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HCS14/16/18 Pro
Hydraulic Cut-off Saw
From serial No. 4505
Revised 30.08.2011
Prior to Operation
We thank you for choosing a
HYCON cut-off saw.
To ensure smooth operation
and long-lasting performance
of your new cut-off saw, we
recommend you to study this
operating 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 regards
HYCON A/S
HYCON A/S
Juelstrupparken 11
DK-9530 Støvring
Denmark
Tel: +45 9647 5200
Fax: +45 9647 5201
Mail
www.hycon.dk
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Contents
Page
Safety Precautions .............................................................................................. 2
Oil Flow and Pressure ......................................................................................... 4
Useful Information re. the Use of Cut-off Saw ...................................................... 4
Starting 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
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Safety Precautions
• Read the cut-off saw and power source operating manuals prior to use.
• Only use the cut-off saw in accordance with the local working regulations on al-
lowed working 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 page 4. A too high oil
supply can result in the speed of the diamond disc being too high, causing the
disc to break.
• Make sure that the diamond disc is mounted correctly and firmly fastened.
• Always use diamond discs approved for handheld cutting and for the material to
be cut.
• Always use discs that are in good condition.
• From the factory, the HYCON cut-off saw is mounted with a safety trigger, which
may never be disturbed or dismounted.
• The cut-off saw has an automatic integrated security that makes the saw stop if
the diamond disc jams. However, in case of jamming, always loosen 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 your fingers to check for oil leaks and never to hold your face close to suspected leaks – use a piece of cardboard instead. If oil has penetrated the skin,
you should get 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 right direction.
• 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 cut-off saw, but always maintain a good footing and keep
your balance.
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• The operator must be properly trained in using the cut-off saw or under super-
vision of a qualified instructor.
• The operator must always use protective goggles, earplugs, hard hat and shoes
when operating 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 clothing as it may get entangled in the moving parts of the saw.
• Inspection or cleaning of the cut-off saw, change 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 damage.
• Always connect hoses to the cut-off saw before starting the powerpack. Be sure
that all couplings are tight.
• The cut-off saw may not be operated if 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.
• Always make sure that the saw 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
cut-off saw. If this is not done, there is a risk of damage to the quick release
couplings or the hydraulic system getting superheated.
IMPORTANT
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Oil Flow and Pressure
Your new HYCON cut-off saw 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 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.
On page 6 you will find the technical data, and on page 9 there is a guide to connection to hydraulic power sources and how to ensure that the cut-off saw is not overloaded.
Useful Information re. the Use of Cut-Off Saw
The HYCON cut-off saw is a compact tool with great performance. There are no
other cut-off saws on the market with higher performance in relation to size.
It is the perfect tool for cutting 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 cutting 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 working environments,
even for cutting under water.
The cut-off saw can also be connected to excavators and other machines. We recommend the use of a HYCON oil flow divider, which protects against too high oil
flow, too high pressure and backwards rotations. See page 9.
The cut-off saw is designed for both dry and wet cutting. Usually the best result is
achieved by wet cutting, as this cools the disc and removes the bore meal. This results 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.
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Starting Instrutions
START
• Mount a diamond disc
• Connect hoses – clean couplings before connection. Connect water supply.
• Set the power source on ”ON”.
• Find a good footing for the cutting.
• Activate the safety trigger, press the trigger lever towards the handle and
start the saw.
• Start by holding the disc towards the material. When gradually a groove is
cut, press the disc towards the material and cut through.
• It is important to keep the water supply steady and sufficient as it cools the
disc, removes the boremeal and guarantees you the best result with as little
wear on the disc as possible.
STOP
• Remove the disc from the material, and let go of the trigger lever.
• Set the power source on ”OFF”, and disconnect the water supply.
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Technical Data
14”
Cut-
off Saw
16”
Cut-off Saw
18” Cut
-
off Saw
Weight w/o hoses and disc
8.5 kg 9.0 kg 9.4 kg
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
-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/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
capacity
on power source
1 kW
1 kW
1 kW
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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.
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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
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Connection to Hydraulic Power Sources
The cut-off saw can be connected to various hydraulic power sources, such as excavators, trucks, loaders, tractors etc., and of course HYCON powerpacks, the design
of which ensures your new HYCON cut-off saw the absolute best working conditions.
It is important that the cut-off saw is not subjected to an oil flow and a working pressure beyond its design capability. Please refer to the ID-tag on the saw in case of
doubt.
Check the oil supply and the working pressure by means of test equipment. The test
equipment should comprise a pressure gauge, a flow meter and a valve for adjustment of pressure.
Make sure that:
• the oil supply is not too high
• the working pressure is not too high
• the return pressure is not too high
• the pressure relief valve is not set higher than 172 bar
• the internal diameter of the hoses is sufficient (min. ½”)
• all couplings 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 couplings cause the cut-off saw
to work with incorrect working pressure.
Your dealer can help you check this.
If the output of the power source is too high:
• 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 against overload
• or you can choose one of our HYCON powerpacks. Your dealer can guide you
in choosing the right powerpack.
In case of doubt, please contact your dealer or HYCON A/S.
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Service and Maintenance
Service/Maintenance Daily Weekly Yearly
Check couplings 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
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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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 Støvring
Denmark
Henrik Steen
General Manager
01.09.2003
HYCON A/S
Juelstrupparken 11
DK-9530 Støvring
Denmark
Tel: +45 9647 5200
Fax: +45 9647 5201
Mail [email protected]
www.hycon.dk
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Warranty Conditions
We grant 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 handling, lack of maintenance or the
like, will not be accepted as warranty.
The warranty covers the parts necessary for repair and the suggested average time
needed for repair.
For further warranty details, please contact your local dealer.
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