Diamond CB15E-XL User Manual

HYDRAULIC POWER UNIT

PARTS LIST & OPERATOR’S

MANUAL

MODEL

CB15E XL

December 2013

Part #1801653

CBPOWERPACKFLOWANDPRESSURERATING

CBPOWERPACK MODEL

MAXIMUMNO LOADFLOW GPM/LPM

RELIEF SETTING

PSI/BAR 15Electric 12.75/48.2 2100/145 18BriggsVanguard 11.6 /43.9 2850/196.5 20Electric 14.9/56.4 2400 /165.5 21Honda 14.1 /53.2 2600 /179.3 30Electric 20.4/77.2 2300 /158.6 35BriggsVanguard 17.2 /65.1 3000 /206.9



Maximumnoloadflowisbasedonpumpandmotormanufacturer’s specificationsforpumpdisplacementandnoloadRPM.Reliefissettoinsuregas enginescannotreachtheirstalltorqueandelectricmotorswillnotexceedthe recommendedcurrentlimit.

  

MAXNO



LOADFLOW

                

FLOW



USEABLEFLOW/PRESSURE

BELOWDARKLINE

>>>PRESSURE>>> CRACKING

RELIEF

PRESSURE



Flowdecreasesasengine/motorRPMdropsunderload.Reliefvalvesbeginto openandshuntflowtotankat75‐80%ofthereliefsetting(crackingpressure). Thisfurtherreducesflowtothetool.Atrelief,allflowisdirectedtotank.

IssuedAugust2011



16 2900013 4 Cap Screw, Hex Hd., 3/8-16 x 1-1/4" 17 2900018 4 Lock Nut, 3/8-16 Nylon 18 2701801 1 Coupling Assembly, 1-3/8 - 3/4" Shafts 19 2400309 1 Pump Mount 20 2900084 4 Lock Washer, 1/2" Split 21 2900511 4 Cap Screw, Soc. Hd., 1/2-13 x 1-1/4" 22 2600490 1 Hydraulic Pump, .85 CI 23 2900006 2 Lock Washer, 3/8" Split 24 2900005 2 Cap Screw, Hex Hd., 3/8-16 x 1" 25 3200298 1 Elbow, 3/4" O-Ring to 1/2" M. JIC 26 3200297 1 Elbow, 1" O-Ring to 1" M. JIC 27 4646173 1 Hydraulic Tank Assembly 28 4646174 1 Panel Assembly, CB15 29 4646035 1 Fuel Tank Support 30 2900009 2 Flat Washer, 1/4" SAE

31 2900024 6 Lock Washer, 1/4" Split 32 2900008 2 Cap Screw, Hex Hd., 1/4-20 x 1" 33 4641098 1 Starter Box Platform 34 2900138 4 Cap Screw, Hex Hd., 5/16-18 x 1" 35 4646049 1 Side Panel 36 2900144 4 Cap Screw, Hex Hd., 1/4-20 x 3/4" 37 4646006 2 Handle 38 2500636 2 Handle Grip 39 2900257 2 Lock Pin, T Handle, 3/8" 40 2900053 4 Rivet, 3/32" Dia. 41 4646003 1 Lifting Bar 42 2900248 2 Cap Screw, Hex Hd., 5/16-18 x 3" 43 1800169 1 Serial Number Plate, US 44 4646143 1 Hose Kit

TO EACH WIRE

6

12

IN THE MOTOR

WIRE BOX.

10 10 11

9

DETAIL E

SCALE 1 : 2

4646206 CB15 HYDRAULIC

POWER SUPPLY 208 - 460 VOLT

1

40

27

33

39

37

38

28

2X

32 31 30

34 5

4X

DETAIL F

SCALE 1 : 3

6 57

5

7

5

25

22

29

4

DETAIL D

43

40

SCALE 1 : 3

26

4646206 CB15 HYDRAULIC

7

POWER SUPPLY, 208 - 460 VOLT

ITEM PART NO. QTY. DESCRIPTION

1 4646156 1 CB-XL Frame Assembly

2 2400643 2 Wheel, 12 x 2-5/8 x 3/4"

3 2400615 2 Set Collar, 3/4"

4 2501767 2 Rubber Bumper

5 2900022 16 Flat Washer, 5/16" SAE

6 2900508 2 Cap Screw, Hex Hd., 5/16-18 x 1-1/2"

7 2900039 8 Lock Nut, 5/16-18 Nylon

8 4600079 1 Electric Motor, 15 HP, 3 Ph., 230/460 V.

