HYCON HCS14 Pro Workshop Manual Download Page 1

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Hydraulic
Cut-Off Saw

HCS14 Pro
HCS16 Pro
HCS18 Pro

HYCON A/S

Juelstrupparken 11
DK-9530 Støvring
Denmark

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

[email protected]

www.hycon.dk

Summary of Contents for HCS14 Pro

Page 1: ...Hydraulic Cut Off Saw HCS14 Pro HCS16 Pro HCS18 Pro HYCON A S Juelstrupparken 11 DK 9530 Støvring Denmark Tel 45 9647 5200 Fax 45 9647 5201 Mail hycon hycon dk www hycon dk ...

Page 2: ...nd Pressure 4 3 Technical Data 5 4 Dimensions 6 5 Service and Maintenance 7 6 Testing 8 7 Fault Location 9 8 Dismounting and Mounting of Main Components 10 9 Repair of Handle 21 10 Repair of Valve Block 23 11 Tool List 25 12 Spare Part Drawings Lists 26 ...

Page 3: ...osen the disc from the material before you start cutting again Start the cut off saw just before you start cutting and stop it again once the cut ting is done Do not let the cut off saw run freely in the air In case of horizontal cutting or cutting above the head always be aware of mate rial falling down A fine jet of oil at pressure can penetrate the skin It is therefore important never to use yo...

Page 4: ... the oil temperature is above 80 C Ope ration at higher temperatures may result in the cut off saw 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 cut off saw not in use should always be kept in a safe and dry place A...

Page 5: ...sure results in overload of the cut off saw 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 cut off saw 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 ...

Page 6: ...essure 40 bar 40 bar 40 bar Max oil temperature 80 C 80 C 80 C Number of revolutions 2500 3800 r p m 2000 3800 r p m 2000 3300 r p m Circumferential speed 46 70 m s 42 80 m s 47 80 m s Disc size ø350 ø360 mm ø400 ø410 mm ø450 ø460 mm Arbor size ø25 4 mm ø25 4 mm ø25 4 mm Cutting depth 137 mm 162 mm 187 mm Vibration level 2 5 m s 2 5 m s 2 5 m s Sound pressure level 1 m LPA 92 dB 93 dB 93 dB Sound ...

Page 7: ...6 4 Dimensions Tool Length mm Height mm Width mm Radius mm 14 saw 600 373 236 188 16 saw 600 373 236 215 18 saw 600 373 236 238 ...

Page 8: ...t off saw 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 y...

Page 9: ... off saw by mounting the test equipment at the pressure hose just before the saw 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 cut off saw Measure oil flow and working pressure when the saw has warmed up The oil flow must correspond to the technical data of the saw and at this oil flow the working pressure of the saw...

Page 10: ...ling Check Q R coupling Saw does not start there is pressure in P hose Oil supply is made to T connection Switch pump and tank line Safety trigger does not work Spring is too slack Replace spring see section 9 Impurities in hydraulic oil Replace oil and oil filter see workshop manual of power source Saw works irregularly Oil level in power source too low Add hydraulic oil Internal leak Dismount va...

Page 11: ...ointing downwards as oil will come out when the hoses are disconnected Dismount the water hose Then loosen the two screws on the handle and carefully pull off the handle Dismount the two fittings and unscrew the three screws going through the valve block The bracket for the trigger piston can now be removed ...

Page 12: ...the plastic cover This way there will be no damage on the valve block Dismount the set screw from the adaptor for the disc and remove the adaptor Unscrew the screw with hole for water supply Dismount the two star knobs and remove the guard Dismount the four washers and the distance pipe ...

Page 13: ...motor plate and then loosen the nuts on the elbow fittings between pipes and motor Now remove the motor Unscrew the four screws on the motor plate and push the steel frame out of the plastic cover To be able to pull the steel frame fully out of the plastic cover it is necessary to adjust the pipes Twist the pipes while pulling them out of the cover ...

