HYCON HRD20 Instruction manual

Hydraulic Rock Drill
HRD20
HYCON A/S
Juelstrupparken 11
DK-9530 Stoevring
Denmark
Tel: [phone]
Fax: [phone]

-
4
-
CONTENT
1. SPECIFICATIONS 1
2. PURPOSE 2
3 . D E S C R I P T I O N O F E A C H P A R T 3
4. OPERATION 4
5. SAFTEY PRECAU T I O N 5
6. CONSTRUCTION 6
7. MAINTENANCE 7
8. CAUSE OF TROUBLE AND COUNTERMEASURE 8
9. DISASSEMBLE 12
10. POST DISASSEMBLE INSPECTION AND REPAIR 15
11. ASSEMBLE 21
12. ACCUMULATOR AS CHAR IN 31
13. MAINTENANCE STANDARD 32
14. SPECIAL TOOLS 37

-
1
-
1.
1.1.
1. SPECIFICATIONS
SPECIFICATIONSSPECIFICATIONS
SPECIFICATIONS
Specifications
1. Type HRD20
2. Working Pressure 8.8-11.8MPa
3. Max Pressure 150 Bar
4. Mass 20 kg
5. Dimensions 626mm (L) x 412mm (W)
6. Tool Chuck Size 7/8” x 108mm Hex
7. Hose Connection 3/8”
8. Connecting Self-Seal Coupling
9. Required Oil Flow 25-30L/min
10. Dust Scavenging Built-in Compressor
11. Compressor Pressure Max 0.2MPa
12. Air Displacement Max 0.08m3/min

-
2
-
2. PURPOSE
2. PURPOSE2. PURPOSE
2. PURPOSE
1. Connect the drill through a hydraulic hose and coupling to a hydraulic hose
conforming to the specifications
2. Mount a tool ( drill rod/bit ) confirming to the chuck size of the drill.
3. Support the drill handle with hand and operate the lever on the handle in order to
start and stop the drill.
4. Hydraulic energy supplied to the drill is converted to the force for hitting and
rotating a tool and compressing the air.
The following works are mad4 by utilizing these hitting and rotating power and
compressed air.
The R.P.M. is variable from 0-400 and only hitting power can be used.
1) Drilling a hole in the concrete and rock.
2) Breaking concrete, asphalt and rock.
5. The following using manners are forbidden:
1) Using the drill by installing it on an operating section ( arm, boom etc of a
construction vehicle.
2) Using the drill while it is soaked in water, saltwater, or muddy water.
3) Connecting the breaker to a hydraulic source which capacity is beyond the
allowable specifications.
4) Operating the drill while oil temperature below – 10C or over + 100C.
5) Dropping the drill by using its weight and giving an impact to a mounted tool.
6) Using a tool which size is different from the breaker chuck size.
7) Using the drill for other purpose than described in this section.

-
3
-

-
4
-
4. OPERATION
4. OPERATION4. OPERATION
4. OPERATION
1) Connect extension hoses to the hoses of this drill.
2) Connect another end of the extension hoses to a suitable hydraulic source.
Connection should be don securely after stopping the hydraulic source.
3) Open the drill stay and attach a suitable tool ( drill rod ).
Then close the drill stay and check that the attached tool does not come off easily.
4) Start the hydraulic source and change over the valve so that hydraulic oil may flow
into the circuit with which the drill is connected.
The drill control lever will rise once the hydraulic oil starts to circulate.
5) Support the drill handle and press the tool end to the drilling section.
Then grasp the control lever, and the drill will start drilling accordingly.
6) When oil temperature of the hydraulic source is low during the winter, warm up the
drill until the temperature reaches + 10C.
Also, stop operating the drill if the temperature exceeds + 100C.
7) After finishing the operation, stop the hydraulic source and disconnect the hoses
from the drill.
8) Open the drill stay and detach the tool.
9) Notes to Users
1) Connection and disconnection of the hose should be carefully done so that dust
or dirt may not adhere to the couplings.
2) Prepare a suitable platform so that the operator may not stumble while holding
the drill during operation.
3) Other personnel than the operator should not enter the area within 5m from the
working position during operation.
4) Pay much attention to the drill bit so that it may not damage your feet during
operation.
Make sure to wear safety boots and other protective clothing as designated.
5) Place the drill flat on the ground while it is not being used so that it may not fall
accidentally and damage something or injure somebody.
6) When connecting the drill to a hydraulic source, check that pressure and flow
are within the allowable range under specifications.
7) Extension hose to use should be of 1/2” in diameter and 10m in max length.
8) If the hose is damaged accidentally and causes oil injection, stop the hydraulic
source immediately.

