Hydraulic Core Drill

HCD25-100 • HCD50-200

HYCON A/S

Juelstrupparken 11 DK-9530 Støvring

Denmark

Tel: +45 9647 5200 Fax: +45 9647 5201

Mail: hycon@hycon.dk

www.hycon.dk

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Contents Page 1. Safety Precautions ...................................................................................... 2

2. Oil Flow, Pressure and Testing ..................................................................... 4

3. Technical Data ............................................................................................ 5

4. Dimensions ................................................................................................. 6

5. Service and Maintenance ............................................................................. 7

6. Fault Location ............................................................................................. 8

7. Dismounting and Mounting of Main Components .......................................... 9

8. Repair of Bearing Housing .......................................................................... 19

9. Repair of Valve Housing ............................................................................. 24

10. Tool List ....................................................................................................26

11. Spare Parts Lists ........................................................................................27

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1. Safety Precautions

• Read the core drill and power source operating manuals prior to use.

• Only use the core drill in accordance with the local working regulations on al-lowed working time.

• Check the oil flow to the core drill. The oil flow may not exceed 20 l.p.m./max.

170 bar. Please refer to page 4.

• Make sure that the core bit is firmly fastened.

• For handheld drilling, always use core bits approved for this purpose.

• The HYCON core drill is supplied with a trigger lock. This may only be used when drilling in a rig.

• The core drill has an automatic integrated security that makes the core drill stop

if the core bit jams. However, in case of jamming, always loosen the core bit from the material, before you start drilling again. The integrated security is set from the factory and may not be disturbed.

• Start the core drill just before you start drilling, and stop it once the drilling is

done. Do not let the core drill run freely in the air.

• In case of horizontal drilling or drilling 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 core drill when connected to the powerpack. • Always use approved hoses. Contact your dealer, if necessary. Mount the hoses

correctly so that the core drill rotates in the right direction (clockwise).

• 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 core drill, but always maintain a good footing and keep your balance.

• The operator must be properly trained in using the core drill or under supervision of a qualified instructor.

• The operator must always use protective goggles, earplugs, hard hat and shoes when operating the core drill.

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• Never use the core drill close to electric cables. Prior to operation, check whether there are hidden or buried cables.

• Never wear loose clothing as it may get entangled in the moving parts of the core drill.

• Inspection or cleaning of the core drill, change of core bit or disconnection of

hoses may never be done while the core drill is connected to the powerpack, as unintentional activation of the core drill can cause severe damage.

• Always connect hoses to the core drill before starting the powerpack. Be sure that all couplings are tight.

• The core drill may not be operated if the oil temperature is above 70 C°.

Operation at higher temperatures may result in the core 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 core drill not in use should always be kept in a safe and dry place.

• Always make sure that the core 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 core drill. If this is not done, there is a risk of damage to the quick release coup-lings or the hydraulic system getting overheated.

IMPORTANT

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2. Oil Flow, Pressure and Testing Your new HYCON core 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 core 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. The core drill should be tested before and after servicing – before servicing to check if there are certain problems related to the core drill, and after servicing to ensure that the core drill works satisfactorily. Efficient testing can only be done by means of test equipment that includes a flow and pressure gauge. It is important to check that the core 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. The table below shows the pressure range of the core drills.

Working Pressure

HCD25-100/HCD50-200

Free Air

(without drilling) Drilling

20 l.p.m. 40-60 bar 120–150 bar

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3. Technical Data

HCD25-100 HCD50-200

Weight w/o hoses, core bit and adaptor

7.6 kg

7.6 kg

Oil flow 20 l.p.m. 20 l.p.m.

Working pressure nominal 100 bar 100 bar

Pressure relief valve in power source

Max. 170 bar

Max. 170 bar

Max. return pressure 40 bar 40 bar

Max. oil temperature 70° C 70° C

Rotary speed at 20 l.p.m. 1500 r.p.m. 600 r.p.m.

