‘Whatever It Takes’ Operator’s Manual CC1800XL Concrete Saw Part Number: 1801038 (800) 321-5336 www.diamondproducts.
Table of Contents Safety Precautions ....................................................... 1 Safety Alerts ............................................................ 1 Proposition 65.......................................................... 1 Spark Arrester Requirement..................................... 1 Respiratory Hazards ................................................ 1 General Safety......................................................... 2 Battery and Electrical Safety ........................
Tensioning the Blade Drive Belts ........................26 Replacing the Blade Drive Belts ..........................26 Replacing the Transmission V-Belt .....................26 Engine/Motor ..........................................................27 Cleaning the Engine/Motor..................................27 Fuel Filter (GX620 Honda) ......................................27 Replacing the Fuel Filter .....................................27 Storing ........................................................
Safety Precautions Operate the CC1800XL and all of its components according to this manual. Failure to comply with and understand the following safety, operations, and maintenance instructions can result in serious injuries and/or death. All operators must be properly trained or supervised by experienced personnel prior to using this saw and should understand the risks and hazards involved. Diamond Products discourages improper or unintended saw usage and cannot be held liable for any resulting damages.
General Safety • • • Read and understand all of the safety, operations, and maintenance instructions provided in this manual prior to operating or servicing the saw. Keep saw components clean and free of slurry, concrete dust, and debris. Inspect water hoses prior to operating the saw. Clean, repair, or replace damaged components. • Raise the saw to a proper height for access when working underneath the saw.
• Always use the correct size fuses (amps) to prevent fires. • Always pivot the front of the blade guard 180° (fully upward) so the guard does not swing down unexpectedly, causing serious injuries. • DO NOT install or remove the blade guard with the engine/motor running. Always use a blade guard that corresponds with the blade size. Inspect the blade guard and water tubes prior to starting the saw. Clean or replace dirty/damaged components immediately.
• DO NOT leave the engine/motor running unattended. • Always operate the saw in wellventilated areas. Concentrated engine exhaust can cause loss of consciousness and/or death. • DO NOT touch the engine/muffler assembly with the engine running, and always let them cool down prior to touching or servicing the saw. Handle hot oil carefully when changing the oil. Wipe down the engine/motor exterior and guards daily or regularly to prevent high operating temperatures.
Lifting Safety • Move yourself and all others away from the lifting area when hoisting the saw to prevent being crushed. • Secure the appropriate hoisting cables, straps, and/or chains to the saw’s designated lift points prior to hoisting. DO NOT attempt to lift the saw irresponsibly and/or improperly.
Introducing the CC1800XL Components 5 4 1 6 8 13 7 14 2 15 9 16 10 11 17 18 12 3 Figure 1: CC1800XL Components 1. 2. 3. 4. 5. 6. 7. 8. 9. Handlebars Water Valve Frame Handwheel Lift Bar Air Cleaner Air Intake Front Pointer Engine CC1800XL Concrete Saw Manual 10. 11. 12. 13. 14. 15. 16. 17. 18.
Controls 12 11 1 10 9 8 7 2 6 3 5 4 Figure 2: Control Panel (Gas Model) Controls Shown Above: 1. Fuel Tank Cap–Opening to add fuel; indicates fuel level (tank located above engine on certain models). 2. Tachometer/Hour Meter–Indicates engine speed and total number of saw hours operated. 3. Transmission Lever–Engages/disengages transmission. 4. Master Disconnect–Connects/disconnects battery circuit. 5. Water Pump Switch (optional item)–Pumps water to blade. 6.
Dimensions Figure 3: CC1800XL Dimensions Table 1: CC1800XL Dimensions A B C D E F G H I J K Saw Height (Minimum/Maximum) Saw Length (Minimum, Pointer Up, Handle Down) Saw Length (Maximum, Pointer Down, Handle Up) Saw Height to Hand Wheel Saw Height to Lift Bar Frame Width Rear Frame Length with Weights Frame Width Front Front Axle Center Length Rear Axle Center Length Wheel Base Length Handlebar Width (Handles In) Handlebar Width (Handles Out) Crated Dimensions Dimensions for saw with optional water tank
Specifications Table 2: CC1800XL Specifications Maximum Cutting Depth Maximum Cutting Depth Blade Shaft Diameter Blade Shaft RPM Arbor Diameter Blade Shaft Bearings Blade Shaft Drive Blade Mounting Blade Raise/Lower Blade Coolant Blade Guard Attachment Handlebars Transmission Drive Speed Electric Start Fuel Capacity Tachometer/Hour Meter Quick Disconnect Blade Flanges Frame Lift Uncrated Dry Weight 4-5/8” with 14” blade 7-5/8” with 20” blade 1-1/4” 2,600 1” with single alignment pin Self-aligning pillow bl
Operating the CC1800XL Handlebars The handlebars help the operator guide and maneuver the saw. Adjusting the Handlebars 1. Remove the screws securing the handlebar to the frame upright. 2. Holding the handlebar grip, move the handlebar up or down (matching the holes on the handlebar shaft to the holes on the frame upright) to adjust the handlebar to the desired height. Turn the handlebar 90° to change the position if desired.
