Diamond CB240 User Manual

DIAMOND

PRODUCTS

HYDRAULIC POWER UNIT

PARTS LIST &

OPERATOR’S MANUAL

MODELS:

CB150/240

March 2013

PART#: 1800944

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.

31 3200479 1 32 3201434 1 Plug, 1/2" SAE O-Ring Hex 33 3200137 1 Hex Nipple, 3/4" NPT 34 3200383 1 35 3200371 1 36 3200330 1 37 4646010 1 Pump Mount (Machined) 38 2600490 1 39 2900006 2 Lock Washer, 3/8" Split 40 2900005 2 41 3200298 1 42 3200297 1 43 4646106 1 44 4646105 1 Hydraulic Tank Assembly 45 3201671 1 Hex Nipple, 1" NPT 46 3200289 1 47 3200288 2 Plug, 1" NPT

Plug, 3/4" NPT Square Head

Nipple, Hex, 3/4" MPT TO 1/2" MPT Adaptor, 1/2" MPT to 1/2" O-Ring Adapter, 3/4" M. Pipe to 3/4" O-Ring

Hydraulic Pump, .85 CI, W/ Key

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. JIC Tank / Box Mounting Bracket

Elbow, 1" M. Pipe to 1" M. JIC

24

29

290100019

3200400

320129127

Flat Washer, 1/4" SAE20290000918 Cap Screw, Hex Hd., 1/4-

8

20 x 2-1/4" Cap Screw, Hex Hd., 1/4-

2290100120

20 x 2-1/2" Lock Nut, 1/4-20 Nylon10290001021 Fitting, 3/4" M. Pipe to 3/4"

2320165922

M. Garden Fitting, 3/4" F. Garden

1320017723

Union Swivel Elbow, 3/4" O-Ring to 3/4"

2

Male JIC Elbow, 5/8" O-Ring to 1/2"

3320036625

Male JIC, 90 Deg. Elbow, 1/2" O-Ring to 1/2"

1320028526

Male JIC Adapter, 1/2"M.O-Ring to

1

1/4" MJIC Adapter, 3/4" M. JIC to 3/4"

1320009728

M. Pipe Elbow, 3/4" F. JIC to 3/4"

13200417

M. JIC Adapter, 3/4" M. Pipe to

1320152230

1/2" M. JIC

48 3200505 1 Filter Head 49 3200111 1

50 3201175 1 Hydraulic Filter Element 51 3200502 1 Gauge, Hydraulic Pressure 52 3200100 1 53 3200101 1 54 3200104 1 Coupler, 1/2" Q.D. 55 3200105 1 Nipple, 1/2" Q.D. 56 4646138 1

57 1800924 1 Decal, CB 15/24XL Valve 58 1800941 1

59 1800169 1 Serial Number Plate, US 60 2900096 2 Rivet, 3/32" Dia.

Not Shown: PUMP SEAL KIT, #2703142

Elbow, 1" M. Pipe to 3/4" M. JIC

Coupler, 3/4" Quick Disconnect Nipple, 3/4" Quick Disconnect

Brake Assembly, CB150/240

Decal, Hydraulic Power Supply

4646107 CB150/240 COMMON PARTS

6

18 21

18 21 20

11

48

49

DETAIL F

SCALE 1 : 4

3x

25

50

51

45

DETAIL C

SCALE 1 : 3

46

47

32

DETAIL B

SCALE 1 : 4

30

F

29

47

26

7

28

TANK & FILTER

POSITION

FOR GAS UNIT

12

17

9 9

BRACKET POSITION

FOR GAS UNIT

39

40

DETAIL E

SCALE 1 : 3

38

42

43

C

24

8

1

2

E

B

56

4

3

16

15

9 9

17

4646107 CB150/240 COMMON PARTS.

7

PART NO.

