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 2500 p.s.i. (172 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.
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Do not use flammable solvents around the power unit motor.
Allow the engine 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.
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
38
Pump: Gear, pump rotation is clockwise (motor is CCW).
Maximum GPM: 15 GPM (56.7L/M) 230/460/575 Volt
12.5 GPM (47.5L/M) 380 Volt
Hydraulic Fluid Tank Capacity: 11 gallons (41.6Liters)
Hose Couplings: Bruning quick disconnect, 3/4 inch & ½ inch
Relief Pressure: Factory set at 2400 PSI /165.5 Bar (at valve outlet port). Adjustable to 750
PSI, Current limited to 2400 psi.
Motor: Baldor 20 hp, 3450 RPM, 3 Phase, 60 Hz, C-Face, 230/460/575 Volt.
Baldor 20 hp, 2920 RPM, 3 Phase, 50 Hz, C-Face, 380 Volt.
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
allows full flow control
Flow settings are: 0-2, all flow routed to
tank; 2-10, adjustable range.
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 2400 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 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 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
39
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 15 GPM
and oil at 100 deg. F (37.8C), this could
result in a 400 psi (27.5 Bar) pressure loss
with ½” hose and a 140 psi (9.6 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:
Be certain the unit is plugged into the
proper voltage.
Set the flow control valve to zero.
Be certain the stop button has been
pulled out.
Press the start button on 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 and the radiator, 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: Monitor the thermometer
at the top of the hydraulic tank.
Maximum recommended oil
temperature is 180 degrees Fahrenheit
(82 deg C).
Shutting Down:
Shift the flow control valve to zero to
unload the system.
Press the stop button on top of the
starter box.
OPERATING DRIVEN
40
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. Failure to thoroughly
clean 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 for specifications. A ½”
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.
41
TROUBLESHOOTING
PROBLEM POSSIBLE SOLUTIONS
Motor will not start.
1) Pull out stop button on starter box.
2) Press Reset button on starter box.
3) Confirm proper voltage.
Running with no flow.
The motor may be running backwards.
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.
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.