Diamond CB21H-XL User Manual

DIAMOND

PRODUCTS

HYDRAULIC POWER UNIT

PARTS LIST &

OPERATOR’S MANUAL

MODEL:

CB21H-XL

AUGUST 2012

PART#: 1801397

Proposition 65

State of California

Warning !

Engine exhaust and some its constituents are known to the State
of California to cause cancer, birth defects, and/or other
reproductive harm.

Notification of Spark Arrester Requirement for

State of California

It is a violation of Section 4442 or 4443 to use or operate the
engine on any forest-covered, brush-covered, or grass-covered land
unless the engine is equipped with a spark arrester, as defined in
Section 4442, maintained in effective working order or the engine
is constructed, equipped, and maintained for the prevention of fire
pursuant to Section 4443.

Table of Contents

Description Page No.

1. CB21 Top Level Assembly……………………………………..…4-9

2. Hydraulic Schematic ………….……………………………………10

3. Hose Kit …………..…………………………………………………..11

4. Fuel Line Routing…………………………………………………….12

5. Gas Tank Assembly……………………………………………..….13

6. Electric Schematic ………………………………………..……..…14

7. Hydraulic Tank Assembly…………………………,,………….….16-17

5. Front Panel Assembly ……..……….…………………..……….18-19

6. Oil to Air Cooler Option……………………………,…….………..20-21

9. Reference Views ……………………………………………………23

10. General Safety Precautions ……………………………..……...24-25

11. Specifications & Description……………………………,………26-27
Hydraulic Fluid
Control Valve
Cooler and Radiator
Hoses

12. Operating Instructions……………………………………………27-28
Hose Connections
Engine
Fuel
Starting Procedure
Heating Cold Oil
Maintaining Oil Temperature
Shutting Down

13. Operating Driven Equipment……………………………….………28

14. Maintenance and Troubleshooting ………………………..…….29

15. Flow & Pressure Ratings, CB Power Packs…………..…………31

16. Warranty………………………….……………………….…Rear Cover

4646190 CB21XL HYDRAULIC POWER SUPPLY

4

49

50

57

1

2

8

5

7

47

45

46

34

55

56

41

3

DETAIL A

SCALE 1 : 4

42

36
19

36

43

44

44

DETAIL B

SCALE 1 : 1

54

ENGINE IGNITION

CIRCUIT TO

STOP SWITCH.

4x

31
32

4646190 CB21XL HYDRAULIC POWER SUPPLY

5

ITEM

10 2900317 4
11 2900304 4 Lock Nut, M10 Nylon
12 3201968 1

13 3201969 1
14 3202315 1 3/8 NPT Hex Cap
15 2708046 2

16 2701670 1 Rectifier Assembly
17 2900009 4 Flat Washer, 1/4" SAE

18 2900052 2
19 2900010 4 Lock Nut, 1/4-20 Nylon

20 4646018 1 Wire Assembly, 12 Gage
21 6048134 1 Key, 1/4" Sq. x 2-1/4"
22 2702225 1 Coupling Assembly
23 4646010 1 Pump Mount, SAE 2 Bolt
24 2900006 6 Lock Washer, 3/8" Split

25 2900183 4
26 2600490 1 Hydraulic Pump, .85 CI
27

28
29

PART

NO.

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
7 2900039 8 Lock Nut, 5/16-18 Nylon
8 4641051 1
9 2900014 8 Flat Washer, 3/8" SAE

2900005 2
3200298

464601130

QTY. DESCRIPTION

Cap Screw, Hex Hd., 5/16­18 x 1-1/2"

Honda, GX660, Short Shaft
& Elec. Con.

Cap Screw, Hex Hd., M10
x 45mm

Adapter, M20x1.5 M. to
3/8" F. Pipe
Nipple, 3/8 MPT x 2-1/2",
Sched. 40, Galv.

