Diamond CC1800XL User Manual

DIAMOND

P R O D U C T S

OPERATOR’S MANUAL

CONCRETE SAW

MODEL

CC1800XL

February 2007

Part #1801038

Intentionally Blank

GENERAL SAFETY WARNINGS AND PRECAUTIONS

PERSONAL SAFETY

• Read and understand all operating instructions before attempting to operate the sa w.

• Always wear safety approved hearing, eye, head and respiratory protection.

• Always wear sturdy boots with non-slip soles to ensure proper footing. Use of steel toed safety boots is recommended.

• Due to the nature of concrete cutting, sparks may be generated therefore never wear clothing that is made of flammable

material.

• Know how to stop the saw quickly in case of emergency.

• Keep all parts of your body and clothing away from the blade and all other moving parts.

• Use caution and follow all instructions when loading and unloading the saw.

BLADE SAFETY

• Examine cutting blades before each use. Blade should have no cracks, nick, or flaws. The center hole must be
undamaged. Use only blades recommended for you particular model saw.

• The saw should only be used for cutting material that is specified on each cutting blade. Read the instructions provided with
each blade to determine which material the blade is designed to cut.

• Use only reinforced abrasive blades or steel centered diamond blades manufactured for use on concret e saws.

• Inspect blade flanges for damage, excessive wear and cleanliness before mounting the blad e. The blade must fit snuggly

on the clean, undamaged blade shaft.

• Observe the specified maximum speed of the blade. Never use a blade that has a lower maximum operating speed than the
blade shaft speed.

• The ignition governor is designed to limit the maximum no-load engine speed. Speeds in excess of that may cause the
blade to exceed the maximum blade speed. Do not operate the unit at speeds greater than the maximum blade speed.

• Always keep guards in place and never allow the blade exposure on the guard to exceed 180 degrees. Repair or replace
damaged guards immediately.

• Never expose anyone to the direct line of the blade.

• Make sure that the blade does not come in contact with the ground or any other surface when transporting the saw.

GENERAL SAW SAFETY

• The saw must never be left unattended when the engine is running.

• Keep both hands on the handles when operating the saw.

• Never operate the saw if there is a fuel leak.

• Use extreme caution and slow speed when using the self propelled drive to move the saw up or down ramps or when

loading and unloading from trucks or trailers. When going down ramps, DRIVE the saw forward slo wly. When going up
ramps, BACK the saw in reverse slowly.

CUTTING / WORK AREA SAFETY

• Never operate the saw in any application or job in which you are not trained or superv ised.

• Always ensure that the work area does not contain any buried or embedded electrical lines, gas lines or water lines. Ensure

that all electricity in the ground, floor, walls or ceilings is shut off prior to cutting. Ensure that all gas and water lines that may
be buried or embedded in the ground, floor, walls or ceilings are shut off prior to cutting.

• Operate the saw only in well ventilated areas. Engine exhaust contains carbon monoxide which can cau s e loss of
consciousness and death.

• Keep bystanders and animals out of the work area.

• Observe all safety regulations for the safe handling of fuel. Store fuel in appropriate safety containers. Shut off the engine

and allow it to cool prior to fueling. Wipe off any spilled fuel. Always move away from the fueling area prior to starting saw.

• Do not operate the saw in areas which contain combustible material or fumes. Sparks may occur from cutting that could
cause a fire or explosion.

Concrete cutting as all construction work is inherently dangerous!

Failure to comply with the preceding warnings could result in serious bodily injury!

CONCRETE SAW OPERATING INSTRUCTIONS

ASSEMBLY

1. Set handles to desired height and securely
tighten bolts. The handles are mirror image
and can be reversed, depending on operators
preference.

2. Be certain to check engine and transmission
oil levels and service if required. Refer to
engine manual for detailed information.

3. On electric saw models, the proper size power
cord must be provided by the purchaser.

GENERAL INSTRUCTIONS

1. Be certain you have the correct diamond or
abrasive blade. Contact your authorized
servicing dealer for the correct specification.
Getting the correct blade will make a
tremendous difference in your blade costs and
performance.

2. The blade shaft flange and arbor must be
inspected for damage and cleaned before
mounting the blade. If damaged, replace bad
parts. Inspect blade for damage to arbor hole
and flange area before attempting to mount
blade.

3. Mount the blade solidly and firmly on the blade
shaft arbor using the wrench provided. The lock
pin(s) in the outer blade flange must go
completely through the blade and into the
matching hole(s) in the inside blade flange.
Tighten the blade flange bolt very securely
(Approximately 50 lb.ft.). Note that the blade
shaft bolt on the right hand side has left hand
threads, which tightens by turning counter
clockwise. The blade shaft bolt on the left hand
side has right hand threads, which tightened by
turning clockwise.

