DIAMOND
PRODUCTS
HYDRAULIC POWER UNIT
PARTS LIST &
OPERATOR’S MANUAL
MODEL:
CB30E XL
March 2013
PART#: 1801662
CBPOWERPACKFLOWANDPRESSURERATING
CBPOWERPACK
MODEL
MAXIMUMNO
LOADFLOW
GPM/LPM
RELIEF
SETTING
PSI/BAR
15Electric 12.75/48.2 2100/145
18BriggsVanguard 11.6 /43.9 2850/196.5
20Electric 14.9/56.4 2400 /165.5
21Honda 14.1 /53.2 2600 /179.3
30Electric 20.4/77.2 2300 /158.6
35BriggsVanguard 17.2 /65.1 3000 /206.9
Maximumnoloadflowisbasedonpumpandmotormanufacturer’s
specificationsforpumpdisplacementandnoloadRPM.Reliefissettoinsuregas
enginescannotreachtheirstalltorqueandelectricmotorswillnotexceedthe
recommendedcurrentlimit.
MAXNO
LOADFLOW
FLOW
USEABLEFLOW/PRESSURE
BELOWDARKLINE
>>>PRESSURE>>> CRACKING
RELIEF
PRESSURE
Flowdecreasesasengine/motorRPMdropsunderload.Reliefvalvesbeginto
openandshuntflowtotankat75‐80%ofthereliefsetting(crackingpressure).
Thisfurtherreducesflowtothetool.Atrelief,allflowisdirectedtotank.
IssuedAugust2011
Table of Contents
Description Page No.
1. 208/230/460 Volt Hydraulic Power Supply ...........................................4
2. 575 Volt Hydraulic Power Supply .........................................................8
3. Hydraulic Schematic .............................................................................12
4. Hose Kit ..................................................................................................13
5. Hydraulic Tank Assembly .....................................................................14
6. Control Panel Assembly .......................................................................16
8. Starter Box 208-240 Volt .......................................................................18
9. 230 Volt Starter Box Assembly……………………..…………………….20
10. Starter Box 440-480 Volt .....................................................................22
11. 460 Volt Starter Box Assembly…….…………………………………….24
12. Starter Box 550-600 Volt .....................................................................26
13. 575 Volt Starter Box Assembly…………….……………………………28
14. Component Locations ..........................................................................31
15. Safety Precautions ...............................................................................32
16. Descriptions and Specifications .........................................................34
17. Operating Instructions ........................................................................35
18. Operating Driven Equipment ...............................................................36
19. Maintenance Instructions ....................................................................36
20. Troubleshooting ...................................................................................37
21. Warranty……………………………………………………………Rear Cover
4646195 CB30 XL HYDRAULIC
4
1
POWER SUPPLY, 230/460 VOLT
42
19
43
8
2
3
43
4943
39
34
40
13
41
5
7
65
4
DETAIL B
SCALE 1 : 3
46
8
DETAIL A
SCALE 1 : 3
24
23
2627
28
30
25
2627
4646195 CB30 XL HYDRAULIC POWER SUPPLY 230/460 VOLT
5
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 18 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 4646185 2 Spacer Plate, CB30
9 2900473 4 Flat Washer, 3/8" USS
10 2900006 4 Lock Washer, 3/8" Split
11 2900005 4 Cap Screw, Hex Hd., 3/8-16 x 1"
12 4646187 1 Hydraulic Tank Assembly
13 4645062 1 Panel Assembly, CB30
14 3202318 1 Valve, Relief, 5KSI
15 3202061 1 Fitting, 5/8" MORB x 5/8" MJIC x 90 DEG
16 3202079 1 5/8" O-Ring - 5/8" MJIC
17 2900031 2 Lock Washer, 5/16" Split
18 2900726 2 Cap Screw, Hex Hd., 5/16-18 x 2-1/2"
19 4641146 1 Elec. Motor, 30HP, Short Shaft, W/Terminals
20 2802056 2 Washer, Reducer, 2.62 - 1.36"
21 2800312 1 Connector, 1" Sealtite Elbow
22 2800193 1 Lock Nut, 1"
23 6013061 1 Key, 1/2" Sq. x 2"
24 2401299 1 Coupling Assembly, 1-7/8 - 7/8"
25 2400312 1 Pump Mount, C-Face - SAE 2 Bolt
26 2900084 10 Lock Washer, 1/2" Split
27 2900499 10 Cap Screw, Hex Hd., 1/2-13 x 1-1/2"
28 2601703 1 Pump, 2.68 CI, 2 Bolt SAE
29 3200112 1 Elbow, 1" O-Ring to 3/4" M. JIC
30 3202316 1 1" MJIC - 1-1/4" MOR, 90 Deg.