9 2800083 9 Terminal, #10 Ring (16-14 AWG) Blue 10 2900016 18 Flat Washer, #10 USS 11 2900159 9 Machine Screw, Rd. Hd., #10-24 x 5/8"

12 2900017 9 Lock Nut, #10-24 Nylon 13 2800193 1 Lock Nut, 1" 14 2800312 1 Connector, 1" Sealtite Elbow 15 2900014 8 Flat Washer, 3/8" SAE

16 2900013 4 Cap Screw, Hex Hd., 3/8-16 x 1-1/4" 17 2900018 4 Lock Nut, 3/8-16 Nylon 18 2701801 1 Coupling Assembly, 1-3/8 - 3/4" Shafts 19 2400309 1 Pump Mount 20 2900084 4 Lock Washer, 1/2" Split 21 2900511 4 Cap Screw, Soc. Hd., 1/2-13 x 1-1/4" 22 2600490 1 Hydraulic Pump, .85 CI 23 2900006 2 Lock Washer, 3/8" Split 24 2900005 2 Cap Screw, Hex Hd., 3/8-16 x 1" 25 3200298 1 Elbow, 3/4" O-Ring to 1/2" M. JIC 26 3200297 1 Elbow, 1" O-Ring to 1" M. JIC 27 4646173 1 Hydraulic Tank Assembly 28 4646174 1 Panel Assembly, CB15 29 4646035 1 Fuel Tank Support 30 2900009 2 Flat Washer, 1/4" SAE

31 2900024 6 Lock Washer, 1/4" Split 32 2900008 2 Cap Screw, Hex Hd., 1/4-20 x 1" 33 4641098 1 Starter Box Platform 34 2900138 4 Cap Screw, Hex Hd., 5/16-18 x 1" 35 4646049 1 Side Panel 36 2900144 4 Cap Screw, Hex Hd., 1/4-20 x 3/4" 37 4646006 2 Handle 38 2500636 2 Handle Grip 39 2900257 2 Lock Pin, T Handle, 3/8" 40 2900053 4 Rivet, 3/32" Dia. 41 4646003 1 Lifting Bar 42 2900248 2 Cap Screw, Hex Hd., 5/16-18 x 3" 43 1800169 1 Serial Number Plate, US 44 4646143 1 Hose Kit

4640037 CB15 HYDRAULIC POWER SUPPLY, 575 VOLT

8

1

4X

13

14 15

3

DETAIL A

SCALE 1 : 4

16

17

41

35

42

5

7

4X

31 36

DETAIL C

SCALE 1 : 2

8

4X

21 20

2

18

DETAIL B

SCALE 1 : 3

19

2X

22

26

2324

4640037 CB15 HYDRAULIC POWER SUPPLY, 575 VOLT

9

ITEM PART NO. QTY. DESCRIPTION

1 4646156 1 CB-XL Frame Assembly 2 2400643 2 Wheel, 12 x 2-5/8 x 3/4" 3 2400615 2 Set Collar, 3/4"

4 2501767 2 Rubber Bumper 5 2900022 16 Flat Washer, 5/16" SAE

6 2900508 2 Cap Screw, Hex Hd., 5/16-18 x 1-1/2" 7 2900039 8 Lock Nut, 5/16-18 Nylon 8 4600080 1 Electric Motor, 15HP, 3 PH., 575V.

9 2800083 9 Terminal, #10 Ring (16-14 AWG) Blue 10 2900016 18 Flat Washer, #10 USS 11 2900159 9 Machine Screw, Rd. Hd., #10-24 x 5/8"

12 2900017 9 Lock Nut, #10-24 Nylon 13 2800193 1 Lock Nut, 1" 14 2800312 1 Connector, 1" Sealtite Elbow 15 2900014 8 Flat Washer, 3/8" SAE