146460971

2

4

6

8

10 11 3201654 1 Valve, Flow Control

12 4646080 13

14 15 2900538 12

17

2900303

3200250 3201675

2900039

2 Lock Nut, M8 Nylon

1 1

1

4290006916

16

DESCRIPTIONQTY.ITEM

Frame, Power Supply Flat Washer, 3/4" SAE42900003

Wheel, 8 x 2 x 3/4"425014393 Set Collar, 3/4"42400615 Instrument Panel146461005 Manifold, 3/4 NPT14646101

Manifold, SAE O-Ring146461027 Heat Exchanger12400256

Flat Washer, 5/16" SAE3429000229

Handle Gauge, Hydraulic, 3000

PSI Elbow, 1/4" M. JIC to 1/4" F. Pipe Cap Screw, Hex Hd., 5/1618 x 1-3/4" Cap Screw, Hex Hd., 5/1618 x 2-3/4"

Lock Nut, 5/16-18 Nylon

ITEM PART NO. QTY. DESCRIPTION

31 3200479 1 32 3201434 1 Plug, 1/2" SAE O-Ring Hex 33 3200137 1 Hex Nipple, 3/4" NPT 34 3200383 1 35 3200371 1 36 3200330 1 37 4646010 1 Pump Mount (Machined) 38 2600490 1 39 2900006 2 Lock Washer, 3/8" Split 40 2900005 2 41 3200298 1 42 3200297 1 43 4646106 1 44 4646105 1 Hydraulic Tank Assembly 45 3201671 1 Hex Nipple, 1" NPT 46 3200289 1 47 3200288 2 Plug, 1" NPT

Plug, 3/4" NPT Square Head

Nipple, Hex, 3/4" MPT TO 1/2" MPT Adaptor, 1/2" MPT to 1/2" O-Ring Adapter, 3/4" M. Pipe to 3/4" O-Ring

Hydraulic Pump, .85 CI, W/ Key

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. JIC Tank / Box Mounting Bracket

Elbow, 1" M. Pipe to 1" M. JIC

24

29

290100019

3200400

320129127

Flat Washer, 1/4" SAE20290000918 Cap Screw, Hex Hd., 1/4-

8

20 x 2-1/4" Cap Screw, Hex Hd., 1/4-

2290100120

20 x 2-1/2" Lock Nut, 1/4-20 Nylon10290001021 Fitting, 3/4" M. Pipe to 3/4"

2320165922

M. Garden Fitting, 3/4" F. Garden

1320017723

Union Swivel Elbow, 3/4" O-Ring to 3/4"

2

Male JIC Elbow, 5/8" O-Ring to 1/2"

3320036625

Male JIC, 90 Deg. Elbow, 1/2" O-Ring to 1/2"

1320028526

Male JIC Adapter, 1/2"M.O-Ring to

1

1/4" MJIC Adapter, 3/4" M. JIC to 3/4"

1320009728

M. Pipe Elbow, 3/4" F. JIC to 3/4"

13200417

M. JIC Adapter, 3/4" M. Pipe to

1320152230

1/2" M. JIC

48 3200505 1 Filter Head 49 3200111 1

50 3201175 1 Hydraulic Filter Element 51 3200502 1 Gauge, Hydraulic Pressure 52 3200100 1 53 3200101 1 54 3200104 1 Coupler, 1/2" Q.D. 55 3200105 1 Nipple, 1/2" Q.D. 56 4646138 1

57 1800924 1 Decal, CB 15/24XL Valve 58 1800941 1

59 1800169 1 Serial Number Plate, US 60 2900096 2 Rivet, 3/32" Dia.

Not Shown: PUMP SEAL KIT, #2703142

Elbow, 1" M. Pipe to 3/4" M. JIC

Coupler, 3/4" Quick Disconnect Nipple, 3/4" Quick Disconnect

Brake Assembly, CB150/240

Decal, Hydraulic Power Supply

SQUARE HOLE

8

ALWAYS AT FILTER END.