31 2900058 4 Flat Washer, 1/2" SAE
32 4646035 1 Fuel Tank Support
33 2900009 6 Flat Washer, 1/4" SAE
34 2900024 6 Lock Washer, 1/4" Split
35 2900008 2 Cap Screw, Hex Hd., 1/4-20 x 1"
36 4641098 1 Starter Box Platform
37 2900138 4 Cap Screw, Hex Hd., 5/16-18 x 1"
38 4646049 1 Side Panel
39 2900144 4 Cap Screw, Hex Hd., 1/4-20 x 3/4"
40 4646006 2 Handle
41 2500636 2 Handle Grip
42 2900257 2 Lock Pin, T Handle, 3/8"
43 2900053 4 Rivet, 3/32" Dia.
44 4646003 1 Lifting Bar
45 2900248 2 Cap Screw, Hex Hd., 5/16-18 x 3"
46 4641055 1 Motor Guard
47 2900379 2 U-Bolt, 1" Pipe, 1/4-20
48 2900010 4 Lock Nut, 1/4-20 Nylon
49 1800169 1 Serial Number Plate, US
50 4600504 1 Hose Kit, CB30XL
4646195 CB30 XL HYDRAULIC
6
POWER SUPPLY 230/460 VOLT
DETAIL C
SCALE 1 : 5
22
20
21
POSITION CHAMFERS
TO OUTSIDE REAR.
DETAIL F
SCALE 1 : 4
47
27 31
4x
26
7
45
5
12
44
8
36
14
12
15
2726
4833
3435
33
46
7
5
5
37
36
32
29
28
30
DETAIL D
SCALE 1 : 5
DETAIL G
SCALE 1 : 4
DETAIL E
16
17
5 18
SCALE 1 : 4
11
10 9
4646195 CB30 XL HYDRAULIC POWER SUPPLY 230/460 VOLT
7
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 18 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 4646185 2 Spacer Plate, CB30
9 2900473 4 Flat Washer, 3/8" USS
10 2900006 4 Lock Washer, 3/8" Split
11 2900005 4 Cap Screw, Hex Hd., 3/8-16 x 1"
12 4646187 1 Hydraulic Tank Assembly
13 4645062 1 Panel Assembly, CB30
14 3202318 1 Valve, Relief, 5KSI
15 3202061 1 Fitting, 5/8" MORB x 5/8" MJIC x 90 DEG
16 3202079 1 5/8" O-Ring - 5/8" MJIC
17 2900031 2 Lock Washer, 5/16" Split
18 2900726 2 Cap Screw, Hex Hd., 5/16-18 x 2-1/2"
19 4641146 1 Elec. Motor, 30HP, Short Shaft, W/Terminals
20 2802056 2 Washer, Reducer, 2.62 - 1.36"
21 2800312 1 Connector, 1" Sealtite Elbow
22 2800193 1 Lock Nut, 1"
23 6013061 1 Key, 1/2" Sq. x 2"
24 2401299 1 Coupling Assembly, 1-7/8 - 7/8"
25 2400312 1 Pump Mount, C-Face - SAE 2 Bolt
26 2900084 10 Lock Washer, 1/2" Split
27 2900499 10 Cap Screw, Hex Hd., 1/2-13 x 1-1/2"
28 2601703 1 Pump, 2.68 CI, 2 Bolt SAE
29 3200112 1 Elbow, 1" O-Ring to 3/4" M. JIC
30 3202316 1 1" MJIC - 1-1/4" MOR, 90 Deg.
