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Summary of Contents for HYCON HCS14 Pro
- Page 1 Hydraulic Cut-Off Saw HCS14 Pro HCS16 Pro HYCON A/S Juelstrupparken 11 DK-9530 Støvring HCS18 Pro Denmark Tel: +45 9647 5200 Fax: +45 9647 5201 Mail: hycon@hycon.dk www.hycon.dk...
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Page 2: Table Of Contents
Contents Page Safety Precautions ..................2 Oil Flow and Pressure.................. 4 Technical Data.................... 5 Dimensions....................6 Service and Maintenance................7 Testing....................... 8 Fault Location ..................... 9 Dismounting and Mounting of Main Components .........10 Repair of Handle ..................21 10. Repair of Valve Block ................23 11. -
Page 3: Safety Precautions
• 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. - Page 4 • 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.
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Page 5: Oil Flow And 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. -
Page 6: Technical Data
3. 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. -
Page 7: Dimensions
4. Dimensions Tool Length mm Height mm Width mm Radius mm 14” saw 16” saw 18” saw... -
Page 8: Service And Maintenance
Check hoses 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... -
Page 9: Testing
6. Testing The cut-off saw should be tested before and after servicing – before servicing to check if there are certain problems related to the saw, and after servicing to ensure that the saw works satisfactorily. Efficient testing can only be done by means of test equipment that includes a flow and pressure gauge. -
Page 10: Fault Location
7. 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 Saw does not start, there is... -
Page 11: Dismounting And Mounting Of Main Components
8. Dismounting and Mounting of Main Components Dismount tail-hoses (place the cut-off saw with the hoses pointing 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. - Page 12 Now carefully remove the trigger piston. Fix the valve block in a vice and pull off 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).
- Page 13 Remove the two screws that fix the front handle. Then dismount the four screws in the plastic cover. Dismount the screws that fix the motor to the motor plate, and then loosen the nuts on the elbow fittings between pipes and motor. Now remove the motor.
- Page 14 Hydraulic Cut-Off Saw – Main Components Mounting of Main Components 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.
- Page 15 For mounting the steel frame you need two steel bars (HYCON special tool No. 9992079) to be inserted in the pipes. Pull the pipes away from each other and push in the steel frame in between. Push the frame a little into the plastic cover, pull out the steel bars, and then push the frame completely into the cover.
- Page 16 Place O-rings in the three holes and 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.
- Page 17 Push the valve block into the plastic cover (place the two seal rings in the valve block before pushing it in). It is very important to push the valve block very carefully into the plastic cover in order not to damage the three O-rings on the inner side of the valve block when they are pushed down over the pipes.
- Page 18 Add Loctite 243 to the two threads in the valve block, and mount the handle. 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 Now tighten the nuts on the elbow fittings between 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 Mount the two star knobs. Add Loctite 243 to the thread in the adaptor, and tighten the screw with a torque 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.
- Page 21 Finally mount the tail-hoses. Mount 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.
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Page 22: Repair Of Handle
9. Repair of Handle Dismounting Start by checking the trigger lever for clearance. Replace the worn parts, if clearance 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). - Page 23 Mounting Add Loctite 243 to the two threads in the safety trigger, and mount the leaf spring with the two screws. Insert the safety trigger in the handle and push the pin w/hole through the handle and safety trigger. Insert the trigger lever in the handle and mount the pin through handle and trigger lever.
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Page 24: Repair Of Valve Block
10. Repair of Valve Block Dismounting Dismount the check valve, degrease with 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. - Page 25 Mounting of Valve Block 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.
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Page 26: Tool List
Centre punch j. Screw driver PZ 2 k. End cutter 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...
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