4646107 CB150/240

COMMON PARTS

47

FILTER POSITION FOR

ELECTRIC UNIT

TANK POSITION FOR

ELECTRIC UNIT

4646107 CB150/240 COMMON PARTS.

9

PART NO.

146460971

2

4

6

8

10 11 3201654 1 Valve, Flow Control

12 4646080 13

14 15 2900538 12

17

2900303

3200250 3201675

2900039

2 Lock Nut, M8 Nylon

1 1

1

4290006916

16

DESCRIPTIONQTY.ITEM

Frame, Power Supply Flat Washer, 3/4" SAE42900003

Wheel, 8 x 2 x 3/4"425014393 Set Collar, 3/4"42400615 Instrument Panel146461005 Manifold, 3/4 NPT14646101

Manifold, SAE O-Ring146461027 Heat Exchanger12400256

Flat Washer, 5/16" SAE3429000229

Handle Gauge, Hydraulic, 3000

PSI Elbow, 1/4" M. JIC to 1/4" F. Pipe Cap Screw, Hex Hd., 5/1618 x 1-3/4" Cap Screw, Hex Hd., 5/1618 x 2-3/4"

Lock Nut, 5/16-18 Nylon

ITEM PART NO. QTY. DESCRIPTION

31 3200479 1 32 3201434 1 Plug, 1/2" SAE O-Ring Hex 33 3200137 1 Hex Nipple, 3/4" NPT 34 3200383 1 35 3200371 1 36 3200330 1 37 4646010 1 Pump Mount (Machined) 38 2600490 1 39 2900006 2 Lock Washer, 3/8" Split 40 2900005 2 41 3200298 1 42 3200297 1 43 4646106 1 44 4646105 1 Hydraulic Tank Assembly 45 3201671 1 Hex Nipple, 1" NPT 46 3200289 1 47 3200288 2 Plug, 1" NPT

Plug, 3/4" NPT Square Head

Nipple, Hex, 3/4" MPT TO 1/2" MPT Adaptor, 1/2" MPT to 1/2" O-Ring Adapter, 3/4" M. Pipe to 3/4" O-Ring

Hydraulic Pump, .85 CI, W/ Key

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. JIC Tank / Box Mounting Bracket

Elbow, 1" M. Pipe to 1" M. JIC

24

29

290100019

3200400

320129127

Flat Washer, 1/4" SAE20290000918 Cap Screw, Hex Hd., 1/4-

8

20 x 2-1/4" Cap Screw, Hex Hd., 1/4-

2290100120

20 x 2-1/2" Lock Nut, 1/4-20 Nylon10290001021 Fitting, 3/4" M. Pipe to 3/4"

2320165922

M. Garden Fitting, 3/4" F. Garden

1320017723

Union Swivel Elbow, 3/4" O-Ring to 3/4"

2

Male JIC Elbow, 5/8" O-Ring to 1/2"

3320036625

Male JIC, 90 Deg. Elbow, 1/2" O-Ring to 1/2"

1320028526

Male JIC Adapter, 1/2"M.O-Ring to

1

1/4" MJIC Adapter, 3/4" M. JIC to 3/4"

1320009728

M. Pipe Elbow, 3/4" F. JIC to 3/4"

13200417

M. JIC Adapter, 3/4" M. Pipe to

1320152230

1/2" M. JIC

48 3200505 1 Filter Head 49 3200111 1

50 3201175 1 Hydraulic Filter Element 51 3200502 1 Gauge, Hydraulic Pressure 52 3200100 1 53 3200101 1 54 3200104 1 Coupler, 1/2" Q.D. 55 3200105 1 Nipple, 1/2" Q.D. 56 4646138 1

57 1800924 1 Decal, CB 15/24XL Valve 58 1800941 1

59 1800169 1 Serial Number Plate, US 60 2900096 2 Rivet, 3/32" Dia.