4. WARNING: Do not operate without proper
blade guard in place. Do not operate with front
of blade guard raised. Blade exposure cannot
exceed 180 degrees when cutting.

5. The front pointer must be checked for alignment
with blade. It must be in line with a blade
mounted shaft. Use a chalk line or a long
straight edge to verify alignment.

6. Do not use conventional (wet) diamond blades
without water! You must have from 2-1/2 to 5
gallons of water per minute flowing over the
blade for proper cooling and to get maximum
blade life. For wet sawing, are sure the spray
holes in the blade guard tubes are open and that
each side of the blade has an adequate supply
of water. Test your water supply for pressure
and flow before starting to saw.

7. Saw in a straight line. Mark the cutting line
clearly so the saw operator can follow the line
without difficulty. The saw should not be twisted
from side to side trying to force the blade back
on line.

8. Saw only as deep as the specifications and job
conditions require. This will save blade life and
reduce sawing costs. Sawing excessively deep
is wasteful and should be avoided. Step cut in
increments of 2 inches for best results.

TO START SAW

1. Fill the fuel tank and check the engine oil level.
Refer to the engine manual for details.

WARNING: On self-propelled models, always

disengage the transmission drive system before
starting the engine.

2. Start engine. Follow procedure in engine manual.

3. Let engine warm up at half throttle.

4. All sawing is done at full throttle. Governor is
factory set for correct engine speed.

TO STOP SAW

GAS SAWS: Push and hold down the stop button
at the right, center of the control panel until the
engine completely stops. If unit is key start, turn key
to OFF.
ELECTRIC SAWS: Press stop button at top of
starter box.
HYDRAULIC SAWS: Turn ball valve to off position.

TO MANEUVER SAW

1. Raise blade as high as possible so blade will not
strike pavement when maneuvering. Pull index
plunger and turn handwheel counter clockwise.

2. To turn, lift rear wheels just above pavement
and maneuver saw as desired.

3. On Self-propelled units, engage the
transmission by pushing the lever at the rear of
the control panel down. Pull lever up to
disengage.

WARNING: Be certain the speed control lever
is at neutral before engaging to avoid sudden
movement. Move the speed
control lever from the neutral position. This lever
permits infinitely variable ground speed (up to 70
feet per minute) in both forward and reverse.
When maneuvering with power, the engine
should be running at half throttle or more so the
hydrostatic transmission can operate efficiently.
For maximum speed forward or reverse, the
engine must be running at full throttle.

4. To push manually, the transmission must be
disengaged.

TO START SAWING

1. Align blade with cut.

2. For wet sawing open water valve Full
Confirm flow and adjust before lowering into cut.
If water supply is interrupted, stop cutting
immediately.

3. Lower blade into cut (never deeper than
required) by slowly turning hand wheel

open.

CONCRETE SAW OPERATING INSTRUCTIONS

clockwise. When the blade reaches desired
depth, release index plunger.

4. During cutting do not exert excessive side
pressure on handles to steer. Use only enough
pressure to follow previously marked line.

5. Move the speed control handle forward until
desired speed is obtained allowing the blade to
cut and not climb out of cut or stall.

6. If the saw should stall for any reason raise the
blade completely and disengage transmission
before starting engine again.

7. When lowering the blade into a partially-made
cut, use extreme care to be certain the blade is
perfectly aligned within the cut before starting to
cut again. Do not force blade into material by
lowering blade to fast or by propelling too fast
while sawing.

AT FINISH OF CUT

1. On self-propelled models, move speed control
lever to neutral position.

2. Bring the blade out of the cut by pulling the
index plunger and turning handwheel counter­clockwise. Raise blade high enough to clear the
pavement when maneuvering the saw.

3. Turn off water valve. If saw is equipped with the
optional electric water pump, make sure it is
turned off.

4. Close engine throttle to idle position. Let engine
cool down before stopping.

5. Do not leave the saw until the blade and saw have
completely stopped.

MAINTENANCE INSTRUCTIONS

1. Lubricate the blade shaft bearings daily! If
cutting dry, lubricate blade shaft bearing two or
three times daily. All other fittings (wheels,
bearings, depth control shaft, etc.) should be
greased every 40 hours of operation. Use only
premium lithium-based grease conforming to
NLGI No. 2 consistency.

2. Check the engine oil daily. Keep oil clean and
at proper level. Since the engine often operates
at an angle, check the engine oil level (with the
engine horizontal) frequently to ensure that the
oil level never fails below the minimum mark on
the dip stick. Follow the engine manufacturer’s
recommendations for changing oil.