Honda Muffler, R Side
Exhaust

Cap Screw, Hex Hd., 1/4­20 x 1-1/4"

Capscrew, Soc Hd., 3/8"­16 X 1-3/8"

Cap Screw, Hex Hd., 3/8­16 x 1"
Elbow, 3/4" O-Ring to 1/2"

1

M. JIC
Elbow, 1" O-Ring to 1" M.

13200297

JIC
Heat Shield1

ITEM

31 2900024 10 Lock Washer, 1/4" Split
32 2900144 8
33 4646173 1 Hydraulic Tank Assembly

34 4646189 1 Panel Assembly, CB21 XL
35 4646035 1 Fuel Tank Support
36 2900009 6 Flat Washer, 1/4" SAE

37 2900008 2
38 4641099 1 Gas Tank Mounting Plate
39 2900138 4

40 4646205 1
41 2500584 1

42 4646122 1 BatterySupport
43 2901405 2
44 4646049 1 Side Panel

45 4646006 2 Handle
46 2500636 2 Handle Grip

47 2900257 2 Lock Pin, T Handle, 3/8"
48 2900053 4 Rivet, 3/32" Dia.
49 4646003 1 Lifting Bar

50 2900248 2
51 4600160 1
52 2501434 1

53 4641105 1 Hose Assy., 3/8 x 54"
54 4645036 1
55 4646015 1 Battery Cable Assy., Red

56 4646016 1 Battery Cable Assy., Black
57 2800068 6 Wire Tie, 7-1/2"
58 4646165 1 Hose Kit

59 1800537 1 Label, HOT
60 1801716 1
61 1800169 1 Serial Number Plate, US

PART

NO.

QTY. DESCRIPTION

Cap Screw, Hex Hd., 1/4­20 x 3/4"

Cap Screw, Hex Hd., 1/4­20 x 1"

Cap Screw, Hex Hd., 5/16­18 x 1"
Gas Tank Assembly, 4.4
Gallon
Battery, 12 Volt Group Size
U1

Cap Screw, Hex Hd., 1/4­20 x 7-1/2"

Cap Screw, Hex Hd., 5/16­18 x 3"
Hose Assy., Gas, 1/4 x 40­3/4"
Hose Clamp, 5/8" x 3/4"
Wide

Wire Assy., Emergency Off,
65-1/2"

Decal, EPA EVAP
Standard

A CATALYTIC MUFFLER

IS AVAILABLE: 2702624.

DETAIL C

6

SCALE 1 : 3

4646190 CB21XL POWER SUPPLY

910

8

15

33

34

14

4X

21

13

12

2425

23

26

28

35

38

DETAIL E

4XSCALE 1 : 3

5
5

39

7

60

22

24
27

29

16

2X

36
31
37

DETAIL D

48

61

48

SCALE 1 : 3

4646190 CB21XL HYDRAULIC POWER SUPPLY

7

ITEM

10 2900317 4
11 2900304 4 Lock Nut, M10 Nylon
12 3201968 1

13 3201969 1
14 3202315 1 3/8 NPT Hex Cap
15 2708046 2

16 2701670 1 Rectifier Assembly
17 2900009 4 Flat Washer, 1/4" SAE

18 2900052 2
19 2900010 4 Lock Nut, 1/4-20 Nylon

20 4646018 1 Wire Assembly, 12 Gage
21 6048134 1 Key, 1/4" Sq. x 2-1/4"
22 2702225 1 Coupling Assembly
23 4646010 1 Pump Mount, SAE 2 Bolt
24 2900006 6 Lock Washer, 3/8" Split

25 2900183 4
26 2600490 1 Hydraulic Pump, .85 CI
27

28
29

PART

NO.

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
7 2900039 8 Lock Nut, 5/16-18 Nylon
8 4641051 1
9 2900014 8 Flat Washer, 3/8" SAE

2900005 2
3200298

464601130

QTY. DESCRIPTION

Cap Screw, Hex Hd., 5/16­18 x 1-1/2"

Honda, GX660, Short Shaft
& Elec. Con.

