintenance
Service/Maintenance Daily Weekly Yearly
Check couplings and clean carefully X
Check hoses X
Lock ring in nose part
Check Replace
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 plastic cover.
6. Te ting
The breaker should be tested before and after servicing – before servicing to check if
there are certain problems related to the breaker, and after servicing to ensure that the
breaker works satisfactorily. Efficient testing can only be done by means of test equipment
that includes a flow and pressure gauge.
The breaker only works satisfactorily if the return pressure of the power source is not too
high - therefore check this prior to testing the breaker. Mount the test equipment at the
end of the extension hose without the breaker connected. If the test equipment has a flow
valve, it must be fully open during the entire test. Set the power source on “ON”, and
check that the oil flow corresponds to the technical data of the breaker. At this time the
pressure may not exceed 15 bar.
Test the breaker by mounting the test equipment at the pressure hose just before the
breaker. If the test equipment has a flow valve, it must be fully open during the entire
test. Set the power source on “ON” and activate the breaker. Measure oil flow and
working pressure when the breaker has warmed up. The oil flow must correspond to the
technical data of the breaker, and at this oil flow the working pressure of the breaker must
be in accordance with the technical data. A deviation of up to 15 bar is, however, within
normal.
The above measurements and a visual control will ensure a fully functional breaker.

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7. Fault Location
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
Cau e
Solution
Breaker does not start, there is
no pressure in P-hose
Trigger mechanism does not
actuate trigger piston correctly
Replace worn parts in handl
e
See section 12
Breaker does not start, there
is
pressure in P-hose
S
triking piston is stuck in
cylinder
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
Chisel retainer gets loose
during operation
Replace lock ring in chisel
retainer
Chisel bushing or chisel
retainer are worn
Replace parts, see section 8
Wrong chisel size
Check
Bre
aker works irregularly
Impurities in hydraulic oil
Replace oil and oil filter
(see workshop manual of
power source)
Oil level in power source too
low
Add hydraulic oil
Wrong chisel size or worn
chisel bushing
Check
Bad performance
Intern
al leak
Dismo
unt valve housing and
replace O-rings, see section 10
Oil flow from the power source
is not correct for the breaker
Check oil flow
Accumulator pressure too low
Charge with Nitrogen/replace
accumulator, see section 11
Chisel retainer gets loose
Replac
e lock ring in chisel
retainer
Defective Q.R. coupling
Check Q.R. coupling
Return pressure too high
Check power source/hoses
Hose diameter too small
Check hoses
Trigger piston not fully
activated
Replace parts in handle
See section 12

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8. Mounting and Di mounting of Main Component
Dismount chisel retainer and nose part.
Dismount tail-hoses, fittings
and plastic cover.

9
Dismount handle.
Dismount accumulator.
IMPORTANT: There are two screws in the same hole – loosen them carefully.

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Dismount cylinder.
Main components of HH10 breaker.
Mounting of Main Component
Start by mounting the
cylinder on the valve
block. Make sure to
degrease all parts
carefully with Loctite
063.
Add a drop of Loctite
243 in the four
threads, and tighten
with a torque of
40 Nm.

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Then mount the accumulator. Clean all threads carefully with Loctite 063. Mount the seal
ring on the accumulator, and grease the thread with Loctite 638. Tighten the accumulator
with a torque of 90 Nm. Then make a mark by means of a 5 mm drill. Clean the set screw,
add Loctite 243 and tighten it with a torque of 5 Nm. Insert the screw plug and tighten.

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N
ow mount the
handle.
Clean the thread and
screws with Loctite
063.
Make sure that the
distance piece is
attached to the rod of
the trigger piston.
Tighten the screws
with a torque of
25 Nm.
Then mount the
plastic cover.
Screw in the fittings
and tighten with a
torque of 80 Nm.

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Now mount the nose part. Clean all threads with Loctite 063, and add Loctite 243 to all
threads. Tighten screws with a torque of 25 Nm. Mount the lock ring on the chisel
retainer. Grease the thread of the nose part with copper paste, and mount the chisel
retainer. Mount tail-hoses. Mount the pressure hose with female coupling at ”P”, and
mount the return hose with male coupling at ”T”.

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9. Repair of Cylinder
At repair carefully check the inner surface of the cylinder. Visible wearing marks are
acceptable, but they may not be so distinct that you can feel them with a nail. Also check
the cylinder contact surface towards the valve housing for errors.
Di mounting
Mounting
At every repair, replace all seals at the bottom of the cylinder. When mounting a new rod
wiper, use HYCON special tool, part No. 9991 5.
Be careful not to damage the surfaces when removing the old seals.

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10. Repair of Valve Hou ing and Trigger Pi ton
Remove the trigger piston carefully. Then loosen the screws and also remove the spool
carefully.
Di mounting

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When repairing the trigger piston,
never loosen the piston from the
piston rod. These parts are adapted
to each other and are delivered as
one spare part.
Visible wearing marks are accept-
able, but the surface may not have
scratches you can feel with a nail.
If the breaker is leaking oil around
the trigger rod, replace seals in the
seal housing.
Mount new O-rings first.
Mount new seal. Press the seal into
position with your finger.
Carefully hammer the rod wiper into
position with HYCON special tool
part No. 9991664
When mounting the washer, it is
important to place it correctly. The
plane side of the washer must turn
upwards.

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Mounting of Spool
Clean carefully with Loctite 063 degreaser. If necessary, use an M6 threaded pin to
remove old Loctite. Add Loctite 243 when mounting, and tighten the screws with a torque
of 12.5 Nm.

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Mounting of Trigger Pi ton
Carefully grease the trigger piston before pushing it in, add Loctite 243 to the two threads,
and tighten the screws with a torque of 12.5 Nm.

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11. Charging of Accumulator
First put a long rod down the hole of the
accumulator to check if the accumulator is
pressurized.
If the diaphragm can be pushed a lot, the
accumulator must be charged with Nitrogen
or the diaphragm is defective.
In case of a defective diaphragm, the
accumulator must be replaced. Loosen the
charging screw.
If the accumulator is in order, you can hear a
clear whistling sound of Nitrogen. In this case
merely recharge the accumulator.
If there is no whistling sound, the diaphragm
is probably damaged and must be replaced.
HYCON filling device part No. 4040061. We can
supply adaptors for other filling devices – both
between bottle and filling device and between
filling device and charging screw. Ask for further
information.