3. Air filter. When cutting dry, clean two or three
times per day. See engine manual for
additional information.

4. Blade shaft V-belts tension: This model
concrete saw is equipped with 3VX premium V­belts. These belts are properly tensioned at the
factory. Severe damage or even breakage of
the crankshaft might occur if the belts are
tensioned too tight. Check belt tension as set on
the new saw and never set belts beyond original
factory tension. Not enough tension will result in
poor saw performance and short belt life. Belts

should never be allowed to slip. After four hours
of use, re-tension belts to make up for initial
stretch. To re-tension the belts, turn the engine
off. Loosen the four bolts on the sides of the
engine base. Turn the vertical tensioning bolt on
the front of the engine base clockwise until the
belts are tight. Re-tighten the four bolts on the
engine base. Continue to check the belt tension
on a daily basis, and re-tension as necessary.
To obtain accurate V-belt setting, a V-belt
tension tester should be used. Check the setting
on a single belt of a matched set of V-belts.
Apply load on the center of the span. Deflection
should be 3/16” with a 5 to 6 lb. load.

5. Tighten fasteners regularly: Nuts and bolts
may become loose particularly after the first few
hours of operation. Most fasteners on this unit
are metric. Please use the correct tool

6. Engine care: See engine manual. Clean dust
and dirt from cooling fans, as required, to
provide adequate cooling.

MAINTENANCE OF TRANSMISSION DRIVE

1. Check hydrostatic transmission oil daily.
Check level in transparent oil reservoir.
Transmissions are factory filled with an oil
having a viscosity equivalent to SAE 20W20.
Do not use multiple viscosity oils. If erratic
operation occurs during hot weather, drain oil
and refill with an oil having a viscosity
equivalent to SAE 30 or SAE 40 with API
classification SE, CC, CD or better.

2. Loose chain drive: The chain drive will stretch
during normal operation. It can be tightened by
loosing the four transmission attaching bolts and
moving the transmission up in the slots of the
transmission platform. Do not over tighten
chain, but allow a slight amount of slack.
Lubricate chain with oil to reduce chain wear.

3. Hydrostatic transmission cooling fins: Do
not allow the fan or cooling fins of the
transmission to become covered, or clog with
dust or dirt. This will not allow proper cooling of
the transmission oil.

4. Drive wheels: If the drive wheels do not
engage the rear wheels with sufficient pressure,
slippage may occur. To correct this, lengthen
the engagement linkage by loosening the two
adjustment bolts, lengthen the linkage
assembly, and re-tighten the bolts.

GOVERNOR SPEEDS

It is critical that the governor and throttle on all internal
combustion engines are adjusted properly. Engine
speed is preset at the factory for proper sawing speed It
is not normally necessary to change this setting. It
should be periodically verified after the saw is placed in
service. To change governor setting, refer to the engine
manual.

CONCRETE SAW OPERATING INSTRUCTIONS

WARNING: Over speeding the engine and

blade shaft can cause serious damage to the blade and
could result in injury to the operator and bystanders. Do
not exceed the following speeds: No load blade shaft –
2800 RPM, no load engine – 3900 RPM.

ASSEMBLY OPTIONS, OPERATOR’S PREFERENCE

1. The handles are mirror image and can be
reversed.

2. The water valve can be mounted on the left or
right side on units without the gas tank
assembly.

3. On hydraulic motor models, the hydraulic hoses
and tube assembly can be mounted on the left
or right side. If moved to the right side, the water
valve must be moved to the left side.

OPTIONAL ITEMS
HYDROSTATIC TRANSMISSION KIT

A kit is available to make the saw a self-propelled unit
with a forward and reverse ground speed of up to 70 feet
per minute. The saw can still be a push unit simply by
disengaging the transmission.

ELECTRIC WATER PUMP
A kit is available for use with electric start engine models
only. The pump is powered directly from the battery and
must be switched off when not in use or it will run until
the battery is dead.

WEIGHT KIT
Two weights are included which bolt to the front of the
saw frame. Total weight is ~26 lbs. This is standard on
all 20” models and all models over 15HP.

WATER TANK KIT

A five gallon (19Liter) tank is available for all models and
mounts to the lift bar. This option is intended for dust
suppression during dry cutting and is not sufficient for
blade cooling.

TACHOMETER / HOUR METER

A digital display meter is available for all gas models and
is standard on all 20 HP units. It is installed by simply
mounting it to the control panel and wrapping the pickup
wire around the engine spark plug wire 4 to 5 times.

BLADE SIZE MAXIMUM DEPTH

10” 2-5/8”
12” 3-5/8”
14” 4-5/8”
16” 5-5/8”
18” 6-5/8”
20” 7-5/8”

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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

[phone] • [phone] • Fax [phone]

www.diamondproducts.com

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