31 2900058 4 Flat Washer, 1/2" SAE
32 4646035 1 Fuel Tank Support
33 2900009 6 Flat Washer, 1/4" SAE
34 2900024 6 Lock Washer, 1/4" Split
35 2900008 2 Cap Screw, Hex Hd., 1/4-20 x 1"
36 4641098 1 Starter Box Platform
37 2900138 4 Cap Screw, Hex Hd., 5/16-18 x 1"
38 4646049 1 Side Panel
39 2900144 4 Cap Screw, Hex Hd., 1/4-20 x 3/4"
40 4646006 2 Handle
41 2500636 2 Handle Grip
42 2900257 2 Lock Pin, T Handle, 3/8"
43 2900053 4 Rivet, 3/32" Dia.
44 4646003 1 Lifting Bar
45 2900248 2 Cap Screw, Hex Hd., 5/16-18 x 3"
46 4641055 1 Motor Guard
47 2900379 2 U-Bolt, 1" Pipe, 1/4-20
48 2900010 4 Lock Nut, 1/4-20 Nylon
49 1800169 1 Serial Number Plate, US
50 4600504 1 Hose Kit, CB30XL
4646204 CB30 XL HYDRAULIC
8
POWER SUPPLY, 575 VOLT
1
42
19
43
2
46
3
43
38
39
34
40
13
41
7
65
5
4
DETAIL B
SCALE 1 : 3
24
8
23
28
DETAIL A
SCALE 1 : 3
264x27
30
25
27 26
2x
4646204 CB30 XL 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 18 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 4646185 2 Spacer Plate, CB30
9 2900473 4 Flat Washer, 3/8" USS
10 2900006 4 Lock Washer, 3/8" Split
11 2900005 4 Cap Screw, Hex Hd., 3/8-16 x 1"
12 4646187 1 Hydraulic Tank Assembly
13 4645062 1 Panel Assembly, CB30
14 3202318 1 Valve, Relief, 5KSI
15 3202061 1 Fitting, 5/8" MORB x 5/8" MJIC x 90 DEG
16 3202079 1 5/8" O-Ring - 5/8" MJIC
17 2900031 2 Lock Washer, 5/16" Split
18 2900726 2 Cap Screw, Hex Hd., 5/16-18 x 2-1/2"
19 4641161 1 Elec. Motor, 30HP, 575V, Short Shaft, W/Terminals
20 2802056 2 Washer, Reducer, 2.62 - 1.36"
21 2800312 1 Connector, 1" Sealtite Elbow
22 2800193 1 Lock Nut, 1"
23 6013061 1 Key, 1/2" Sq. x 2"
24 2401299 1 Coupling Assembly, 1-7/8 - 7/8"
25 2400312 1 Pump Mount, C-Face - SAE 2 Bolt
26 2900084 10 Lock Washer, 1/2" Split
27 2900499 10 Cap Screw, Hex Hd., 1/2-13 x 1-1/2"
28 2601703 1 Pump, 2.68 CI, 2 Bolt SAE
29 3200112 1 Elbow, 1" O-Ring to 3/4" M. JIC
30 3202316 1 1" MJIC - 1-1/4" MOR, 90 Deg.
31 2900058 4 Flat Washer, 1/2" SAE
32 4646035 1 Fuel Tank Support
33 2900009 2 Flat Washer, 1/4" SAE
34 2900024 6 Lock Washer, 1/4" Split
35 2900008 2 Cap Screw, Hex Hd., 1/4-20 x 1"
36 4641098 1 Starter Box Platform
37 2900138 4 Cap Screw, Hex Hd., 5/16-18 x 1"
38 4646049 1 Side Panel
39 2900144 4 Cap Screw, Hex Hd., 1/4-20 x 3/4"
40 4646006 2 Handle
41 2500636 2 Handle Grip
42 2900257 2 Lock Pin, T Handle, 3/8"
43 2900053 4 Rivet, 3/32" Dia.