Not Shown: PUMP SEAL KIT, #2703142

Elbow, 1" M. Pipe to 3/4" M. JIC

Coupler, 3/4" Quick Disconnect Nipple, 3/4" Quick Disconnect

Brake Assembly, CB150/240

Decal, Hydraulic Power Supply

4646105 CB150/240 HYDRAULIC TANK

10

5

8

76

9

10

11

4

3

13

2

1

12

ITEM NO. PART NO. QTY. DESCRIPTION

1 4646099 1 Hydraulic Tank Weldment 2 4646103 1 Gasket

3 3200409 1 Street Elbow, 1" NPT 4 2400258 1 Fluid Level Sight Port

5 2400184 1 Thermometer, Panel Mount 6 2900092 3 Lock Washer, #6 Split

7 2900090 3 Machine Screw, Rd. Hd., #6-32 x 1/2" 8 2401305 1 Filler/Breather Cap (Top Mount)

9 2900339 6 Cap Screw, Hex Hd., M5 x 12mm 10 4646098 1 Cover, Hydraulic Tank 11 2900144 14 Cap Screw, Hex Hd., 1/4-20 x 3/4" 12 3200160 1 Plug, 1/2-14 NPT 13 1800535 1 Decal, "Hydraulic Fluid Only"

END TO MANIFOLD

11

HOSE 4646056

90

4646078

HOSE

RETURN PORTS

4646108 (ELECTRIC)

6017344 (GAS)

HOSE

HEAT

EXCHANGER

EX

HOSE

4646057 (ELECTRIC)

4646160 (GAS)

IN

FLOW CONTROL VALVE

CF

1801441 CB150/240 HYDRAULIC SCHEMATIC

HOSE 4646109

FILTER

PUMP

TANK

HOSE

4646124 (ELECTRIC)

6040057 (GAS)

TANK

HOSE 6040061

ALL HOSES ARE IN KITS

4646114 ELECTRIC

PRESSURE PORTS

4646162 GAS

4646162 CB 240 HOSE KIT

12

FOR CB240 UNITS MANUFACTURED AFTER DECEMBER 2009

13.25

19.25

21.3

18.0

41.4

19.4

34.0

1

2

3

4

5

6

ITEM PART NO. QTY. DESCRIPTION

1 6040061 1 Hose Assembly, 1/2"X 13-1/4"

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

2 4646056 1 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.

3 4646160 1 Hose Assembly, 1/2"X 21-1/4"

4646160A 1 Hose, 1/2", 2500psi

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

4 6017344 1 Hose Assembly 3/4" x 18"

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

5 4646161 1 Hose Assembly, 3/4 x 41-1/2"

3200129 2 Fitting, 3/4" F. JIC to 3/4" Hose Crimp

6 4646109 1 Hose Assembly, 1/4" x 19-3/8"

3200128 2 Fitting, 1/4" F. JIC to 1/4" Hose Crimp

7 6040057 1 Hose Assy., 1 x 34"

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

7

4646114 CB 150/240 HOSE KIT

13

FOR ALL CB150 UNITS AND CB240 UNITS MANUFACTURED PRIOR TO JANUARY 2010

13.25

19.25

16.40

15.06

21.56

19.38

26.24

1

2

3

4

5

6

ITEM PART NO. QTY. DESCRIPTION

1 6040061 1 Hose Assembly, 1/2"X 13-1/4"

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

2 4646056 1 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.

3 4646057 1 Hose Assembly, 1/2" X 16.4"

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

4 4646078 1 Hose Assembly, 3/4 x 15"

3200129 2 Fitting, 3/4" F. JIC to 3/4" Hose Crimp

5 4646108 1 Hose Assembly, 3/4 x 21-1/2"

3200129 2 Fitting, 3/4" F. JIC to 3/4" Hose Crimp

6 4646109 1 Hose Assembly, 1/4" x 19-3/8"

3200128 2 Fitting, 1/4" F. JIC to 1/4" Hose Crimp

7 4646124 1 Hose Assembly, 1" X 26-1/4"