16 2900013 4 Cap Screw, Hex Hd., 3/8-16 x 1-1/4" 17 2900018 4 Lock Nut, 3/8-16 Nylon 18 2701801 1 Coupling Assembly, 1-3/8 - 3/4" Shafts 19 2400309 1 Pump Mount 20 2900084 4 Lock Washer, 1/2" Split 21 2900511 4 Cap Screw, Soc. Hd., 1/2-13 x 1-1/4" 22 2600490 1 Hydraulic Pump, .85 CI 23 2900006 2 Lock Washer, 3/8" Split 24 2900005 2 Cap Screw, Hex Hd., 3/8-16 x 1" 25 3200298 1 Elbow, 3/4" O-Ring to 1/2" M. JIC 26 3200297 1 Elbow, 1" O-Ring to 1" M. JIC 27 4646173 1 Hydraulic Tank Assembly 28 4646174 1 Panel Assembly, CB15 29 4646035 1 Fuel Tank Support 30 2900009 2 Flat Washer, 1/4" SAE 31 2900024 6 Lock Washer, 1/4" Split 32 2900008 2 Cap Screw, Hex Hd., 1/4-20 x 1" 33 4641098 1 Starter Box Platform 34 2900138 4 Cap Screw, Hex Hd., 5/16-18 x 1" 35 4646049 1 Side Panel 36 2900144 4 Cap Screw, Hex Hd., 1/4-20 x 3/4" 37 4646006 2 Handle 38 2500636 2 Handle Grip 39 2900257 2 Lock Pin, T Handle, 3/8" 40 2900053 4 Rivet, 3/32" Dia. 41 4646003 1 Lifting Bar 42 2900248 2 Cap Screw, Hex Hd., 5/16-18 x 3" 43 1800169 1 Serial Number Plate, US 44 4646143 1 Hose Kit

4640037 CB15 HYDRAULIC POWER SUPPLY, 575 VOLT

10

12

TO EACH WIRE IN THE MOTOR

10 10 11

WIRE BOX.

9

DETAIL E

SCALE 1 : 2

1

40

39

37

38

27

33

28

DETAIL F

SCALE 1 : 3

2X

32 31 30

34 34

4X

57

56

5

25

22

29

4

43 40 26

DETAIL D

SCALE 1 : 3

4640037 CB15 HYDRAULIC POWER SUPPLY, 575 VOLT

11

ITEM PART NO. QTY. DESCRIPTION

1 4646156 1 CB-XL Frame Assembly

2 2400643 2 Wheel, 12 x 2-5/8 x 3/4"

3 2400615 2 Set Collar, 3/4"

4 2501767 2 Rubber Bumper

5 2900022 16 Flat Washer, 5/16" SAE

6 2900508 2 Cap Screw, Hex Hd., 5/16-18 x 1-1/2"

7 2900039 8 Lock Nut, 5/16-18 Nylon

8 4600080 1 Electric Motor, 15HP, 3 PH., 575V.

9 2800083 9 Terminal, #10 Ring (16-14 AWG) Blue 10 2900016 18 Flat Washer, #10 USS 11 2900159 9 Machine Screw, Rd. Hd., #10-24 x 5/8"

12 2900017 9 Lock Nut, #10-24 Nylon 13 2800193 1 Lock Nut, 1" 14 2800312 1 Connector, 1" Sealtite Elbow 15 2900014 8 Flat Washer, 3/8" SAE

16 2900013 4 Cap Screw, Hex Hd., 3/8-16 x 1-1/4" 17 2900018 4 Lock Nut, 3/8-16 Nylon 18 2701801 1 Coupling Assembly, 1-3/8 - 3/4" Shafts 19 2400309 1 Pump Mount 20 2900084 4 Lock Washer, 1/2" Split 21 2900511 4 Cap Screw, Soc. Hd., 1/2-13 x 1-1/4" 22 2600490 1 Hydraulic Pump, .85 CI 23 2900006 2 Lock Washer, 3/8" Split 24 2900005 2 Cap Screw, Hex Hd., 3/8-16 x 1" 25 3200298 1 Elbow, 3/4" O-Ring to 1/2" M. JIC 26 3200297 1 Elbow, 1" O-Ring to 1" M. JIC 27 4646173 1 Hydraulic Tank Assembly 28 4646174 1 Panel Assembly, CB15 29 4646035 1 Fuel Tank Support 30 2900009 2 Flat Washer, 1/4" SAE 31 2900024 6 Lock Washer, 1/4" Split 32 2900008 2 Cap Screw, Hex Hd., 1/4-20 x 1" 33 4641098 1 Starter Box Platform 34 2900138 4 Cap Screw, Hex Hd., 5/16-18 x 1" 35 4646049 1 Side Panel 36 2900144 4 Cap Screw, Hex Hd., 1/4-20 x 3/4" 37 4646006 2 Handle 38 2500636 2 Handle Grip 39 2900257 2 Lock Pin, T Handle, 3/8" 40 2900053 4 Rivet, 3/32" Dia. 41 4646003 1 Lifting Bar 42 2900248 2 Cap Screw, Hex Hd., 5/16-18 x 3" 43 1800169 1 Serial Number Plate, US 44 4646143 1 Hose Kit