44 4646003 1 Lifting Bar
45 2900248 2 Cap Screw, Hex Hd., 5/16-18 x 3"
46 1800169 1 Serial Number Plate, US
47 4600504 1 Hose Kit, CB30XL
DETAIL C
10
SCALE 1 : 5
22
20
21
4646204 CB30 XL HYDRAULIC
POWER SUPPLY 575 VOLT
44
4x
2627 31
45
7
5
12
12
POSITION CHAMFERS
TO OUTSIDE REAR.
15
DETAIL G
SCALE 1 : 4
8
36
2726
34 3335
5
36
327537
29
28
30
DETAIL D
SCALE 1 : 5
14
17
5 18
16
DETAIL E
SCALE 1 : 4
10
11 9
4646204 CB30 XL 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 18 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 4646185 2 Spacer Plate, CB30
9 2900473 4 Flat Washer, 3/8" USS
10 2900006 4 Lock Washer, 3/8" Split
11 2900005 4 Cap Screw, Hex Hd., 3/8-16 x 1"
12 4646187 1 Hydraulic Tank Assembly
13 4645062 1 Panel Assembly, CB30
14 3202318 1 Valve, Relief, 5KSI
15 3202061 1 Fitting, 5/8" MORB x 5/8" MJIC x 90 DEG
16 3202079 1 5/8" O-Ring - 5/8" MJIC
17 2900031 2 Lock Washer, 5/16" Split
18 2900726 2 Cap Screw, Hex Hd., 5/16-18 x 2-1/2"
19 4641161 1 Elec. Motor, 30HP, 575V, Short Shaft, W/Terminals
20 2802056 2 Washer, Reducer, 2.62 - 1.36"
21 2800312 1 Connector, 1" Sealtite Elbow
22 2800193 1 Lock Nut, 1"
23 6013061 1 Key, 1/2" Sq. x 2"
24 2401299 1 Coupling Assembly, 1-7/8 - 7/8"
25 2400312 1 Pump Mount, C-Face - SAE 2 Bolt
26 2900084 10 Lock Washer, 1/2" Split
27 2900499 10 Cap Screw, Hex Hd., 1/2-13 x 1-1/2"
28 2601703 1 Pump, 2.68 CI, 2 Bolt SAE
29 3200112 1 Elbow, 1" O-Ring to 3/4" M. JIC
30 3202316 1 1" MJIC - 1-1/4" MOR, 90 Deg.
31 2900058 4 Flat Washer, 1/2" SAE
32 4646035 1 Fuel Tank Support
33 2900009 2 Flat Washer, 1/4" SAE
34 2900024 6 Lock Washer, 1/4" Split
35 2900008 2 Cap Screw, Hex Hd., 1/4-20 x 1"
36 4641098 1 Starter Box Platform
37 2900138 4 Cap Screw, Hex Hd., 5/16-18 x 1"
38 4646049 1 Side Panel
39 2900144 4 Cap Screw, Hex Hd., 1/4-20 x 3/4"
40 4646006 2 Handle
41 2500636 2 Handle Grip
42 2900257 2 Lock Pin, T Handle, 3/8"
43 2900053 4 Rivet, 3/32" Dia.
44 4646003 1 Lifting Bar
45 2900248 2 Cap Screw, Hex Hd., 5/16-18 x 3"
46 1800169 1 Serial Number Plate, US
47 4600504 1 Hose Kit, CB30XL
END TO MANIFOLD
12
HOSE 4646170
90
HOSE
4646086
RETURN PORTS
COOLER
EX
IN
FLOW
CB30XL HYDRAULIC SCHEMATIC
CONTROL
CF
HOSE
4600162
HOSE
4641067
1
PUMP
2
FILTER
RELIEF
HOSE
6040057
TANK
TANK
END TO MANIFOLD
HOSE 4646170
90
GAGE
HOSE
4646055
4600504.
ALL HOSES ARE IN KIT
PRESSURE PORTS
4600504 HOSE KIT, CB30XL
13
34.0
23.1
20.1
23.6
1
2
3
4
31.2
16.6
ITEM PART NO. QTY. DESCRIPTION
1 6040057 1 Hose Assy., 1 x 34"
3202317 2 Fitting, 1" FJIC to 1" Hose Barb
3200135 2 Hose Clamp #16
2 4600162 1 Hose Assembly, 3/4" x 23.1"
3200129 2 Fitting, 3/4" F. JIC to 3/4" Hose Crimp
3 4646170 2 Hose Assy., 5/8" x 20"
3201883 1 5/8" FJIC Parkrimp, 90 Deg.