-
5
-
9) Deteriorated or damaged hose should not be used as it is hazardous.
10) Stop the hydraulic source before connecting or disconnecting the hose.
11) While the drill is being used, temperature of each section rises as temperature
rises.
Use gloves to avoid unnecessary damage due to the high temperature.
5. SAFETY PRECAUTIONS
5. SAFETY PRECAUTIONS5. SAFETY PRECAUTIONS
5. SAFETY PRECAUTIONS
1) Check that the hydraulic source to connect to the breaker satisfies the following
conditions;
Max pressure: 9.0 ~ 17.2MPa
Oil flow : As indicated in the specifications
2) A tool to use should conform to a chuck size of the breaker.
3) When connecting the breaker to the hydraulic source, use extension hose which has
been manufactured according to the hydraulic source coupling fittings.
4) When using the breaker, wear protective clothing as described below.
Helmet------------------To avoid chips and damages caused by
stumbling
Dustproof glasses---To protect eyes from being damaged by a
splash of work piece chips.
Dustproof musk-----To protect lungs from drilling dust.
Safety boots-----------To protect feet from being damaged by
chisel.
Thick gloves-----------To prevent hands from touching high
temperature section directly or from vibrating.
Ear plugs/ covers-----To protect ears from being damaged by
excessive nose.
5) Check the following points before using the breaker;
Check that no clamping bolts or nuts are loosened, and there is no oil leakage.
Check that the hose attached on the breaker is not loosened, damaged, or
clacked extremely. Also check that there is no oil leakage.
Check that the extension hose is not damaged or cracked, and there is no oil
leakage.
Check that a tool to use has no damage or crack on the surface, as it may result
in breakage.
Check that the handle is securely mounted.
Check that the accumulator is securely tightened, and there is no oil leakage in

-
6
-
the power port.
- 5 -

-
7
-
7. MAINTENANCE
7. MAINTENANCE7. MAINTENANCE
7. MAINTENANCE
1) Check hydraulic oil condition so timely as to keep it always clean.
If it sticks or changes the color, replace it.
2) Check oil volume before starting if it is sufficient as it decreases by connecting and
disconnecting the hoses.
3) The air cleaner protects the built-in compressor from suctioning dust.
Take out the cleaner element and sponge from the cleaner case and clean them daily.
The negligence if this cleaning causes fast wear of the compressor cylinder, piston
ring and valve.
Inspection time
Inspection point
200hours
or 1year
400 hours
or 2 year
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

-
8
-
8
88
8. CAUSE OF TROUBLE AND COUNTERMEASURE
. CAUSE OF TROUBLE AND COUNTERMEASURE. CAUSE OF TROUBLE AND COUNTERMEASURE
. CAUSE OF TROUBLE AND COUNTERMEASURE
1. Drill does not start operation even though control lever is grasped.
Cause Solution
1. Hydraulic source is not in operation ( or
the selector valve is not correctly set )
1. Start hydraulic source ( switch
selector valve setting to let work oil
flow into breaker circuit )
2. The hose is disconnected 2. Connect the hose
3. Trouble of quick coupler 3. Check each coupler
4. Connection on high pressure hose and
return hose are revered.
4. Check the connections; with
hydraulic breaker set upright, connect
upper hose to high pressure
side( pump side ) and lower hose to
return side ( tank side).
5. Relief valve setting for hydraulic source
is wrong
5. Set to 150 Bar
6. Control valve is damaged 6. Replace
7. Control valve malfunction 7. Disassemble the drill and improve
control valve and valve body fitting
and eliminate foreign matter.
2. Drill strikes but does not rotate
Cause Solution
1. The rotation adjust knob is turned fully
clockwise and closed
1. Adjust the knob to a proper position.
2. Breakage of the gear motor key 2. Replace
3. Obstacles stick in the gear motor 3. Disassemble and clean