3202317 2 Fitting, 1" FJIC to 1" Hose Barb

3200135 2 Hose Clamp #16

7

4646163 CB240

14

GAS COMPONENTS

35 36

DETAIL B

SCALE 1 : 5

11

34

33

34 37 35

40

39

PHANTOM PARTS

ARE REFERENCE ONLY

5

TO FUEL

FILTER

41

44

16

17 184X

16

4

38

24

7 9 7

25

DETAIL C

SCALE 1 : 3

45

43

23

12

13

28

3029

31

14

26

27

15

VENT

LINE

1

2

32

42

20

19

DETAIL A

SCALE 1 : 4

21

4X

22

9

10

7 7 8

6

ITEM PART NO. QTY. DESCRIPTION

15

1 4646097 1 Frame, Power Supply 2 4646100 1 Instrument Panel

3 4646106 1 Tank / Box Mounting Bracket 4 4641051 1 Honda, GX660, Short Shaft & Elec. Con. 5 2708046 1 Honda Muffler, R Side Exhaust

6 2701670 1 Rectifier Assembly 7 2900009 8 Flat Washer, 1/4" SAE

8 2900052 2 Cap Screw, Hex Hd., 1/4-20 x 1-1/4"

9 2900010 4 Lock Nut, 1/4-20 Nylon 10 4646018 1 Wire Assembly, 12 Gage 11 3201968 1 Adapter, M20x1.5 M. to 3/8" F. Pipe 12 3201468 1 3/8" MPT to 3/8" FJIC, Swivel 13 3205603 1 3/8 MJIC - 3/8 MJIC, 90 Deg. 14 4645037 1 Hose Assy., 3/8 x10-3/4", FJIC-FJIC 15 3201897 1 3/8" JIC Plug 16 2900014 8 Flat Washer, 3/8" SAE 17 2900317 4 Cap Screw, Hex Hd., M10 x 45mm 18 2900304 4 Lock Nut, M10 Nylon 19 6048134 1 Key, 1/4" Sq. x 2-1/4" 20 2702225 1 Coupling Assembly, 3/4 - 1-1/8" 21 2900006 4 Lock Washer, 3/8" Split 22 2900183 4 Capscrew, Soc Hd., 3/8"-16 X 1-3/8" 23 2500584 1 Battery, 12 Volt Group Size U1 24 4646122 1 BatterySupport 25 2901405 2 Cap Screw, Hex Hd., 1/4-20 x 7-1/2" 26 4646015 1 Battery Cable Assy., Red 27 4646016 1 Battery Cable Assy., Black 28 6010869 1 Fuel Tank, 4.4 Gallon 29 2506716 1 Grommet 30 2505503 1 Roll Over Vent, 3/8" Hose Barb

4646163 CB240 GAS COMPONENTS

31 2500649 1 Fuel Tank Cap 32 4641107 1 CB240 Vent Line 33 4646136 1 Heat Shield 34 2900022 6 Flat Washer, 5/16" SAE

35 2900019 4 Cap Screw, Hex Hd., 5/16-18 x 3/4" 36 2900039 2 Lock Nut, 5/16-18 Nylon 37 2900031 2 Lock Washer, 5/16" Split 38 3200012 1 Street Elbow, 1/4" NPT 39 3200108 1 Fuel Shut-Off Valve, 1/4" 40 3200418 1 Adapter, 1/4" M. Pipe to 1/4" M. JIC 41 4646210 1 Hose Assy., Fuel, 1/4 x 7.5" 42 2800120 1 Tach/Hour Meter, W/#6 Screws 43 2801367 1 E-Stop Switch 44 4646188 1 Wire Assy., Emergency Off, 46.6" 45 1800943 1 Decal, Core Bore CB240 46 4646162 1 Hose Kit, CB 240

A CATALYTIC

MUFFLER IS

AVAILABLE:

2702624.