3202075 1 5/8"FJICS x 5/8" Parkrimp Hose End Fitting
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 4641067 2 Hose Assy., 5/8" x 31-1/4"
3202075 2 5/8"FJICS x 5/8" Parkrimp Hose End Fitting
6 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
5
6
4646187 HYDRAULIC TANK ASSEMBLY
14
24
23
22
14
7
19
20
18
17
16
15
9 12
6
11
13
21
10
4
1
8
5
2
3
4646187 HYDRAULIC TANK ASSEMBLY
15
ITEM PART NO. QTY. DESCRIPTION
1 4640120 1 Hydraulic Tank Weldment
2 3200409 1 Street Elbow, 1" NPT
3 3200427 1 Nipple, 1" NPT x 4", Schedule 40
4 3200288 1 Plug, 1" NPT
5 3200289 1 Elbow, 1" M. Pipe to 1" M. JIC
6 3200431 1 NIpple, 1"MPT - 3/4" MPT
7 2400166 1 Sight Gauge, Liquid Level
8 3200160 1 Plug, 1/2-14 NPT
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"
4645062 CB30 XL PANEL ASSEMBLY
16
6X
2
3
4
42
43
28
41
32
2
7
33 35
36
40
7
1
8
7 9
19
22
21
37
38
13
25
23
20
17
5
24
26
17
18
10
17
30
31
29
16
12
1077
14
15
27
29
11
4645062 CB30 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 4645054 1 Manifold, SAE O-Ring, 5/8 & 3/4" Ports
6 4646101 1 Manifold, 3/4 NPT
7 2900009 20 Flat Washer, 1/4" SAE
8 2900667 4 Cap Screw, Hex Hd., 1/4-20 x 3"
9 2901001 4 Cap Screw, Hex Hd., 1/4-20 x 2-1/2"
10 2900010 10 Lock Nut, 1/4-20 Nylon
11 3200479 1 Plug, 3/4" NPT Square Head
12 3200097 1 Adapter, 3/4" M. JIC to 3/4" M. Pipe
13 3200417 1 Elbow, 3/4" F. JIC to 3/4" M. JIC
14 3200082 2 5/8" MJIC TO 3/4" MPT
15 3200626 1 Adapter, 5/8" O-Ring to 1/4" M. JIC
16 3201241 1 Elbow, 1/4" M. JIC to 1/4" F. JIC
17 3202077 3 5/8 MJIC - 3/4" MOR, 90 Deg.
18 3202079 1 5/8" O-Ring - 5/8" MJIC
19 3200330 1 Adapter, 3/4" M. Pipe to 3/4" O-Ring
20 3201899 1 Adapter, 1/2" MPT to 3/4" O-Ring
21 3200105 1 Nipple, 1/2" Q.D.
22 3200101 1 Nipple, 3/4" Quick Disconnect
23 3200137 1 Hex Nipple, 3/4" NPT
24 3200383 1 Nipple, Hex, 3/4" MPT TO 1/2" MPT
25 3200100 1 Coupler, 3/4" Quick Disconnect
26 3200104 1 Coupler, 1/2" Q.D.
27 2400307 1 Heat Exchanger
28 2900303 2 Lock Nut, M8-1.25 Nylon Insert
29 3200400 2 Elbow, 3/4" O-Ring to 3/4" Male JIC
30 3201972 1 Valve, Flow Control, 20 GPM
31 3200458 1 3/4" O-Ring to 3/4" MJIC, 45 Deg.
