HYCON HCS14 Pro User manual

HCS14/16/18 Pro
Hydraulic Cut-off Saw
From serial No. 4505
Revised 30.08.2011
Prior to Operation
We thank you for choosin a
HYCON cut-off saw.
To ensure smooth operation
and lon -lastin performance
of your new cut-off saw, we
recommend you to study this
operatin manual carefully and
pay special attention to the
chapters about
Safety and Service
Precautions
We hope you will be satisfied
with your new HYCON cut-off
saw.
Best re ards
HYCON A/S
HYCON A/S
Juelstrupparken 11
DK-9530 Støvring
Denmark
Tel: [phone]
Fax: [phone]
Mail [email protected]k
www.hycon.dk

1
Contents
Page
Safety Precautions .............................................................................................. 2
Oil Flow and Pressure ......................................................................................... 4
Useful Information re. the Use of Cut-off Saw ...................................................... 4
Startin Instructions ........................................................................................... 5
Technical Data ................................................................................................... 6
Performance Chart ............................................................................................. 7
Dimensions ........................................................................................................ 8
Connection to Hydraulic Power Sources ............................................................... 9
Service and Maintenance ................................................................................... 10
Oil Types .......................................................................................................... 10
EC-Declaration of Conformity ............................................................................ 11
Warranty Conditions ......................................................................................... 12
Spare Parts List ................................................................................................ 13

2
Safety Precautions
•Read the cut-off saw and power source operatin manuals prior to use.
•Only use the cut-off saw in accordance with the local workin re ulations on al-
lowed workin time
•Check the oil flow to the cut-off saw. The oil flow may not exceed 30 l.p.m./
172 bar for the 14” version, 40 l.p.m./172 bar for the 16” version, and 34 l.p.m./
172 bar for the 18” version, respectively. Please refer to pa e 4. A too hi h oil
supply can result in the speed of the diamond disc bein too hi h, causin the
disc to break.
•Make sure that the diamond disc is mounted correctly and firmly fastened.
•Always use diamond discs approved for handheld cuttin and for the material to
be cut.
•Always use discs that are in ood condition.
•From the factory, the HYCON cut-off saw is mounted with a safety tri er, which
may never be disturbed or dismounted.
•The cut-off saw has an automatic inte rated security that makes the saw stop if
the diamond disc jams. However, in case of jammin , always loosen the disc from
the material, before you start cuttin a ain.
•Start the cut-off saw just before you start cuttin , and stop it a ain once the cut-
tin is done. Do not let the cut-off saw run freely in the air.
•In case of horizontal cuttin or cuttin above the head, always be aware of mate-
rial fallin down.
•A fine jet of oil at pressure can penetrate the skin. It is therefore important never
to use your fin ers 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 et medical treatment immediately.
•Never leave the cut-off saw when connected to the powerpack.
•Always use approved hoses. Contact your dealer, if necessary. Mount the hoses
correctly so that the cut-off saw rotates in the ri ht direction.
•The operator must pay extra attention and show caution when workin in difficult
workin areas, such as slopes and other dan erous nature of the round. Do not
reach too far with the cut-off saw, but always maintain a ood footin and keep
your balance.

3
•The operator must be properly trained in usin the cut-off saw or under super-
vision of a qualified instructor.
•The operator must always use protective o les, earplu s, hard hat and shoes
when operatin the cut-off saw.
•Never use the cut-off saw close to electric cables. Prior to operation, check
whether there are hidden or buried cables.
•Never wear loose clothin as it may et entan led in the movin parts of the saw.
•Inspection or cleanin of the cut-off saw, chan e of diamond disc or disconnec-
tion of hoses may never be done while the saw is connected to the powerpack, as
unintentional activation of the saw can cause severe dama e.
•Always connect hoses to the cut-off saw before startin the powerpack. Be sure
that all couplin s are ti ht.
•The cut-off saw may not be operated if the oil temperature is above 80 C°. Ope-
ration at hi her temperatures may result in the cut-off saw ettin warmer than
normal and the operator risks ettin burnt on it.
•To avoid all personal injury and dama e 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.
•Always make sure that the saw labels and warnin si ns are le ible.
•Always use hoses, couplin s and spares as such recommend by HYCON A/S.
•Repairs may only be carried out by experienced personnel.
•Make sure that all couplin s are cleaned before connection.
•Always disconnect the hydraulic circuit before connectin or disconnectin the
cut-off saw. If this is not done, there is a risk of dama e to the quick release
couplin s or the hydraulic system ettin superheated.
IMPORTANT
GTIGT

4
Oil Flow and Pressure
Your new HYCON cut-off saw is desi ned for a certain oil flow, workin pressure and
maximum pressure. A too hi h oil flow and/or a too hi h pressure results in overload
of the cut-off saw, meanin that the lifetime of your new HYCON tool will not be as
expected, and that your service and repair costs will be too hi h.
It is important to check that the cut-off saw is not supplied with an oil flow beyond
its desi n capacity, that the workin pressure is correct and that the maximum
allowed pressure is not exceeded.
On pa e 6 you will find the technical data, and on pa e 9 there is a uide to connec-
tion to hydraulic power sources and how to ensure that the cut-off saw is not over-
loaded.
seful Information re. the se of Cut-Off Saw
The HYCON cut-off saw is a compact tool with reat performance. There are no
other cut-off saws on the market with hi her performance in relation to size.
It is the perfect tool for cuttin in all types of concrete, brick wall, asphalt etc.
The cut-off saw can be mounted in a HYCON cart, but most frequently it is used for
handheld cuttin jobs. This is only possible due to an automatic safety function that
makes the cut-off saw stop immediately if the disc jams.
The cut-off saw has two handles for optimum operator comfort.
The saw is unaffected by water and can be operated in all workin environments,
even for cuttin under water.
The cut-off saw can also be connected to excavators and other machines. We re-
commend the use of a HYCON oil flow divider, which protects a ainst too hi h oil
flow, too hi h pressure and backwards rotations. See pa e 9.
The cut-off saw is desi ned for both dry and wet cuttin . Usually the best result is
achieved by wet cuttin , as this cools the disc and removes the bore meal. This re-
sults in as little wear on the disc as possible.
The utility values of your HYCON cut-off saw are numerous, and you will be pleased
with your investment.