4646163 CB240 ELECTRIC SCHEMATIC

16

4646188

STOP SWITCH TO

MATING CONNECTORS

AT IGNITION SWITCH

ENGINE

23

24

4646016

GROUND

TO ENGINE

MOUNTING BOLT

12

11

SWITCH

STOP

4646015

TO COIL

+ -

BATTERY

FOR EASE OF ASSEMBLY, ATTACH WIRES TO STOP SWITCH

BEFORE INSTALLING IN PANEL.

4646138 BRAKE ASSEMBLY

17

2

3

4

1

5

6 7

6 8

ITEM PART NO. QTY. DESCRIPTION

1 4646137 1 Bracket, Brake Mount 2 2500847 1 Clamp

3 2900247 4 Cap Screw, Soc. Hd., 1/4-20 x 3/4" 4 2900141 1 Hex Nut, 5/16-18

5 2900019 1 Cap Screw, Hex Hd., 5/16-18 x 3/4" 6 2900022 4 Flat Washer, 5/16" SAE

7 2900538 2 Cap Screw, Hex Hd., 5/16-18 x 1-3/4" 8 2900039 2 Lock Nut, 5/16-18 Nylon

4646111(230/460V)

18

4646113 (575V)

CB 150 ELECTRICAL

COMPONENTS

23

22

DETAIL A

SCALE 1 : 2

21

13

1414

16 15

4

7

668

CRIMP TO

109

MOTOR LEADS.

17

5

18 18

19 20

12

11

ITEM

NO.

PART

NUMBER

4600079

4

4600080 Electric Motor, 15 HP, 3 Ph., 575V.

5

2701801 1 Coupling Assembly, 1-3/8 - 3/4" Shafts

6 2900014 8 Flat Washer, 3/8" SAE 7 2900005 4 Cap Screw, Hex Hd., 3/8-16 x 1" 8 2900018 4 Lock Nut, 3/8-16 Nylon

9 2900084 4 Lock Washer, 1/2" Split 10 2900511 4 Cap Screw,Soc. Hd., 1/2-13 x 1-1/4" 11 2800193 1 Lock Nut, 1" 12 2800312 1 Connector, 1" Sealtite Elbow

4646126

13

4646127

QTY.

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

1

DESCRIPTION

Starter Box Assy., 230/460V

Starter Box Assy., 575 Volt

ITEM

NO.

PART

NUMBER

14 2900009 8 Flat Washer, 1/4" SAE 15 2900008 4 Cap Screw, Hex Hd., 1/4-20 x 1" 16 2900010 4 Lock Nut, 1/4-20 Nylon 17 2800083 9 Terminal, #10 Ring (16-14 AWG) Blue

18 2900016 18 Flat Washer, #10 USS 19 2900159 9 Machine Screw, Rd. Hd., #10-24 x 5/8" 20 2900017 9 Lock Nut, #10-24 Nylon 21 2500549 1 Plug, 7/8" Hole 22 1800942 1 Decal, Core Bore CB150 23 4646114 1 Hose Kit

QTY. DESCRIPTION

4646125 STARTER BOX 208-460 Volt

19

13

11

16

14

16

15

9

10

7

5

12

6

8

4

3

1

2

ITEM ITEM

NO.

PART

NUMBER

2 2901332 4 1/4-20 Threaded Insert 3 6040301B 1 Backup Plate, Starter Box

4 2900676 4 5 2800899 1 Overload Relay, 13-52 Amp 6 2900016 5 Flat Washer, #10 USS

7 2900087 2 Cap Screw, Soc. Hd., #10-32 x 5/8" 8 2800449 1 Contactor Coil, 208-240V, 15HP

QTY.

11 6040300G Electrical Box Base

Machine Screw, Pan Hd., M4-0.7 x 8mm

DESCRIPTION

PART

NO.