Cap Screw, Hex Hd., M10
x 45mm

Adapter, M20x1.5 M. to
3/8" F. Pipe
Nipple, 3/8 MPT x 2-1/2",
Sched. 40, Galv.

Honda Muffler, R Side
Exhaust

Cap Screw, Hex Hd., 1/4­20 x 1-1/4"

Capscrew, Soc Hd., 3/8"­16 X 1-3/8"

Cap Screw, Hex Hd., 3/8­16 x 1"
Elbow, 3/4" O-Ring to 1/2"

1

M. JIC
Elbow, 1" O-Ring to 1" M.

13200297

JIC
Heat Shield1

ITEM

31 2900024 10 Lock Washer, 1/4" Split
32 2900144 8
33 4646173 1 Hydraulic Tank Assembly

34 4646189 1 Panel Assembly, CB21 XL
35 4646035 1 Fuel Tank Support
36 2900009 6 Flat Washer, 1/4" SAE

37 2900008 2
38 4641099 1 Gas Tank Mounting Plate
39 2900138 4

40 4646205 1
41 2500584 1

42 4646122 1 BatterySupport
43 2901405 2
44 4646049 1 Side Panel

45 4646006 2 Handle
46 2500636 2 Handle Grip

47 2900257 2 Lock Pin, T Handle, 3/8"
48 2900053 4 Rivet, 3/32" Dia.
49 4646003 1 Lifting Bar

50 2900248 2
51 4600160 1
52 2501434 1

53 4641105 1 Hose Assy., 3/8 x 54"
54 4645036 1
55 4646015 1 Battery Cable Assy., Red

56 4646016 1 Battery Cable Assy., Black
57 2800068 6 Wire Tie, 7-1/2"
58 4646165 1 Hose Kit

59 1800537 1 Label, HOT
60 1801716 1
61 1800169 1 Serial Number Plate, US

PART

NO.

QTY. DESCRIPTION

Cap Screw, Hex Hd., 1/4­20 x 3/4"

Cap Screw, Hex Hd., 1/4­20 x 1"

Cap Screw, Hex Hd., 5/16­18 x 1"
Gas Tank Assembly, 4.4
Gallon
Battery, 12 Volt Group Size
U1

Cap Screw, Hex Hd., 1/4­20 x 7-1/2"

Cap Screw, Hex Hd., 5/16­18 x 3"
Hose Assy., Gas, 1/4 x 40­3/4"
Hose Clamp, 5/8" x 3/4"
Wide

Wire Assy., Emergency Off,
65-1/2"

Decal, EPA EVAP
Standard

A CATALYTIC MUFFLER

IS AVAILABLE: 2702624.

16

8

4646190 CB21XL POWER SUPPLY

1917

18

17

20

GROUND

TO ENGINE

DETAIL J

SCALE 1 : 2

DETAIL H

SCALE 1 : 4

57

33

59

40

52

GAS TANK

VENT TO

VACUUM

PORT

53

51

GAS TANK

TO GAS

FILTER

4

5

6

30

4x TO

ENGINE

10

9

DETAIL F

SCALE 1 : 1

4x TO

ENGINE

11

9

4x

32 31

DETAIL G

SCALE 1 : 3

4646190 CB21XL HYDRAULIC POWER SUPPLY

9

ITEM

10 2900317 4
11 2900304 4 Lock Nut, M10 Nylon
12 3201968 1

13 3201969 1
14 3202315 1 3/8 NPT Hex Cap
15 2708046 2

16 2701670 1 Rectifier Assembly
17 2900009 4 Flat Washer, 1/4" SAE

18 2900052 2
19 2900010 4 Lock Nut, 1/4-20 Nylon

20 4646018 1 Wire Assembly, 12 Gage
21 6048134 1 Key, 1/4" Sq. x 2-1/4"
22 2702225 1 Coupling Assembly
23 4646010 1 Pump Mount, SAE 2 Bolt
24 2900006 6 Lock Washer, 3/8" Split

25 2900183 4
26 2600490 1 Hydraulic Pump, .85 CI
27 2900005 2

28 3200298 1
29

PART

NO.