Battery (Gas Model) Diamond Blades WARNING • WARNING • Ignitable explosive gases are emitted from the battery. DO NOT expose the battery to sparks or open flames, and keep the area around the battery well-ventilated. • • CAUTION • • Use a proper battery tester when testing the battery strength. Use protective eyewear or a face shield, and avoid contact with the skin when handling/servicing the battery.
Figure 8: Wrench Installing the Blade WARNING • • DO NOT install a blade with the engine/motor running. Failure to properly secure the outer flange and blade may cause parts to loosen or fall off the saw. CAUTION • Wear gloves and be alert to the surrounding environment when handling blades. Install the blade on either the right or left side of the saw; utilize the side most appropriate for the cutting task. 1.
This measurement can be verified with a torque wrench. Blade Guard WARNING • • • • Figure 12: Tightening Nut 13. Replace the blade guard or pivot the front of the guard down and over the blade to secure. Removing the Blade CAUTION • DO NOT remove a blade with the engine/motor running. 1. Remove the blade guard or pivot the front of the guard 180° (fully upward) to gain access to the blade flanges. Note: Failure to fully pivot the guard may cause serious injuries. 2.
Water Valve and Supply Hose(s) 1. Connect the water source hose to the water supply fitting. Figure 14: Connecting Water Hose Removing the Blade Guard 1. Disconnect the water supply hose from the blade guard. 2. Use the handle on the blade guard to rock the guard back and forth while lifting the guard off of the tapered mount. Flange Guard Installing the Flange Guard 1. Fit the tapered mount on the backside of the flange guard over the tapered blade guard mount on the frame.
2. Remove the water valve from the 1–1/4” plug hole. 3. Fit the water valve through the 1–1/4” plug hole on the opposite side of the saw. 4. Secure the valve to the frame upright. Water Pump The water pump (optional item) pumps water from the water source to the saw as necessary. DO NOT leave the water pump on when finished cutting to avoid draining the battery. 2. Turn the index plunger 90° to lock it back into the plunger groove. Turn the handwheel slightly to lock the handwheel.
Fuel Shutoff Valve 1. Open the shutoff valve to open the fuel line. 2. Close the shutoff valve to close the fuel line. Storage Refer to the engine manual for fuel recommendations when storing the saw. Engine/Motor Refer to the engine/motor manual as the primary source for information. WARNING Figure 20: Transmission Lever • • Engaging the Transmission 1. Place the speed control lever at Neutral. 2. Start the engine. 3. Pull the transmission engagement lever down to Engage.
Tasks Prior to Starting the Engine/Motor Make sure to complete the following tasks prior to starting the engine/motor: • • • • • • • • • Fill all liquids to appropriate levels for proper saw operation. Turn off water valve. Turn off water pump. Set speed control lever at Neutral (self-propelled model). Disengage transmission (self-propelled model). Set engine throttle to slowest position (gas saw). Turn off hydraulic ball valve (hydraulic motor saw). Remove tools from work area. Raise blade off ground.
• CAUTION • DO NOT leave the saw unattended until the engine/motor is off and the blade has stopped spinning. Gasoline Engine 1. Decrease the throttle to the slowest position for several minutes. 2. Hold down the stop button (on the control panel) to stop the engine (applicable models). Note: This action does not permanently stop the engine. 3. Turn off the engine switch (applicable models).
4. Turn off the water pump. Brake The brake (optional item) stops the saw from moving forward or backward unintentionally. DO NOT assume at any time the transmission will act as a brake when at Neutral. Note: On extreme slopes chock the tires to prevent unnecessary saw movement. 1. Push the brake pedal down and pivot it into the left brake groove (on the frame) to engage the brake. 2. Push the brake pedal down and pivot it into the right brake groove (on the frame) to disengage the brake.
Maintaining the CC1800XL Failure to read and comply with the maintenance instructions provided in this manual prior to performing maintenance may result in serious injuries and/or death, and may harm the saw. DO NOT attempt to perform maintenance on the saw if you are not properly trained for it, or are not supervised by an experienced person. Refer to the CC1800XL Parts List for additional information and part diagrams when performing maintenance tasks.
Hydraulic Motor Lubricate the pillow block grease fitting every 40 hours of operation. Inner Blade Flange Figure 26: Front Wheels 1. 2. 3. 4. Figure 25: Inner Blade Flange Installing the Inner Blade Flange 1. Inspect the inner blade flange for damages and clean or replace as necessary. 2. Place the flange onto the tapered portion of the blade shaft. 3. Apply Loctite 262 (red) or an equivalent to the setscrew threads. 4.