NUMBER

9 2900121 3 Cap Screw, Soc. Hd., #10-32 x 3/8"

10 4645254 1 Cover, Electric Box, 2 Hole 11 2800322 1 Start Button 12 2701414 4 Fastener, Electrical Box Top

13 2800222 1 Clear Protective Boot 14 1801638 1 Decal, Start

15 1801639 1 Decal, Stop 16 2801636 1 E-Stop Switch, 600V

QTY. DESCRIPTION

4646126(230/460V), ...127(575V) STARTER BOX ASSEMBLY

20

ROUTE INTO

16

STARTER BOX

B

TO STOP

SWITCH

6

5

1

8

15

13

14

6

7

TO CUSTOMER

SUPPLIED PLUG.

3

4

DETAIL B

SCALE 1 : 4

2

TO MOTOR

REPLACE COIL WITH

2800277 FOR 575 VOLT

10

DETAIL A

SCALE 1 : 2

A

9

11

12

ITEM NO. PART NUMBER QTY. DESCRIPTION

1 4646125 1 Starter Box, 208-460 Volt 2 2800315 1 Grounding Lug

3 2900016 1 Flat Washer, #10 USS 4 2900448 1 Machine Screw, Hex Hd., #10-32 x 1/2" 5 2800898 1 Connector, 1", Sealtite, 90 Deg. 6 2800193 2 Lock Nut, 1" 7 2804009 1 Cord Connector, 1"Thd., .87-1.02" Cord, Nylon

8 4646134 1 Conduit, Seal Tite, 1" x 34"

9 4646133 1 Wire Assy., 6 Gage, Green, 55" 10 4646132 3 Wire Assy., 8 Gage, Black, 60" 11 4646130 1 Wire Assy., 14 Gage, 52" 12 4646131 1 Wire Assy., 14 Gage, Orange, 50" 13 4646128 1 Wire, 14 Gage, Orange, 11" 14 4646129 1 Wire Assy., 14 Gage, Brown, 15" 15 4646135 1 Cable, 8 Gage, 4 Wire, 16" 16 1800810/11/12 1 Voltage Label, 230/460/575V

4646126/27 WIRING SCHEMATIC, CB 150, 3 PHASE, 230/460/575 VOLT

21

WIRES IN MOTOR WIRING BOX MUST BE JOINED PER SCHEMATIC ON MOTOR.

230V:

SET OVERLOAD TO 34 AMPS. SET OVERLOAD TO 17 AMPS.460V:

SET OVERLOAD TO 14 AMPS. REPLACE COIL WITH 2800277.575V:

4646128

ORANGE,

14 GA.

95 96

1

3

5

2

STOP

4646135

POWER CORD

4646129

BROWN,

14 GA.

COIL

OVERLOAD

4646132

BLACK, 8 GA.

4646131 ORANGE, 14 GA.

230/460V, TO MOTOR WIRE 7

575V, TO MOTOR WIRE 1.

RELAY

SETTINGS

5

30

PHASE UNBALANCE - ON

PHASE LOSS - ON

RESET MODE - AUTO

GROUND FAULT - OFF

4646130 BROWN, 14 GA.

230/460V, TO MOTOR WIRE 8

575V, TO MOTOR WIRE 2.

GREEN

4646133

GREEN, 6 GA.

GROUND

LUG

NOTES

22

____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________



(

)

23



GASLINEVALVE,



BELOWTANK



KEYSTART



&THROTTLE

GAGE,OIL

FILTER

CHOKE



EMERGENCY STOP

GASUNITS

RELIEF

CARTRIDGE

FLOW

CONTROL

QUICK

DISCONNECTS

WATER

CONNECTIONS

GENERAL SAFETY PRECAUTIONS

24

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 2600 p.s.i. (179 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.

 Never operate the gas power unit in a closed space. Inhalation of engine exhaust can

be fatal.

 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

25

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

 Keep clear of hot engine exhaust.  Do not add fuel to the power unit while the power unit is still running or is still hot.  Do not operate the power unit if a gasoline odor is present.  Do not use flammable solvents around the power unit engine.  Do not operate the power unit within 3 ft. (1 meter) of buildings or flammable objects.  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.