5
Starting Instrutions
START
•Mount a diamond disc
•Connect hoses – clean couplin s before connection. Connect water supply.
•Set the power source on ”ON”.
•Find a ood footin for the cuttin .
•Activate the safety tri er, press the tri er lever towards the handle and
start the saw.
•Start by holdin the disc towards the material. When radually a roove is
cut, press the disc towards the material and cut throu h.
•It is important to keep the water supply steady and sufficient as it cools the
disc, removes the boremeal and uarantees you the best result with as little
wear on the disc as possible.
STOP
•Remove the disc from the material, and let o of the tri er lever.
•Set the power source on ”OFF”, and disconnect the water supply.

6
Technical Data
14”
C
ut
-
off Saw
16”
Cut
-
off Saw
18” Cut
-
off Saw
Weight w/o hoses and disc
8.
5
k
9.0
k
9.4
k
Oil flow
20
-
30 l.p.m.
20
-
40 l.p.m.
20
-
34 l.p.m.
Working pressure nominal
120 bar
120 bar
120 bar
Pressure relief valve on
power source
Max. 172 bar
Max. 172 bar
Max. 172 bar
Max. return pressure
40 bar
40 bar
40 bar
Max. oil temperature
80° C
80° C
80° C
Number of revolutions
2500
-
3800 r.p.m.
2000
-
38
00 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
-
ø
410
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/s²
‹ 2.5 m/s²
‹ 2.5 m/s²
Sound pressure level 1 m L
PA
92 dB
93 dB
93 dB
Sound power level L
WA
103 dB
104 dB
104 dB
Necessary cooling
cap
a
city
on power source
1 kW
1 kW
1 kW

7
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0m 5m 10m 15m 20m 25m 30m 35m 40m 45m 50m
3/4" hose 5/8" hose 1/2" hose 3/8" hose
Performance Chart
HCS14/HCS16/HCS18 Cut-Off Saw
Performance loss with different lengths of hoses:
Hose length
Pressure from power pack: 150 bar. Flow: 30 l.p.m. zero elevation 2 set couplings per 10 m hose.

8
Dimensions
Tool
Length
mm
Height
mm
Width
mm
Radius
mm
14” saw
6
00
373
236
188
16” saw
6
00
373
236
215
18” saw
6
00
373
236
238

9
Connection to Hydraulic Power Sources
The cut-off saw can be connected to various hydraulic power sources, such as ex-
cavators, trucks, loaders, tractors etc., and of course HYCON powerpacks, the desi n
of which ensures your new HYCON cut-off saw the absolute best workin conditions.
It is important that the cut-off saw is not subjected to an oil flow and a workin pres-
sure beyond its desi n capability. Please refer to the ID-ta on the saw in case of
doubt.
Check the oil supply and the workin pressure by means of test equipment. The test
equipment should comprise a pressure au e, a flow meter and a valve for adjust-
ment of pressure.
Make sure that:
•the oil supply is not too hi h
•the workin pressure is not too hi h
•the return pressure is not too hi h
•the pressure relief valve is not set hi her than 172 bar
•the internal diameter of the hoses is sufficient (min. ½”)
•all couplin s are in order
•the power source is equipped with an oil filter of min. 25 Micron
Hoses with too small internal diameter and/or defect couplin s cause the cut-off saw
to work with incorrect workin pressure.
Your dealer can help you check this.
If the output of the power source is too hi h:
•the power source must be adjusted to correct output
•or you can choose to mount a HYCON oil flow divider to protect the cut-off
saw a ainst overload
•or you can choose one of our HYCON powerpacks. Your dealer can uide you
in choosin the ri ht powerpack.
In case of doubt, please contact your dealer or HYCON A/S.

10
Service and Maintenance
Service/Maintenance Daily Weekly Yearly
Check couplin s and clea
n
carefully X
Check hoses X
NB. At service/repair it is important to mount the hoses correctly.
Oil Types
The HYCON cut-off saw uses standard hydraulic oil, i.e. all types of mineral oil and
biode radable oil, which comply with the followin values:
Recommended viscosity
20
-
40 cSt
Permitted viscosity
15
-
1000 cSt
Viscosity index
Min. 100
Temperature area
-
20° to +70° C
If usin biode radable oil, we recommend the use of oil based on rape. Other types
of oil can be a ressive towards the seals. If you are in doubt, please ask your
dealer.

11
EC-Declaration of Conformity
From Serial No.
We hereby confirm that cut-off saws HCS14, HCS16 and HCS18 4505
are manufactured in conformity with EC-directive 2006/42/EC.
HYCON A/S
Juelstrupparken 11
DK-9530 Støvrin
Denmark
Henrik Steen
General Mana er
01.09.2003
HYCON A/S
Juelstrupparken 11
DK-9530 Støvrin
Denmark
Tel: [phone]
Fax: [phone]
Mail [email protected]
www.hycon.dk

12
Warranty Conditions
We rant 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 handlin , lack of maintenance or the
like, will not be accepted as warranty.
The warranty covers the parts necessary for repair and the su ested avera e time
needed for repair.
For further warranty details, please contact your local dealer.