-
9
-
3. Drill operates but striking and rotating at low rate
Cause Solution
1. Low hydraulic source flow rate 1. Increase flow rate to 25-30L/min by
rev-up the engine
2. relief valve setting for hydraulic source
is too low
2. Replace
4. Striking rate is normal but blows are weak
Cause Solution
1. Low accumulator gas pressure(not
higher than 25kg/cm2)
1. Increase pressure to 25kg/cm2 by
filling nitrogen gas.
2. Accumulator diaphragm is damaged 2. Replace
5. Scavenging bore dust is weak
Cause Solution
1. The air cleaner element or the cleaner
sponge is clogged.
1. Clean them
2. Obstacles stick in the compressor lead
valve.
2. Disassemble and remove them
3. Wear of the piston ring 3. Replace
4. Wear of the bushes 4. Replace

-
10
-
6. Striking rate is high and percussion is strong
Cause Solution
1. Excessive oil flow 1. Decrease flow rate to 25-30l/min by
slowing down the engine
7. Oil leaks from control lever
Cause Solution
1. Worn or hardened o-ring 1. Replace
8. Oil is included in the air for scavenging
Cause Solution
1. Wear of the piston rod seal 1.Replace
2. Scratch of the piston rod seal 2. Replace or remove the scratch
9. Oil leaks from the gear case ass’y
Cause Solution
1. Wear of the motor shaft o-ring 1.Replace
2. Damage of the packing 2. Replace
3. Wear of the motor housing o-ring 3. Replace
10. Oil leaks from internal shaft
Cause Solution
1.Wear of o-ring in gear housing 1.Replace

-
11
-
11. Drill rod rotates but does not strike
Cause Solution
1. The rotation adjust knob is turned fully
clockwise
1. Turn clockwise for proper position
2. Damage of the control valve 2. Replace
3. Damage of the piston 3. Replace the piston and the hammer
12. The air compressor does not supply air for scavenging
Cause Solution
1. Damage of the lead valve 1.Replace
2. Damage of the piston 2. Replace the piston and the hammer
3. Wear of the bush 3. Replace

-
12
-
9. DISASSEMBLE
9. DISASSEMBLE9. DISASSEMBLE
9. DISASSEMBLE
9-1 Notice before disassembling
Carry out disassembling in clean environment.
Dust or dirt will impede the proper operation of the drill.
9-2 Disassembling procedure ( See Fig.1 )
(1) Set the drill on a stand.
(2) Remove no.85, no.86 hydraulic hoses and their seal washers.
(3) Remove accumulator ass’y using the special tool T-1616 handle (S) for shell.
(4) Remove each 2 pieces of no.43 nut and no.56 washer.
(5) Holding handle grip, remove no.37 valve body.
(6) Extract no.4 cylinder from no.7 compressor cylinder.
9-3 Disassembling of each component
9-3-1 Disassembling of accumulator
(1) fix the accumulator ass’y on a vise.
(2) Remove no.31 cap.
(3) Loose the screw of no.32 cap bolt slowly and allow the enclosed gas discharge.
(4) Using the special tool T-1620 handle (S), loose no.33 lid and remove it.
(5) Take out no.34 diaphragm using a tool such as screw driver but being careful not to
damage it.
9-3-2 Disassembling of valve body ass’y ( see Fig.4 )
(1) Take our no.42 control valve.
(2) Take out no.76 spring pin ( dia 5mm) and remove no.38 control lever.
(3) Loose no.87 bolt and remove no.36 handle grip.
(4) Loose no.41 valve guide and remove valve guide ass’y.
(5) Take out no.40 valve rod from no.41 valve guide.
(6) To remove no.3 stud bolt, heat up the valve body by burner where stud bolts are
fixed.
After burned the glue on the stud bolts, they will be removed easily.
9-3-3 Disassembling of cylinder ass’y and hammer piston ( see Fig.5 )
(1) Take out the seal liner.
(2) Take out no.77 pin.
(3) Set cylinder ass’y using T-2014 pipe and T-2015 holder as in Fig.5.