IMPORTANT: The red stop button at the front panel (gas units) or top of the starter box (electric units) will immediately stop the engine. 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

26

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: 12-1/2 gallons (47.3Liters) Hose Couplings: Bruning quick disconnect, 3/4 inch & ½ inch Relief Pressure: CB240, Factory set at 2600 PSI /179.3 Bar (at valve outlet port).

A higher relief setting will stall the engine. Adjustable to750 PSI, CB150, Factory set at 2100 PSI/145 Bar (at valve outlet port). Adjustable to 750 PSI, CURRENT LIMITTED TO 2100 PSI.

Gas Engine: Honda 21H (15.7KW) Net @3600RPM, Air-cooled, RPM set at 3550. Fuel tank: 5 Gal (18.9L). Electric Motor: Baldor 15 HP, C Face, 3450 RPM, 230/460 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 allows full flow control while the gas engine remains at its most efficient wide-open throttle. This allows a higher operating pressure at all flows. 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 2600 psi (gas) or 2100 psi (electric). 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 2600 psi (gas) and 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.

27

HOSES: Large diameters and short 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.

Gas Engine: Make sure that the engine crankcase is filled with oil to the proper level! Refer to your engine manual for oil checking and changing procedures, along with oil specifications, etc.

IMPORTANT: Operating the engine without oil will ruin the engine.

Fuel: Use regular grade unleaded

gasoline to fuel the engine. Premium grade may be used if necessary. Fill the tank when the engine is off and has been allowed to cool. Care should be taken to prevent spilling fuel. Do not overfill the fuel tank. Always leave enough space for expansion due to environmental heating.

WARNING: In the event of fuel spillage, do not start the engine or operate any nearby electrical component until the spilled fuel has been removed.

Starting Procedure:

GAS:

 Set the flow control valve to zero.  Open the fuel shut off valve below the

gas tank.

 Be certain the emergency off switch

has been pulled out.

 Set throttle at about 1/3, set choke if

necessary (cold engine). Turn key to start and release. Refer to engine manual for details of control functions.

 Let engine warm and gradually open

the choke and set the throttle to maximum.

ELECTRIC:

28

 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.

DANGER

: Exhaust from the gas engine contains carbon monoxide, a poisonous, odorless, invisible gas, which can cause serious illness or death. Do not operate the gas engine where ventilation is restricted. Open windows and doors may not be sufficient to prevent this hazard.

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

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

Shutting Down:

GAS:  Shift the flow control valve to zero to

unload the system.

 Throttle the engine back to a low RPM.  Turn the key to the off position.

IMPORTANT button at the front panel will immediately stop the engine. Hydraulic pressure and flow will go to zero. This button must be in the out position to start the engine.

ELECTRIC:  Shift the flow control valve to zero to

unload the system.

 Press the stop button at the top of the

starter box.

zero or shut the power unit down to avoid heating and conserve energy.

: Monitor the thermometer

: The red emergency stop

OPERATING DRIVEN

29

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 for specifications. A ½” pipe thread oil drain port is at the bottom of the hydraulic tank.

 Gas Engine Oil: Change engine oil and

filter and perform other routine maintenance as recommended in the engine operation manual.

 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.

30

TROUBLESHOOTING

PROBLEM POSSIBLE SOLUTIONS

Gas engine will not start.

1) Pull out emergency stop button.

2) Open gas line valve below gas tank.

3) Dead battery?

4) Low engine oil?

Electric motor will not start.

1) Pull out stop button on starter box.

2) Press reset button on starter box.

3) Confirm proper voltage.

Low oil flow.

Check gas engine RPM at tachometer on front panel. Adjust governor to 3550 RPM if required. See engine manual.

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. Running with no pressure. Electric units only.

The motor may be running backwards,

should be counter clockwise. Reverse

any 2 of the 3 power lines coming into

the starter box.

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

31

____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________

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 CB240 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

GENERAL SAFETY PRECAUTIONS

OPERATING INSTRUCTIONS

TROUBLESHOOTING

WARRANTY