END TO MANIFOLD

12

90

HOSE 4646056

HOSE

4646086

HOSE

RETURN PORTS

COOLER

EX

IN

CB15 XL HYDRAULIC SCHEMATIC

CF

HOSE 4646055

HOSE

4646085 ELECTRIC

FILTER

HOSE

4699980 ELECTRIC

TANK

HOSE 4646056

90 END TO VALVE

GAGE

PRESSURE PORTS

ALL HOSES ARE IN KIT 4646143

4646143 CB15XL HOSE KIT

13

22.0

28.8

19.25

23.6

1

2

3

16.6

ITEM PART NO. QTY. DESCRIPTION

1 4699980 1 Hose Assembly, 1 x 22"

3202317 2 Fitting, 1" FJIC to 1" Hose Barb 3200135 2 Hose Clamp #16

2 4646085 1 Hose Assembly, 1/2"X 28-3/4"

3200290 2 Fitting, 1/2" Female JIC to 1/2" Hose Crimp

3 4646056 2 Hose Assembly, 1/2" X 19-1/4"

3200290 1 Fitting, 1/2" Female JIC to 1/2" Hose Crimp 3200408 1 Elbow, 1/2" F. JIC to 1/2" Parkrimp 90 deg.

4 4646086 2 Hose Assembly, 3/4" x 23.6"

3201989 2 Fitting, 3/4" F.JIC to 3/4" Hose Barb 3200135 2 Hose Clamp #16

5 4646055 1 Hose Assembly, 1/4" x 16.6"

3200128 1 Fitting, 1/4" F. JIC to 1/4" Hose Crimp 3200145 1 1/4 MPT - 1/4 Hose Crimp 3201110 1 Coupling, 1/4" NPT

4

5

4646173 HYDRAULIC TANK ASSEMBLY

14

23

24

22

14

8

19

18

17

16

15

12

9

6

11

13

20

21

4

2

1

7

5

3

10

2

3

4646173 HYDRAULIC TANK ASSEMBLY

15

ITEM PART NO. QTY. DESCRIPTION

1 4640120 1 Hydraulic Tank Weldment 2 3200409 2 Street Elbow, 1" NPT

3 3200427 2 Nipple, 1" NPT x 4", Schedule 40 4 3200289 1 Elbow, 1" M. Pipe to 1" M. JIC 5 3200288 1 Plug, 1" NPT 6 3200431 1 NIpple, 1"MPT - 3/4" MPT 7 3200160 1 Plug, 1/2-14 NPT 8 2400166 1 Sight Gauge, Liquid Level 9 2703290 1 Filter Head, 3/4" NPT

10 3201175 1 Hydraulic Filter Element 11 3200156 1 Street Elbow, 1/8" NPT

12 3200502 1 Gauge, Hydraulic Pressure 13 3200097 1 Adapter, 3/4" M. JIC to 3/4" M. Pipe 14 2900441 10 Rivet Nut, 1/4-20 Round 15 4646083 1 Gasket, Hyd Tank 16 4640121 1 Cover, Hydraulic Tank 17 2800459 1 Thermometer, 2", 0 - 200 F 18 2401305 1 Filler/Breather Cap (Top Mount)

2900339 6 Cap Screw, Hex Hd., M5 x 12mm

19 2900567 2 Flat Washer, 5/16" USS 20 2900031 2 Lock Washer, 5/16" Split 21 2900138 2 Cap Screw, Hex Hd., 5/16-18 x 1" 22 2900024 10 Lock Washer, 1/4" Split 23 2900023 10 Cap Screw, Hex Hd., 1/4-20 x 5/8" 24 1800535 1 Decal, "Hydraulic Fluid Only"