32 2900245 2 Cap Screw, Soc. Hd., 1/4-20 x 2-5/8"
33 3200250 1 Gauge, Hydraulic, 3000 PSI
34 2500549 1 Plug, 7/8" Hole
35 2500204 1 Plug, 1/2" Hole
36 2503749 1 Plug, 5/16" Hole (Tapered)
37 3201659 2 Fitting, 3/4" M. Pipe to 3/4" M. Garden
38 3200177 1 Fitting, 3/4" F. Garden Union Swivel
39 1800536 1 "Return" Decal
40 1800941 1 Decal, Hydraulic Power Supply
41 1800531 1 "Hyd. Pressure" Decal
42 1801851 1 Decal, CB30 Flow Control
43 1801396 1 Decal, Core Bore CB30
4646194: STARTER BOX, 208-240 VOLT
18
17
17
16
15
8
1
1
5
10
9
4
6
3
7
2
8
11
1
12
13
14
4646194: STARTER BOX, 208-240 VOLT
19
4646197
4646129
95
96
OVERLOAD
RELAY
STOP START
AUXILIARY
INTERLOCK
CONTACTOR
4646196
C
O
I
4646198L
ITEM PART NO. QTY. DESCRIPTION
1 4641052 1 Starter Box, CB30 XL
2 4641066 1 Back Plate, Starter Box
3 2901331 4 Machine Screw, Truss Hd., #10-32 x 3/8"
4 2800886 1 Contactor, 30 HP, 208-240 Volt
5 2804400 1 Auxiliary Contact, N.O., 75-90 Amp
6 2800906 1 Overload Relay, 25-100 Amp
7 2800315 2 Grounding Lug
8 6011305 1 Start Pushbutton Assembly
2701391 1 Cap, Black Flush
2701392 1 Contact Block (N.O.)
2800222 1 Clear Protective Boot
2701390 1 Push Button Body (Includes Nut)
9 2900016 8 Flat Washer, #10 USS
10 2900708 8 Machine Screw, Rd. Hd., #10-32 x 1/2"
11 4646129 3 Wire Assy., 14 Gage, Brown, 15"
12 4646196 2 Wire, 14 Gage, Orange, 15"
13 4646197 1 Wire, 16 Gage, Yellow, 6"
14 4646198 1 Wire Assy., 16 Gage, Yellow, 6"
15 1801638 1 Decal, Start
16 1801639 1 Decal, Stop
17 2801636 1 E-Stop Switch, 600V
4646201 CB30 STARTER BOX ASSEMBLY, 230 VOLT
20
ROUTE INTO
STARTER BOX
3
11
1
12
13
2x
2
TO CUSTOMER
SUPPLIED PLUG
9
4
5
10
6
6
DETAIL A
SCALE 1 : 2
A
8
7
TO MOTOR
4646201 STARTER BOX ASSEMBLY, 230 VOLT
21
208 VOLT: SET RELAY TO 78 AMP
230 VOLT: SET RELAY TO 72 AMP
BLACK THRU
RELAY TO
CONTACTOR
GREEN
4641056
GROUND NUT
TO ANY SCREW
IN PLATE.
SETTINGS
CLASS 20
PHASE UNBALANCE - ON
PHASE LOSS - ON
RESET MODE - AUTO
GROUND FAULT - OFF
POWER
CABLE
GREEN
GROUND
STUD
ITEM PART NO. QTY. DESCRIPTION
1 4646194 1 Starter Box, 208-240V, 30HP
2 2800898 1 Connector, 1", Sealtite, 90 Deg.
3 2800193 1 Lock Nut, 1"
4 2800342 1 Connector, Cord, 1-1/4"
5 2800934 1 Grounding Nut, 1-1/4"
6 4600161 1 Conduit, Seal Tite, 1" x 24"
7 4641053 1 Wire, 6 Gage, Green
8 4641054 3 Wire Assy., 6 Gage, Black
9 4641065 1 Cable, 4 Gage, 4 Wire, 20"
10 4641056 1 Wire Assy., 12 Gage, Green
11 1800810 1 Voltage Label, 230V
12 2900016 2 Flat Washer, #10 USS
13 2900708 2 Machine Screw, Rd. Hd., #10-32 x 1/2"
16
22
4645256: STARTER BOX, 440-480 VOLT
17
8
1
15
10
17
1
4
9
6
3
3
10
9
7
5
2
8
11
1
12
13
14
4646256: STARTER BOX, 440-480 VOLT
23
4646197
4646129
95
96
OVERLOAD
RELAY
STOP START
AUXILIARY
INTERLOCK
CONTACTOR
4646196
C
O
I
4646198L
ITEM PART NO. QTY. DESCRIPTION
1 4641052 1 Starter Box, CB30 XL
2 4641066 1 Back Plate, Starter Box
3 2901331 4 Machine Screw, Truss Hd., #10-32 x 3/8"
4 2800912 1 Contactor, 30 HP, 440-480 Volt
5 2804400 1 Auxiliary Contact, N.O., 75-90 Amp
6 2800906 1 Overload Relay, 25-100 Amp
7 2800315 2 Grounding Lug
8 6011305 1 Start Pushbutton Assembly
2701390 1 Push Button Body (Includes Nut)
2701391 1 Cap, Black Flush
2701392 1 Contact Block (N.O.)