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
7 2900039 8 Lock Nut, 5/16-18 Nylon
8 4641051 1
9 2900014 8 Flat Washer, 3/8" SAE

464601130

QTY. DESCRIPTION

Cap Screw, Hex Hd., 5/16­18 x 1-1/2"

Honda, GX660, Short Shaft
& Elec. Con.

Cap Screw, Hex Hd., M10
x 45mm

Adapter, M20x1.5 M. to
3/8" F. Pipe
Nipple, 3/8 MPT x 2-1/2",
Sched. 40, Galv.

Honda Muffler, R Side
Exhaust

Cap Screw, Hex Hd., 1/4­20 x 1-1/4"

Capscrew, Soc Hd., 3/8"­16 X 1-3/8"

Cap Screw, Hex Hd., 3/8­16 x 1"
Elbow, 3/4" O-Ring to 1/2"
M. JIC
Elbow, 1" O-Ring to 1" M.

13200297

JIC

1 Heat Shield

ITEM

31 2900024 10 Lock Washer, 1/4" Split
32 2900144 8
33 4646173 1 Hydraulic Tank Assembly

34 4646189 1 Panel Assembly, CB21 XL
35 4646035 1 Fuel Tank Support
36 2900009 6 Flat Washer, 1/4" SAE

37 2900008 2
38 4641099 1 Gas Tank Mounting Plate
39 2900138 4

40 4646205 1
41 2500584 1

42 4646122 1 BatterySupport
43 2901405 2
44 4646049 1 Side Panel

45 4646006 2 Handle
46 2500636 2 Handle Grip

47 2900257 2 Lock Pin, T Handle, 3/8"
48 2900053 4 Rivet, 3/32" Dia.
49 4646003 1 Lifting Bar

50 2900248 2
51 4600160 1
52 2501434 1

53 4641105 1 Hose Assy., 3/8 x 54"
54 4645036 1
55 4646015 1 Battery Cable Assy., Red

56 4646016 1 Battery Cable Assy., Black
57 2800068 6 Wire Tie, 7-1/2"
58 4646165 1 Hose Kit

59 1800537 1 Label, HOT
60 1801716 1
61

PART

NO.

1800169 1 Serial Number Plate, US

QTY. DESCRIPTION

Cap Screw, Hex Hd., 1/4­20 x 3/4"

Cap Screw, Hex Hd., 1/4­20 x 1"

Cap Screw, Hex Hd., 5/16­18 x 1"
Gas Tank Assembly, 4.4
Gallon
Battery, 12 Volt Group Size
U1

Cap Screw, Hex Hd., 1/4­20 x 7-1/2"

Cap Screw, Hex Hd., 5/16­18 x 3"
Hose Assy., Gas, 1/4 x 40­3/4"
Hose Clamp, 5/8" x 3/4"
Wide

Wire Assy., Emergency Off,
65-1/2"

Decal, EPA EVAP
Standard

A CATALYTIC MUFFLER

IS AVAILABLE: 2702624.

END TO MANIFOLD

10

90

HOSE 4646056

HOSE

4646086

4646086

HOSE

RETURN PORTS

COOLER

EX

IN

CF

4646190 CB21XL HYDRAULIC SCHEMATIC

HOSE 4646055

HOSE

6040063

FILTER

PUMP

HOSE

4646124 GAS

OPTION

RADIATOR

TANK

END TO VALVE

HOSE 4646056

90

GAGE

4646165.

PRESSURE PORTS

ALL HOSES ARE IN KIT