6X

16

2 3

40

30

4646174 CB15 XL PANEL ASSEMBLY

7

31

33

34

32

38

4

39

41

35

2

26

21

1

35

36

18

37

22

78

17

19

20

23

24

3X

15

14

29

12

5

79

10

16

13

25

27

10

28

27

11

4646174 CB15 XL PANEL ASSEMBLY

17

ITEM PART NO. QTY. DESCRIPTION

1 4646141 1 Instrument Panel 2 2900022 8 Flat Washer, 5/16" SAE

3 2900031 6 Lock Washer, 5/16" Split 4 2900138 6 Cap Screw, Hex Hd., 5/16-18 x 1" 5 4646102 1 Manifold, SAE O-Ring 6 4646101 1 Manifold, 3/4 NPT 7 2900009 20 Flat Washer, 1/4" SAE 8 2901001 8 Cap Screw, Hex Hd., 1/4-20 x 2-1/2"

9 2900010 10 Lock Nut, 1/4-20 Nylon 10 3200479 2 Plug, 3/4" NPT Square Head 11 3201434 1 Plug, 1/2" SAE O-Ring Hex 12 3200285 1 Elbow, 1/2" O-Ring to 1/2" M. JIC 13 3201291 1 Adapter, 1/2"M.O-Ring to 1/4" MJIC 14 3200097 1 Adapter, 3/4" M. JIC to 3/4" M. Pipe 15 3200417 1 Elbow, 3/4" F. JIC to 3/4" M. JIC 16 3201522 1 Adapter, 3/4" M. Pipe to 1/2" M. JIC 17 3200330 1 Adapter, 3/4" M. Pipe to 3/4" O-Ring 18 3200371 1 Adaptor, 1/2" MPT to 1/2" O-Ring 19 3200105 1 Nipple, 1/2" Q.D. 20 3200101 1 Nipple, 3/4" Quick Disconnect 21 3200137 1 Hex Nipple, 3/4" NPT 22 3200383 1 Nipple, Hex, 3/4" MPT TO 1/2" MPT 23 3200100 1 Coupler, 3/4" Quick Disconnect 24 3200104 1 Coupler, 1/2" Q.D. 25 2400256 1 Heat Exchanger 26 2900303 2 Lock Nut, M8-1.25 Nylon Insert 27 3200400 2 Elbow, 3/4" O-Ring to 3/4" Male JIC 28 3201654 1 Valve, Flow Control

29 3200366 3 Elbow, 5/8" O-Ring to 1/2" Male JIC, 90 Deg. 30 2900245 2 Cap Screw, Soc. Hd., 1/4-20 x 2-5/8" 31 3200250 1 Gauge, Hydraulic, 3000 PSI 32 2500549 1 Plug, 7/8" Hole 33 2500204 1 Plug, 1/2" Hole 34 2503749 1 Plug, 5/16" Hole (Tapered) 35 3201659 2 Fitting, 3/4" M. Pipe to 3/4" M. Garden 36 3200177 1 Fitting, 3/4" F. Garden Union Swivel 37 1800536 1 "Return" Decal 38 1800941 1 Decal, Hydraulic Power Supply 39 1800531 1 "Hyd. Pressure" Decal 40 1801847 1 Decal, CB15 Flow Control 41 1800616 1 "Core Bore CB15E" Decal

4646032 STARTER BOX ASSEMBLY 208 - 460 VOLT

18

ROUTE INTO

STARTER BOX

SUPPLIED CONNECTOR

TO CUSTOMER

& CORD.

B

1

4

TO MOTOR

9

DETAIL B

SCALE 1 : 3

3

2

6

DETAIL A

SCALE 1 : 2

5

A

ITEM PART NO. QTY. DESCRIPTION

1 4600276 1 Starter Box, 230-460V 2 2800898 1 Connector, 1", Sealtite, 90 Deg.