7. Place a set collar, washer, new wheel, and another washer (in this order) onto the end of the axle. Slide the axle back into the axle hole on the right, and then push the assembly parts to the right. Note: The axle should not protrude from either side of the frame base. 8. Raise the saw and retighten the rear axle setscrews to secure the rear axle; lower the saw again. 9.
Figure 29: In-Line Fuse Hydraulic Ball Valve (Hydraulic Model) WARNING • • DO NOT disconnect hydraulic hoses from the hydraulic motor saw when the saw or the hydraulic power unit is running. Always place a piece of cardboard or paper up against hydraulic components, or use a leak detection fluid to check for hydraulic fluid leaks. Keep all body parts away from leaks and/or areas that may eject hydraulic fluid. Pressurized hydraulic fluid can penetrate the skin, causing serious injuries.
Transmission Regularly wipe down the transmission (self-propelled model) to help prevent high oil temperatures. Adding Transmission Oil Check the transmission oil level daily/regularly. 1. Remove the transmission oil reservoir cap. 3. Retighten the nuts to secure the engagement linkage. 4. Engage the transmission to make sure the drive wheels fully engage the rear wheels. Readjust the engagement linkage as necessary.
Tensioning the Blade Drive Belts Figure 36: Tension Bolt 5. Retighten all four engine/motor base nuts. Figure 34: Blade Drive Belts 1. Inspect the belts for fraying, stress cracks, and/or breakage and replace immediately when damaged. 2. Test the belt tension. Proceed to step 3 if the belts need tensioning (refer to Appendix C for the proper tension setting). Operate the saw as needed if no tension adjustments are required. 3. There are four engine/motor base screws; two on the side of both bases.
1. Remove the blade drive belts from the crankshaft sheave. 2. Remove the nut and spring from the front of the idler pulley. 3. Lift the idler pulley up and remove the V-belt from the idler pulley. 4. Release the idler pulley and remove the V-belt from the transmission pulley and from the accessory drive pulley. 5. Loop the new V-belt around the accessory drive pulley. 6. Loop the upper V-belt section around the transmission pulley, and then wrap the lower V-belt section under the idler pulley. 7.
• • Store the saw in a cool, dry area out of reach from children. Refer to the engine/motor manual for engine/motor tasks prior to storing the saw. Disposal Properly dispose of the saw when it’s no longer repairable, and/or contains safety hazards not worth repairing or maintaining. Complete the tasks listed below to properly dispose of the saw when discontinuing usage: • • • 28 Drain all fluids from the saw and dispose according to city, state, and federal regulations.
References Appendix A Serial Tags Record the saw’s serial number below for future reference and customer service purposes. Serial Number Record the engine’s/motor’s model and serial numbers below for future reference and customer service purposes.
Appendix B Daily Maintenance Task Chart Table 6: Daily Maintenance Task Chart Date 1. Lubricate blade shaft bearing grease fittings daily or two to three times daily when dry cutting. 2. Inspect belts after first four hours of use, and then daily for tension and wear. Replace or re-tension as necessary. 3. Inspect saw for damages. 4. Tighten loose nuts and bolts. 5. Verify that drive wheels fully engage rear wheels when transmission is engaged (selfpropelled model). 6.
Appendix C Belt Tension Settings Deflection (in.) should be equal to number of inches listed in chart below when force (lb) listed in chart below is applied to belt using tension gauge. Table 7: Push Saw Belt Tension Settings Model Number Engine/Motor Type CC1875E1 XL-P 7.5HP Baldor Electric 1 PH-230V CC1810E3 XL-P 10HP Baldor Electric 3 PH CC1813H XL-P Belt Tension Setting 3VX375 0.23 in. at 5.7 lb Force 11HP Honda GX390 3VX335 0.20 in. at 5.
Appendix D Troubleshooting Table 9: CC1800XL Troubleshooting Symptom Problem Solution 1. Saw will not raise. Index plunger in? Pull index plunger out to move handwheel. 2. Saw will not lower. Index plunger in? Pull index plunger out to move handwheel. Excessive force applied while sawing? Reduce forward speed. Wrong blade for application? Contact dealer/manufacturer of blade. Loose belts causing slippage? Check belt tension regularly.
Appendix E Additional Resources 1. Diamond Products (www.diamondproducts.com) • CC1800XL Concrete Saw Parts List; Ohio, 2007 • CC1800XL Concrete Saw Parts List–Electric & Hydraulic Units; Ohio, 2007 • A Guide for Professional Concrete Cutters • Training Manual–Introduction to Diamond Blades, Bits, and Equipment • Diamond Products’ Equipment Catalog • Diamond Products’ Website (www.diamondproducts.com) 2. Honda Motor Company (www.honda-engines.
Diamond Products Limited, 2009