2800222 1 Clear Protective Boot
9 2900016 8 Flat Washer, #10 USS
10 2900708 8 Machine Screw, Rd. Hd., #10-32 x 1/2"
11 4646129 3 Wire Assy., 14 Gage, Brown, 15"
12 4646196 2 Wire, 14 Gage, Orange, 15"
13 4646197 1 Wire, 16 Gage, Yellow, 6"
14 4646198 1 Wire Assy., 16 Gage, Yellow, 6"
15 1801638 1 Decal, Start
16 1801639 1 Decal, Stop
17 2801636 1 E-Stop Switch, 600V
4646202 STARTER BOX ASSEMBLY, 440-480 VOLT
24
ROUTE INTO
STARTER BOX
3
1
2
4
TO CUSTOMER
SUPPLIED PLUG
9
11
12
13
A
2x
10
6
TO MOTOR
5
6
DETAIL A
SCALE 1 : 2
8
7
BLACK THRU
25
RELAY TO
CONTACTOR
GREEN
4646202 STARTER BOX ASSEMBLY, 440-480 VOLT
460 VOLT: SET RELAY TO 36 AMP
POWER
4641056
GROUND NUT
TO ANY SCREW
IN PLATE
CABLE
GREEN
GROUND
SETTINGS
STUD
CLASS 20
PHASE UNBALANCE - ON
PHASE LOSS - ON
RESET MODE - AUTO
GROUND FAULT - OFF
ITEM PART NO. QTY. DESCRIPTION
1 4645256 1 Starter Box, 440-480V, 30HP
2 2800898 1 Connector, 1", Sealtite, 90 Deg.
3 2800193 1 Lock Nut, 1"
4 2800342 1 Connector, Cord, 1-1/4"
5 2800934 1 Grounding Nut, 1-1/4"
6 4600161 1 Conduit, Seal Tite, 1" x 24"
7 4641053 1 Wire, 6 Gage, Green
8 4641054 3 Wire Assy., 6 Gage, Black
9 4641065 1 Cable, 4 Gage, 4 Wire, 20"
10 4641056 1 Wire Assy., 12 Gage, Green
11 1800811 1 Voltage Label, 460V
12 2900016 2 Flat Washer, #10 USS
13 2900708 2 Machine Screw, Rd. Hd., #10-32 x 1/2"
16
26
4645257 STARTER BOX, 550-600 VOLT
17
8
1
10
17
15
9
6
3
10
9
2
1
5
8
4
3
2
1
11
12
13
14
4645257: STARTER BOX, 550-600 VOLT
27
4646197
4646129
95
96
OVERLOAD
RELAY
STOP
START
AUXILIARY
INTERLOCK
CONTACTOR
4646196
C
O
I
L 4646198
ITEM PART NO. QTY. DESCRIPTION
1 4641052 1 Starter Box, CB30 XL
2 4641066 1 Back Plate, Starter Box
3 2901331 4 Machine Screw, Truss Hd., #10-32 x 3/8"
4 2800933 1 Contactor, 30 HP, 550-600 Volt
5 2804400 1 Auxiliary Contact, N.O., 75-90 Amp
6 2800906 1 Overload Relay, 25-100 Amp
7 2800315 2 Grounding Lug
8 6011305 1 Start Pushbutton Assembly
2701390 1 Push Button Body (Includes Nut)
2701391 1 Cap, Black Flush
2701392 1 Contact Block (N.O.)