3 2800193 1 Lock Nut, 1" 4 4646144 1 Conduit, Seal Tite, 1" x 29" 5 4646145 1 Wire Assy., 6 Gage, Green, 50"

7

8

6 4646146 3 Wire Assy., 8 Gage, Black, 55" 7 4600165 1 Wire Assy., 14 Gage, Brown, 48-1/2" 8 4646148 1 Wire Assy., 14 Gage, Orange, 45" 9 4646128 2 Wire, 14 Gage, Orange, 12"

4646032 STARTER BOX ASSEMBLY 208 - 460 VOLT

19

GENERAL SAFETY PRECAUTIONS

28

WARNING: Do not operate power unit without reading this entire manual and the engine operation manual first. Keep manuals with power unit at all times for reference.

This manual describes the operating procedures, care, maintenance, adjustments, and safety precautions for proper use of this machine. This equipment is intended for industrial applications by experienced operators. It is to be operated in conformance with applicable federal, state, and local codes or regulations pertaining to safety, air pollution, noise, etc.

Tool operators and maintenance personnel must always comply with the safety precautions given in this manual and on the stickers and tags attached to the equipment.

These safety precautions are given for your safety. Review them carefully before operating the tool and before performing general maintenance or repairs.

Supervising personnel should develop additional precautions relating to the specific work area and local safety regulations.

In addition to this manual, read and understand safety and operating instructions in the Engine Operation Manual furnished with the Power Unit in addition to this manual.

 Establish a training program for all operators to ensure safe operation.  Do not operate the power unit unless thoroughly trained or under the supervision of an

instructor.

 Do not inspect or clean the power unit while it is running.  Always use hoses and fittings rated at a minimum 2100 psi (145 bar) with a 4 to 1

safety factor for pressure lines.

 Be sure all hose connections are tight.  Make sure all hoses are connected for correct flow direction to and from the tool being

used.

 Do not inspect hoses and fittings for leaks by using bare hands. “Pin-hole” pressure leaks

can penetrate the skin.

 Do not operate a damaged or improperly adjusted power unit.  Never wear loose clothing that can get entangled in the working parts of the power unit.  Keep all parts of your body away from the working parts of the power unit.  Always wear appropriate safety equipment such as goggles, ear protection, head

protection and safety shoes. Certain tools used in conjunction with the power unit may require other safety equipment such as breathing filters.

 Do not operate the power unit if a gasoline odor is present.

29

 Do not use flammable solvents around the power unit motor.  Do not operate the power unit within 3 ft. (1 meter) of buildings or flammable objects.  Allow the motor to cool before storing the unit in an enclosed area.  To avoid personal injury or equipment damage, all tool repair, maintenance and service

must only be performed by authorized and properly trained personnel.

IMPORTANT: The red stop button at the top of the starter box will immediately stop the motor. Hydraulic pressure and flow will go to zero. This button must be in the out position to start the unit.

DANGER: Improper use or alteration of this equipment may be extremely hazardous.

SAFETY SYMBOLS

Safety symbols are used to emphasize actions which could result in a life-threatening situation, bodily injury, or damage to equipment.

Always observe safety symbols. They are included for your safety and for the protection of the tool.

! DANGER !

This safety symbol may appear

on the tool. It is used to alert the operator of an action that could place him/her or others in a life threatening situation.

!WARNING: !

This safety symbol appears

in these instructions to identify an action that could cause bodily injury to the operator or to other threatening situation.

! IMPORTANT !

This safety symbol appears in

these instructions to identify an an action or condition that could result in damage to the tool or other equipment.

DESCRIPTION AND SPECIFICATIONS

30

Pump: Gear, pump rotation is clockwise (motor is CCW). Maximum GPM: 12-3/4 GPM (48.2L/M). Flow will decrease as pressure increases. Hydraulic Fluid Tank Capacity: 11 gallons (41.6Liters) Hose Couplings: Bruning quick disconnect, 3/4 inch & ½ inch Relief Pressure: Factory set at 2100 PSI/145 Bar (at valve outlet port). Adjustable to 750

PSI/52 Bar, CURRENT LIMITTED TO 2100 PSI. Electric Motor: Baldor 15 HP, C Face, 3450 RPM, 208-460 Volts, 575 Volts (Canada only).

This unit is compatible with most hydraulically driven sawing and drilling components. The system may not be compatible with components of some manufacturers.