Page 14: ...nts Start by inserting the pipes in the plastic cover twist them while pushing them into position Insert the O ring in the angle plate and grease Add Loctite 243 to the two threads and mount the angle plate on the steel frame Tighten the screws with a torque of 20 Nm ...

Page 15: ...n push the frame completely into the cover Again use the steel bars to catch the pipes inside the plastic cover and push out the two pipes through the steel frame Add Loctite 243 to the four threads and mount the motor plate Tighten the screws with a torque of 20 Nm Place the motor on the motor plate and tighten the nuts on the elbow fittings by hand Mount the two screws with lock nuts through the...

Page 16: ...nd grease To mount the water pipe you need a steel bar HYCON special tool No 9992079 Insert the steel bar through the steel frame and down in the hole at the bottom of the frame Then insert the water pipe over the steel bar and push it into position Remove the steel bar Push the water pipe again to make sure that it is placed correctly at the bottom of the frame ...

Page 17: ... when they are pushed down over the pipes When dismounting the cut off saw always replace the O rings Carefully push in the trigger piston and mount the bracket for the trigger piston Add Loctite 243 to the three screws and tighten with a torque of 20 Nm Mount the distance piece on the trigger rod check the distance piece for wear replace if too worn Push in the trigger rod trigger piston should m...

Page 18: ...dle Tighten the two screws with a torque of 20 Nm Now mount the bracket for the front handle and the screws in the plastic cover Tighten all four screws with a torque of 15 Nm Add Loctite 243 to the thread on the front handle and tighten the two screws with a torque of 15 Nm ...

Page 19: ...etween motor and pipes Place the four washers and the small distance pipe in the motor plate Mount the cover and the retainer plate Add Loctite to the thread for the screw with hole for water supply mount the screw and tighten with a torque of 8 Nm ...

Page 20: ...rque of 15 Nm Push the adaptor down over the motor shaft and carefully tap the shaft key into position Make two centre punch marks on each side of the keyway to prevent the shaft key from slipping out Add Loctite 243 to the small thread in the adaptor and mount the set screw Tighten with a torque of 3 Nm ...

Page 21: ...ount the return hose with male coupling a T and the pressure hose with female coupling at P Add Loctite 542 to the thread and mount the nipple for the water hose Mount the water hose Mount the water hose and fix it with the hose clamp ...

Page 22: ...ance is too big Remove the two retaining rings from the pin and push out the pin Dismount the trigger lever Hammer out the pin for the safety trigger by means of a drift or a screwdriver the pin cannot be used again Now remove the safety trigger Dismount the two screws that fix the leaf spring to the safety trigger ...

Page 23: ...ough the handle and safety trigger Insert the trigger lever in the handle and mount the pin through handle and trigger lever Mount the retaining rings on both sides of the pin Place the entire handle on a firm surface so that the pin does not slip out when hammering on it With a hammer and a punch expand the hole in the pin so that the pin is firmly secured Do this from both sides ...

Page 24: ...th Loctite 7063 and clean it with compressed air Dismount O rings O rings cannot be used again due to risk of leakages If necessary dismount the pipe plugs only dismount if one of them is leaking and clean with Loctite 7063 Finally clean the entire valve block with Loctite 7063 ...

Page 25: ... Add Loctite 542 to the threads and mount the pipe plugs Mount the check valve in the valve block and tighten it with a torque of 40 Nm Place the four cylinder pins in the corner holes Mount O rings in the three holes and grease ...

Page 26: ...for torque wrench Sizes 3 16 2 5 mm 5 mm 6 mm long e 24 mm socket long f 19 mm socket g Hex head wrenches sizes 6 mm 3 16 h Hammer i Centre punch j Screw driver PZ 2 k End cutter l Small external circlip plier m HYCON special tool No 9992079 consisting of 6 mm round steel bars 2 x 31 5 cm 1 x 45 5 cm For mounting of hydraulic pipes and water pipe in the frame ...

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