2800222 1 Clear Protective Boot
9 2900016 8 Flat Washer, #10 USS
10 2900708 8 Machine Screw, Rd. Hd., #10-32 x 1/2"
11 4646129 3 Wire Assy., 14 Gage, Brown, 15"
12 4646196 2 Wire, 14 Gage, Orange, 15"
13 4646197 1 Wire, 16 Gage, Yellow, 6"
14 4646198 1 Wire Assy., 16 Gage, Yellow, 6"
15 1801638 1 Decal, Start
16 1801639 1 Decal, Stop
17 2801636 1 E-Stop Switch, 600V
4646203 STARTER BOX ASSEMBLY, 550-600 VOLT
28
ROUTE INTO
STARTER BOX
1
3
2
TO CUSTOMER
SUPPLIED PLUG
7
5
8
3
9
10
4
6
TO MOTOR
4646203 STARTER BOX ASSEMBLY, 550-600 VOLT
29
THROUGH
RELAY TO
CONTACTOR
GREEN
575 VOLT: SET RELAY TO 30 AMPS
POWER
CABLE
GREEN
GROUND
STUD
SETTINGS
CLASS 20
PHASE UNBALANCE - ON
PHASE LOSS - ON
RESET MODE - AUTO
GROUND FAULT - OFF
ITEM PART NO. QTY. DESCRIPTION
1 4645257 1 Starter Box, 550-600V, 30HP
2 2800897 1 Cord Connector, 1"Thd., .77-.895" Cord, 90 Deg.
3 2800193 2 Lock Nut, 1"
4 2802056 2 Washer, Reducer, 2.62 - 1.36"
5 2803100 1 Cord Connector, 1"Thd., .77-.895" Cord, Nylon
6 4645035 1 Cable Assy., 8 Ga., 4 Wire x 50"
7 4645255 1 Cable, 8 Gage, 4 Wire, 20"
8 1800812 1 Voltage Label, 575V
9 2900016 2 Flat Washer, #10 USS
10 2900708 2 Machine Screw, Rd. Hd., #10-32 x 1/2"
30
Intentionally Blank
31
FLOW
CONTROL
WATER
QUICK
CONNECTIONS
DISCONNECTS
RELIEF
CARTRIDGE
GENERAL SAFETY PRECAUTIONS
32
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 psi (173 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.
33
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
34
Pump: Gear, pump rotation is clockwise (motor is CCW).
Maximum GPM: 19 GPM (72L/M). Flow will decrease as pressure approaches relief.
Hydraulic Fluid Tank Capacity: 11 gallons (41.6Liters)
Hose Couplings: Bruning quick disconnect, 3/4 inch & ½ inch.
Relief Pressure: Factory set at 2300 PSI/158 Bar (at valve outlet port). Adjustable to 750
PSI/52 Bar, CURRENT LIMITTED TO 2300 PSI.
Electric Motor: Baldor 30 HP, C Face, 1760 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.
Flow 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 Valve: Relief pressure can be
adjusted using an Allen wrench at the relief
cartridge, which is mounted just below the
front panel. The relief can be set as low as
750 psi; do not exceed 2300 psi. To adjust,
the flow control must be set at 10 and no
tool should be attached. This will force all
flow over relief. The relief is factory set at
2300 psi and should rarely need
adjustment. Higher relief settings may
cause excessive tripping of the overload
relay.
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
the water must be drained from the
cooler to prevent damage by freezing.
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 20 GPM
and oil at 100 deg. F (37.8C), this could
result in a 600 psi (41 Bar) pressure loss
with ½” hose and a 200 psi (14 Bar) loss
with 5/8” hose. Pressure loss will change
dramatically with oil temperature.
: If there is a risk of frost
35
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: 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 at the top of the
starter box.
OPERATING DRIVEN
36
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.
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.
37
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.
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
Corporate Office
other reproductive harm.
NOTES
38
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NOTES
39
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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.
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