Sound pressure level 1 m LPA 85 dB 84 dB

Vibration level ‹ 2.5 m/s² ‹ 2.5 m/s²

Core bit size ø25-ø100 mm ø50-ø200 mm Up to ø350 mm for the experienced user

Thread: External G ½” or internal 1 ¼” – 7 UNC

Thread: External G ½” or internal 1 ¼” – 7 UNC

Necessary cooling capacity on power source

1 kW

1 kW

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4. Dimensions

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5. Service and Maintenance

Service/Maintenance Daily Weekly Yearly

Check couplings and clean carefully X

Check hoses X

Check bearing for clearance X

NB. At service/repair it is important to mount the hoses correctly.

Oil Types

The HYCON core 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.

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6. 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 Cause Solution

Core drill does not start, there is no pressure in P-hose

Trigger mechanism does not actuate trigger piston correctly

Replace worn parts in handle (nylon distance piece)

Trigger mechanism is stuck in valve block

Dismount trigger piston from valve block, and clean or replace parts

Core drill does not start, there is pressure in P-hose

Defective Q.R. coupling Check Q.R. coupling

Oil supply is made to T-connection

Switch pump and tank line

Trigger lock is too slack Spring is too slack Replace spring

Core drill 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

Bad performance Internal leak because of dirt in pressure relief valve

Clean valve

Oil flow from the power source is not correct for the core drill

Check oil flow

Core drill stops too easily Adjust pressure relief valve

Hose diameter too small Check hoses

Defective Q.R. coupling Check Q.R. coupling

Return pressure too high Check power source/hoses

Trigger piston nut fully activated

Replace worn parts in handle (nylon distance piece)

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7. Dismounting and Mounting of Main Components Dismount the front adaptor and the water hose. Dismount the handle ring for the supporting handle, and remove supporting handle. Mount HYCON service tool No. 1 (special screw) and No. 2 (tightening cup). The bearing housing can now be removed from the motor adaptor. ATTENTION! The thread between bearing housing and motor adaptor is left-handed

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Loosen the three screws, and remove the motor adaptor. Dismount the two screws at the back of the handle, and remove the handle. Dismount the distance piece. Then dismount the tail-hoses. Wait a while to let the hydraulic oil run out. The valve block with motor can now be pulled out of the plastic cover. Dismount the two seal rings.

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Dismount the two banjo bolts, and remove the valve block from the motor.

Core Drill Main Components

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Mounting Place the two O-rings on the motor, and mount the valve housing over the motor. It is important that the O-rings are placed precisely in the grooves on motor and valve block. Mount the seal rings on the banjo bolts, and mount the banjo bolts through the valve block into the motor. Tighten the bolts with a torque of 55 Nm. Place the ball in the banjo bolt, and strike a blow on the ball with a hammer and a drift punch. Place the compression spring in the hole, and mount the threaded plug with seal.

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Mount the pressure relief valve, and tighten with a torque of 30 Nm. Mount the trigger piston, and add Loctite 243 to the two threads. Mount the mounting plate and the two screws. Tighten the screws with a torque of 30 Nm. Mount the four cylinder pins. Mount the seal rings in the valve block before pushing motor and valve block into the plastic cover.

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Push motor and valve block into the plastic cover. Mount the two fittings and tighten with a torque of 70 Nm. Mount the tail-hoses. Mount the hose with male coupling at ”T”, and the hose with female coupling at ”P”. Clean the three threads on the motor with Loctite 7063, and add Loctite 243 to the threads. Mount the motor adaptor with the three screws. Tighten the screws with a torque of 20 Nm.