-
13
-
(4) Insert pulling pin (HRC45 – 50 ) into the center hole of no.5 hammer piston and
make it detach from no.2 piston hammering the pin with hammer ( 4 lb).
(5) Remove no.52 dust seal.
Also, remove no.51 u-cup packing using edge-pointed tool.
This u-cup packing cannot be used any more.
9-3-4 Disassembling of compressor cylinder and air cleaner
(1) Detach no.27 cleaner cover and take out no.26 cleaner sponge, no.25 element and
no.24 packing.
(2) Loose 4 pieces of no.89 bolt and remove no.23 cleaner case and no.21 valve seat.
No.20 seat packing and no.22 packing (B) are attached to no.7 compressor cylinder
no.21 valve seat and no.23 cleaner case with silicon packing, so that remove the
packing using a driver not to damage them.
(3) Loose no.92 screw and remove no.28 retainer (B) and no.29 lead valve from no.7
compressor cylinder and no.21 valve seat.
9-3-5 Disassembling of gear motor
(1) Remove no.62 plug from no.10 motor block and take out no.78 spring and no.59
steel ball.
(2) Loose no.12 valve guide and remove valve guide ass’y.
(3) Take out no.80 spring from no.11 dial knob and take out no.13 selector valve.
(4) Loose no.86 bolt and remove no.18 gear housing ass’y.
(5) Remove no.16 idle gear and no.17 drive gear and no.15 internal shaft.
(6) Take out no.30 air seal from no.15 internal shaft.
(7) Remove no.19 drill stay from no.18 gear housing.
(8) Take out no.53 dust seal from no.18 gear housing.
(9) Remove no.14 thrust washer from no.10 motor block.
9-4 Removing of seals
(1) Pick out o-rings on and inside the valve body, cylinder valve guide, valve rod,
selector valve, compressor cylinder, motor block and gear housing not to damage
them.
** Pick out P5 o-ring attached to no.40 valve rod and no.13 selector valve cutting
them.
(2) O-rings except P5 o-ring can be used if there are no damage or not being hardened.

-
14
-

-
15
-
10. POST DISASSEMBILN INSPECTION AND REPAIR
10-1 Inspection of Different Types of Seal
(1) Replace the o-rings which have alternation in form, abrasion, cracks and hardness.
( no.63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73)
(2) Replace u-cup packings which have change in color, wear and hardness(no.51).
(3) Replace back up packings which have alternation in form and wear (no.74 ).
(4) Replace dust seals which have scratch and wear (no.52, 53 ).
(5) Replace seal washers which have scratches.
10-2 Diaphragm no.34
If there are cracks or damage on the part which includes metal sheet, replace it.
If the cracks have occurred to the upper part of the diaphragm interior, replace it.
10-3 Piston Ring no.6
Replace the piston ring which has wear or scratches.
10-4 Inspection of Moving Parts ( see Fig.4 )
(1) Piston no.2 Using the sand stone, remove the scratches on the section
sliding in the u-cup packing. The piston which has deep
scratches must be replaced, otherwise u-cup packing will
damage.
(2) Control valve no.42 If there are wear, cracks or cavitations erosion on the
surface, replace it.
(3) Valve body no.37 If there is interior wear, or cavitations erosion, replace it.
(4) Hammer piston no.5 If there are wear, or scratches on the circumferential
surface, replace it. The piston which has more than
1.5mm wear on the hitting end also must be replaced.
(5) Compressor cylinder
no.7 If there are scratches on the surface or it wears, replace it.

-
16
-
10-5 Internal Shaft no.15
Inside hexagon of bushing shows the indicated limit of wear, replace it.
10-6 Inspection of Rotating Parts
(1) Idle gear no.116, drive gear no.17
Replace if there are scratches or wear on the teeth or flat side.
(2) Thrust washer no.14
Replace if there are scratches or wear on the edge.
(3) Internal shaft no.15
Replace if there are scratches or wear on the gear of shaft.
(4) Key no.58
Replace if there is wear or un-tighten or alternation in form.
(5) Motor housing no.10
Replace if there are scratches or wear on the inside and shaft bearing.
(6) ear housing no.18
Replace if there are scratches or wear on the inside and shaft bearing.
(7) Selector valve
Replace if there are scratches or wear on it.
10-7 Drill Stay no.19
Replace if there are remarkable wear or scratches.
10-8 Control Lever no.38
When the lever bends, correct it.
If the contact point of lever with valve rod wears, make it thick by welding.
10-9 Bush no.8
Replace if there are scratches or peeling-off on the inside of bearing metal.
10-10 Spring no.9
Replace if there are inelasticity or crack.
10-11 Lead Valve no.29
Replace if there are cracks or breaking-off.
10-12 Handle rip no.36
Replace if there are scratches on it.

-
17
-

-
18
-