Diamond Products CC125BXL-EE6, Operator'S Manual

Page 1: ...CONCRETE SAW OPERATOR S MANUAL CC150XL EE6 Series CC125BXL CC148HXL CC165BVXL CC165LXL October 2019 Part 1802698 ...

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Page 3: ... Transporting Safety 15 Lifting Safety 15 Operating 16 General Operating Precautions 16 Handlebars 16 Handlebars 16 Adjusting the Handlebars 16 Front Pointer 16 Adjusting the Front Pointer 16 Diamond Blades 17 Inspecting the Blade 17 Blade Speed 17 Installing the Blade 17 Removing the Blade 19 Raising and Lowering the Saw Blade 19 Raising the Saw 19 Lowering the Saw Blade 19 Spring Box Assembly 19...

Page 4: ...pect the Drive Belt 28 Belt Tensioning 28 Tensioning the Drive Belts 29 Replacing the Drive Belts 29 Check Engine Oil Level 29 Check Fuel Level 29 Check Air Filter 29 100 Hour Service 29 Clean the Air Filter 29 Replace the Engine Oil 30 Clean the Sediment Cup 30 Check and Adjust Spark Plug 30 Clean the Spark Arrester 31 Honda Lifan Engines 31 Vanguard Engine 31 Yearly Service 31 Replace the Air Fi...

Page 5: ...34 Transporting 34 Storing 34 Disposal 34 Appendix A 38 Troubleshooting 38 Appendix B 40 Belt Tension Specifications 40 Power Cord Specifications 40 Appendix C 41 Additional Resources 41 Appendix D 42 Model and Serial Numbers 42 ...

Page 6: ...nsure safety and design Any modifications made by the owner s are not the responsibility of Diamond Products and void all equipment warranties if a problem arises as a result of the modification Refer to the Diamond Products Parts List for additional information and part diagrams Refer to the engine motor manufacturer as the primary source for all safety operations and maintenance instructions reg...

Page 7: ...ng Knobs 3 Belt Guard 4 Vacuum Hose Attachment 5 Spring Box 6 Lift Cage 7 Motor Controller 8 Motor 9 Handlebar Lever 10 Front Pointer 11 Frame Base 12 Front Wheels 13 Front Axle 14 Rear Wheels 15 Blade Shaft 16 Spring Loaded Skid Plate 17 Belt Drive 18 Blade Flange 7 ...

Page 8: ...dlebar 2 Handlebar Locking Knobs 3 Belt Guard 4 Vacuum Hose Attachment 5 Spring Box 6 Lift Cage 7 Engine 8 Handlebar Lever 9 Front Pointer 10 Frame Base 11 Front Wheels 12 Front Axle 13 Rear Wheels 14 Blade Shaft 15 Spring Loaded Skid Plate 16 Belt Drive 17 Blade Flan 8 ...

Page 9: ...Max Handlebars up Electric 38 965 Saw Height Max Handlebars up Gas 40 1016 C Saw Length Min Handlebars down Pointer up 34 864 D Saw Length Max Handlebars up Pointer down 61 1549 E Rear Axle Center Length 10 254 F Frame Width 14 356 G Saw Width 21 533 H Front Axle Center Length 9 229 J Wheel Base Length 8 1 2 216 K Frame Length 16 1 2 419 9 ...

Page 10: ...eter Blade Shaft Bearings 2 self aligning pillow block bearings Blade Shaft Drive 1 V Belt 3VX280 1 V Belt 3VX300 Spring Box Attachment 2 5 16 18 hex head cap screws Blade Raise and Lower Mechanical with spring loaded release Blade Alignment Telescoping front pointer Axle Size Front Rear 3 4 OD straight Front Wheels 2 3 x 3 x 3 4 sealed ball bearings Rear Wheels 3 3 x 3 x 3 4 sealed ball bearings ...

Page 11: ...E6 Gas Engine Specifications Saw Model CC148HXL CC165BVXL CC165LXL Engine Model Honda GX160 Vanguard 13L3 Lifan LF168F2 Rated Output Power 4 8 HP 3600 rpm 6 5 HP 3600 rpm Fuel Type Gas 87 Octane Fuel Tank 82 Gal 3 1 Liters 1 1 Gal 4 1 Liters 1 0 Gal 3 8 Liters Engine Oil SAE 10W 30 Engine Oil Capacity 61 Qt 58 Liters 69 Qt 65 Liters 63 Qt 6 Liters Spark Plug Gap 028 031 in 70 80 mm 030 in 76 mm 02...

Page 12: ...mbers in Appendix D Notice The information in this manual may be updated at any time Safety Alerts DANGER Serious injuries and or death will occur if these instructions are not followed WARNING Serious injuries and or death could occur if these instructions are not followed CAUTION Mild and or moderate injuries could occur if these instructions are not followed Proposition 65 PROPOSITION 65 WARNIN...