The power unit was inspected and operated before shipment and should not require any additional adjustments prior to its initial use.

Hydraulic Fluid: The reservoir of the hydraulic power unit must be full prior to start-up. The use of high quality petroleum based hydraulic oil with the following properties is recommended:

 Anti-wear  Low foaming  Rust and oxidation inhibitors  Wide temperature range  Fluid viscosity: 8-1000 Centistokes

(52-4600 SUS). The unit is shipped with an ISO 46 Viscosity grade (8Cs/52SUS @ 212F/100C and 46Cs/210SUS @ 104F/40C).

The oil must be kept free of contamination to avoid damage to system components. The strainer in the fill cap must always be in place when adding oil. Quick disconnects must be cleaned before connections are made.

Control Valve: The pressure compensated flow control valve on this unit directs excess flow to tank, not over relief. This conserves horsepower and reduces heat buildup. Flow settings are: 0-2, all flow routed to tank; 2-8, adjustable range, 8-10 full flow. Relief pressure can be adjusted by removing the cap at the top of the main control and using an Allen wrench to adjust the relief cartridge. The relief can be set

as low as 750 psi; do not exceed 2100 psi. To adjust, the flow control must be set at 10 and no tool should be attached. This will force all flow over relief. Securely replace the cap as oil seepage will occur through the relief cartridge. The relief is factory set at 2100 psi (electric) and should rarely need adjustment.

Hydraulic Oil Cooler: The power unit is equipped with a brazed plate style oil cooler. Water should be passed through the cooler before being used for dust control or blade & bit cooling. Some tools will automatically shut off water flow when not actively cutting, drilling, etc. This may result in higher oil temperatures if the power unit continues to run for long periods without cooling water.

IMPORTANT

: If there is a risk of frost

the water must be drained from the cooler to prevent damage by freezing.

HOSES: Large diameters and short

31

lengths are preferred and offer the highest system efficiency. If one is operating 50 ft (15.2M) from the power source, there is also a 50 ft (15.2M) return for a 100 ft (35.5M) total hose length. With 12 GPM and oil at 100 deg. F (37.8C), this could result in a 300 psi (20.6 Bar) pressure loss with ½” hose and a 100 psi (6.9 Bar) loss with 5/8” hose. Pressure loss will change dramatically with oil temperature.

OPERATING INSTRUCTIONS

Operator Responsibilities

It is the operator’s responsibility to use this unit and any attached tools under safe working conditions and to follow proper safety procedures for themselves, coworkers, observers, and the public at large. The operator must be aware of the machine’s capabilities and limitations and follow the safety precautions in each section of this manual. Periodic maintenance is required, in accordance with the instructions herein, to promote safe and reliable operations.

WARNING: Keep bystanders out of the immediate work area.

Wear approved:

 Safety glasses  Ear protection  Hard hat  Gloves  Safety shoes

 Any other protective equipment

required for compliance with standard safety practices or federal, state, and local codes and regulations

Hose Connections: It is best to connect the hoses to the unit before starting as even very low residual pressure can make hose installation more difficult. Push couplings together until you hear it click. Turn locking ring of coupling to the secured position.

Starting Procedure:

 Set the flow control valve to zero.  Be certain the stop switch has been

pulled out.

 Be certain the unit is connected to the

proper voltage and a proper gage power cord is used.

 Press the start button at the top of the

starter box.

Heating Cold Oil: Forcing the oil over relief will quickly increase the oil temperature. With no tool connected to the unit, move the valve setting toward 10. This will force an increasing percentage of oil over relief. Heat cold oil to room temperature or ~100F/38C maximum. Cold oil greatly increases pressure loss in hoses and fittings and may affect tool operation.

Maintaining Oil Temperature: With an ample water supply, it is unlikely overheating will be an issue except in the most extreme ambient temperatures. To force high oil temperatures down, run the unit with the flow control set to zero. This unloads the unit yet circulates oil through the cooling system. The rate of cooling will depend on the ambient temperature and how much water is being passed through the cooler.

Some control valves at the external tool may create backpressure and heat even when off. It is best to set the flow control to zero or shut the power unit down to avoid heating and conserve energy.

IMPORTANT at the top of the hydraulic tank. Maximum recommended oil temperature is 180 degrees Fahrenheit (82 deg C).