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Mount the complete bearing housing on the motor adaptor (beware of left-handed thread). Then use HYCON service tools No. 1 and 2 (special screw and tightening cup). Tighten the bearing housing with a torque of 130 Nm. Set the pressure relief valve by loosening the nut and turning the set screw with a hex head wrench. Setting of the pressure relief valve can be done as follows: Connect the core drill to the powerpack, and insert the test equipment in between (HYCON test equipment No. 4040062). Fasten the core drill in a vice, and activate the trigger lever. CAUTION: Hold on tightly to the core drill before activating the trigger lever Hold on to the core drill so that it does not revolve, and read the pressure on the pressure gauge. Normal setting is 115 bar for the HCD50-200 and 125 bar for the HCD25-100. If the pressure deviates too much, adjust the set screw a little in or out.

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Mounting of Handle Place the trigger lever in the handle, and mount the pin through all three holes. Mount a retaining ring on each side. Mount the trigger lock on the handle.

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Add Loctite 243 to the two threads, and mount the handle on the valve block. Always mount the distance piece between trigger rod and handle (check distance piece for wear. Replace it, if too worn). Tighten the two screws with a torque of 25 Nm. Mount the handle ring for the supporting handle. Then mount the spring ring for the supporting handle. Mount the nipple and the water hose. Fix the hose clamp with an end cutter.

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Mount the supporting handle. Grease the thread on the front adaptor with copper paste, and mount it on the shaft.

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8. Repair of Bearing Housing Dismounting Dismount the retaining ring, and remove the distance ring and the compression rings. Use a drift punch and a hammer to remove the shaft from the bearing housing. Then use HYCON service tool No. 3 to remove the bearing and the seal housing at the other end of the bearing housing. Replace all seals and O-rings on both the inside and the outside of the seal housing.

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Mounting First place the O-rings in the grooves at both ends of the seal housing. Then place the seals in the same grooves as the O-rings. Press with your finger on the seal to ensure it is completely down the groove. Place two O-rings on the outside of the seal housing. Carefully grease seal housing and bearing housing on the inside. Place the seal housing in the bearing housing. Hammer in the seal housing by means of HYCON service tools No. 3 and 4 (top and bottom). By using these special tools, the seal housing will be fitted perfectly into the bearing housing.

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Turn the bearing housing and grease on the inside of the bearing housing and on the bearing. Hammer in the bearing by means of the same HYCON service tools No. 3 and 4. Turn the bearing housing, grease bearing housing and bearing again. Hammer in the bearing at the other end the same way.

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Grease the shaft and mount it down through the bearings. Hammer in the shaft by means of HYCON service tools No. 4 and 5. Position the compression rings with the curves away from each other before mounting them on the shaft. Mount the distance ring on the shaft. Finally mount the retaining ring.

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Turn the bearing housing, and carefully mount the seal on the shaft. Use HYCON service tool No. 7 to fasten the seal. Check that the shaft can revolve.

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9. Repair of Valve Housing Dismounting Dismount the pressure relief valve. Then dismount the banjo bolts, and remove the valve housing from the motor. Dismount the two screws and remove the trigger mounting plate. Carefully remove the seal housing from the valve block with a pair of pliers.

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Mounting

Add Loctite 542 to the four threads, and mount the pipe plugs. Screw the pipe plug 1/8” fully in (only applies to the HCD50-200 model). Add Loctite 542 to the upper part of the thread and mount the pipe plug 1/4”. Mount the threaded plug with seal on the valve block. Carefully push the trigger piston into the valve block. Add Loctite 243 to the two threads, and mount the trigger mounting plate. Tighten the two screws with a torque of 30 Nm. Mount the pressure relief valve, and tighten with a torque of 30 Nm.

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10. Tool List

a

b

c

d

e

f

g

h i

a. Hex head wrenches sizes ¼”, 3/16”, 4 mm, 5 mm, 6 mm

b. Hex head socket drivers ½” 5 mm long, 6 mm c. ½” torque wrenches 5-50 Nm, 10-130 Nm

d. ½” socket 24 mm long, ½” socket 27 mm long e. Combination spanners, sizes 14, 17, 22, 24, 27

f. External circlip pliers small and large

g. End cutter h. Hammer

i. Drift punch

1

2

3

4

5

Part No. 9992245 Puller

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HYCON Service Tools