Page 13: ...ry movement Drop equipment supplies tools etc when handling to help prevent injuries Lift and carry equipment supplies tools etc that are too heavy and or cannot be lifted easily Operate the equipment without using the appropriate safety equipment required for the work task Operate or service the equipment with any clothing hair or accessories that can snag in the machinery which could lead to ser...

Page 14: ...ox removed Blade exposure should not exceed 180 while cutting DO NOT install or remove the spring box with the engine or motor running Fuel Safety Always use caution when refueling Store all fuel in appropriate safety containers DO NOT operate the saw with a fuel leak DO NOT fuel the saw with the engine running Let the engine cool prior to adding fuel Refer to the engine manual for recommended fue...

Page 15: ...ting the equipment DO NOT allow any person animal and or objects in and around the work area while cutting DO NOT install a blade on the machine until it is in the cutting area Ensure the work area is adequately illuminated to ensure safe operation of the machine Belt Safety Turn off the engine motor and let the belt cool down prior to servicing it Regularly inspect the belt for fraying stress cra...

Page 16: ...ob 2 Adjust the handle bars to the desired height by pulling out or pushing in on the handlebar grips 3 Retighten the handlebar lock knob to secure 4 Adjust the handlebar height as necessary Front Pointer The front pointer helps the operator follow the cutting line Adjusting the Front Pointer 1 Raise the saw 2 Remove the vacuum attachment plate from the spring box by turning the two thumbscrews co...

Page 17: ... brochure for diamond blades or www diamondproducts com for additional blade information Inspecting the Blade Inspect each blade prior to installation and discard all damaged blades Inspect all blades for Cracks nicks and dents A damaged and or deformed arbor center hole Darkness and or discoloration near the edge of the blade A deformed blade circumference Segment loss and or segment cracks Core ...

Page 18: ...r blade flange the blade should fit snug on the blade shaft Always point the arrow printed on the blade in the direction of the blade shaft s rotation 9 Fit the outer flange onto the blade shaft and place it against the blade Inserting the Outer Flange 10 Place the blade shaft nut onto the end of the blade shaft and tighten the nut by hand 11 Press the anti rotation pin down located on the front f...

Page 19: ...d clean repair or replace as necessary 7 Fit the outer flange onto the blade shaft against the inner flange 8 Fit the blade shaft nut onto the blade shaft and tighten the nut by hand to secure the flanges together 9 Replace the vacuum attachment plate and tighten the thumbscrews to secure Raising and Lowering the Saw Blade Raising the Saw 1 Ensure the handlebars are locked at a comfortable height ...

Page 20: ...accordance with Appendix B CAUTION Use of a wire gauge that is too small will cause loss of power or overheating and will damage the electric motor 3 Move the starter switch to the ON position 4 Allow the motor to come up to full operating speed Stopping the Motor CAUTION DO NOT leave the saw unattended until the motor is off and the blade has stopped spinning 1 Ensure the saw is in the raised pos...

Page 21: ...ver to the MAX position Repeat steps 5 6 until the engine starts Stopping the Honda Engine CAUTION DO NOT leave the saw unattended until the engine is off and the blade has stopped spinning NOTE to stop the engine in an emergency turn the engine switch to the OFF position Under normal conditions use the following procedure 1 Move the throttle lever to the MIN position 2 Turn the engine switch to t...

Page 22: ...ave the saw unattended until the engine is off and the blade has stopped spinning NOTE Do not choke the carburetor to stop the engine 1 Move the fuel valve lever to the OFF position 2 When the engine stops running move the choke to the CLOSED position Starting the Lifan Engine Refer to the manufacturer s engine manual as the primary source of information regarding the engine Warning DO NOT leave t...

Page 23: ...to the OFF position 3 Move the fuel valve lever to the OFF position Fueling the saw For the gas powered saws fill the take as needed 1 Lower the saw so that the engine is level 2 Stop the engine and let the saw cool down 3 Remove the fuel tank cap 4 Fill the tank with unleaded gasoline 87 Octane 5 Replace the fuel tank cap and tighten to secure Cutting Cutting Guides Use the front pointer as neede...

Page 24: ...in accordance with the operations called out in this manual and let the blade come up to speed 3 Slowly lower the blade into the cutting surface until the skid plate is securely on the cutting surface to prevent spalling 4 Push the saw forward at a proper speed to continue down the cutting line Cut as fast as the blade allows for maximum efficiency If the blade climbs out of the cut reduce the for...

Page 25: ... area to ensure safety Ensure all equipment and tools required for the maintenance task are staged and available for use Prior to any maintenance being performed know the locations of all safety equipment such as fire extinguishers first aid kits etc All maintenance shall be performed by qualified personnel only General Cleaning The saw must be cleaned after each use and prior to conducting any ma...

Page 26: ...ls cables hinges latches and linkages with a spray lubricant when movement becomes stiff and or sluggish Use one half to one full pump of NLGI No 1 premium lithium based grease when lubricating all grease fittings Post Cleaning Lubricate the machine as required Dry all electrical components using compressed air Do not start the machine until it has had time to thoroughly dry 26 ...