: Monitor the thermometer

Shutting Down:

32

 Shift the flow control valve to zero to

unload the system.

 Press the stop button at the top of the

starter box.

OPERATING DRIVEN

EQUIPMENT

The operator must know the hydraulic requirements and limitations of the driven equipment and the appropriate adjustments must be made on the controls. The introduction of other control devices may cause system heating or may render the system inoperative.

IMPORTANT: This power unit is equipped with a positive displacement gear pump. All tools must be equipped with a control valve that allows flow directly to return ports when not in use. Blocking oil flow or abruptly disconnecting the tool can send flow over relief and potentially overheat the system.

Instructions supplied with the driven equipment must be followed to ensure correct connection and operation of each individual piece of equipment. Equipment supplied by Diamond Products will be capable of being connected correctly and will be compatible with this power unit, providing neither has been modified from original factory configuration. With equipment of other manufacturers, it will be necessary to determine the following:  Correct direction of flow through the

equipment.

 Correct pressure and flow required by

the equipment.

 Compatibility of any valves or circuitry

and quick disconnects. Some handheld equipment uses a trigger control, which is operated frequently. These valves must be of the open center type for correct operation.

IMPORTANT: The quick disconnects must be clean when connecting hoses and devices. Dirty connections may result in contamination and premature failure of system or tool components.

MAINTENANCE

INSTRUCTIONS

 Oil Filter: change the filter when

indicated by the gage at the filter.

 Oil Change: establishing an oil analysis

program is the preferred method of determining oil condition and when to change it. If the oil is kept clean, dry, and operated at moderate temperatures, it can last for several years. With no analysis program an oil change every 200 hours is recommended. See the section Hydraulic Fluid pipe thread oil drain port is at the bottom of the hydraulic tank.

 Inspect hoses, couplings, and fittings

daily for leaks, tighten as required. Clean quick disconnects frequently. Replace any leaking or defective components immediately.

 Check hydraulic oil level daily. Fill tank

to upper end of sight tube with unit off.

 Grease the wheel bearings annually.

for specifications. A ½”

33

TROUBLESHOOTING

PROBLEM POSSIBLE SOLUTIONS

Electric motor will not start.

Running with no pressure.

1) Pull out stop button on starter box.

2) Confirm proper voltage. The motor may be running backwards,

should be counter clockwise. Reverse any two of the 3 power wires coming into the starter box.

System builds high pressure with flow control valve set to zero.

Contamination may have plugged an orifice in the CF port of the flow valve. Detach the valve from the front panel and remove the fitting from the CF port. A .015” orifice should be visible at the bottom of the port. Push a fine wire through the orifice and re-install.

Keep this manual and the engine manual readily available at all times for reference.

Corporate Office

The engine exhaust from this product

333 Prospect St., Elyria, Ohio 44035

contains chemicals known to the State of

(216) 323-4616 • Fax: (216) 323-8689

California to cause cancer, birth defects or

Customer Service: 1-800-321-5336

Customer Service Fax: 1-800-634-4035

other reproductive harm.

NOTES

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Intentionally Blank

EQUIPMENT AND PARTS

WARRANTY

Diamond Products warrants all equipment manufactured by it against defects in workmanship or materials for a period of one (1) year from the date of shipment to Customer.

The responsibility of Diamond Products under this Warranty is limited to replacement or repair of defective parts at Diamond Products’ Elyria, Ohio factory, or at a point designated by it, of such parts as shall appear to us upon inspection at such parts, to have been defective in material or workmanship, with expense for transportation and labor borne by Customer.

In no event shall Diamond Products be liable for consequential or incidental damages arising out of the failure of any Product to operate properly.

Integral units such as engines, electric motors, batteries, transmissions, etc., are excluded from this Warranty and are subject to the prime manufacturer’s warranty.

THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, AND ALL SUCH OTHER WARRANTIES ARE HEREBY DISCLAIMED.

333 Prospect Street, Elyria, Ohio 44035

(440) 323-4616  (800) 321-5336  Fax (440) 323-8689

www.diamondproducts.com

Printed in U.S.A.

Diamond CB15E-XL User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

GENERAL SAFETY PRECAUTIONS

OPERATING INSTRUCTIONS

TROUBLESHOOTING

WARRANTY