Page 27: ...ate for damages and clean repair or replace as necessary X Check for loose or frayed wiring Repair replace as necessary X Check for loose nuts and bolts and retighten X Check engine oil level X Check fuel level X Check air filter X Lubricate blade shaft bearings End of work day X Inspect all belts for tension or wear and re tension or replace as necessary X1 Clean air filter X2 3 Replace engine oi...

Page 28: ... spring box using the two thumbscrews Lubricate the Blade Shaft Bearings WARNING DO NOT grease parts with the motor running Lubricating the blade shaft bearings on schedule increases the saw s efficiency and life Use NLGI No 1 premium lithium based grease when lubricating parts Use one half to one full pump of grease when lubricating grease fittings At the end of each work day lubricate the two fr...

Page 29: ...vel position and has had time to cool down 1 Remove the dipstick from the lower back side of the engine 2 Wipe the dipstick off with a clean rag 3 Re insert the dipstick back into the filler neck but do not tighten 4 Pull the dipstick out and visually check the oil level 5 If the oil level is low fill with SAE 10W30 oil to the point of almost overflowing from the filler neck 6 Re install the dipst...

Page 30: ...er cap dipstick and tighten to secure Clean the Sediment Cup WARNING Gasoline is highly flammable and explosive serious burns and injuries can occur when handling fuel Stop the engine and keep heat sparks and flames away Handle fuel only outdoors Wipe up spills immediately 1 Move the fuel valve to the OFF position 2 Using a 10mm wrench loosen the sediment cup located below the fuel shut off valve ...

Page 31: ...e 4 mm screw 6 Re install the muffler protector and secure using the four 5 mm screws 7 Re install the exhaust deflector and secure using the two 4 mm screws Vanguard Engine Ensure the engine is off and has had time to cool down 1 Remove the three 4 mm screws from the exhaust deflector and set the deflector aside Exhaust Deflector Vanguard Engine 2 Remove the spark arrester from the muffler Spark ...

Page 32: ...r manual and manufacturer for a full motor maintenance schedule and additional motor maintenance information Disconnecting the Power to the Motor Whenever maintenance is being conducted on the saw disconnect the power to the motor by unplugging the power cord Inner Blade Flange Inner Flange The inner blade flange may be taken off the blade shaft to clean or replace the part Installing the Inner Bl...

Page 33: ...mages or wear and replace as necessary 1 Remove the two bolts and associated washers from both ends of the rear wheel shaft that attach the axle weldment to the frame Rear Wheel Bolts 2 Loosen the set screw in the cable pivot pin Cable Pivot Pin Set Screw 3 Remove the cable nut from the cable end that attaches to the axle weldment Cable Nut 4 Remove the axle weldment from the frame 5 Remove the re...

Page 34: ...is clear of any obstructions and all personnel are at a safe distance prior to lifting the machine 2 Using a properly rated strap place the strap around the frame lift using a basket style hitch 3 Slowly lift the machine only high enough to conduct the required work Transporting Always secure the machine using tie down straps to avoid damage during transport Storing Complete the tasks listed below...

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Page 38: ...ngine lacks power Air filter element restricted Clean or replace air filter element 4 Saw will not lower Handlebar lever out Push lever in to lower saw 5 Saw will not lower completely Blade misaligned Adjust skid plates to align blade 6 Blade does not cut straight Excessive force used when sawing Reduce forward speed DO NOT twist blade from side to side Wrong blade Contact dealer manufacturer of b...

Page 39: ...te for excessive wear burrs twists bends or irregularities and replace as necessary Uneven spring tension Check spring box tension springs and replace as necessary Improper belt tension Check drive belt and idler for proper tension Clean cutting surface Ensure the cutting surface is free of any debris that can cause the skid plate to raise 39 ...

Page 40: ... 1 7 to 1 8 lbf Sonic Tension Meter 133 to 143 N 114 to 124 N Belt Frequency 107 to 111 Hz 99 to 103 Hz Power Cord Specifications CC125BXL EE6 Recommended Power Cord Gauge 1 Phase Horsepower Phase Voltage Amps 50ft Cord 100ft Cord 150ft Cord 2 5 1 115 21 10 8 6 2 5 1 230 11 14 12 10 NOTE Electric saws do not ship with electric cord or pigtails CAUTION Use of a wire gauge that is too small will cau...

Page 41: ...has many helpful concrete cutting publications available to members and non members 3 Association of Equipment Manufacturers www aem org The AEM has a variety of safety and technical manuals available for various types of equipment along with a list of industry standardized safety symbols 4 Occupational Safety Health Administration OSHA www osha gov OSHA provides information on work related safety...

Page 42: ...Numbers Record the saw s serial number below for future reference and customer service purposes Serial Number Record the motor s model and serial numbers below for future reference and customer service purposes Model Number Serial Number 42 ...

Page 43: ...REFERENCES ...

Page 44: ...cts 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...