Related Manuals for Diamond Products CC3538JK Series
Summary of Contents for Diamond Products CC3538JK Series
- Page 1 CORE CUT OPERATOR’S MANUAL CC3538JK (Electronic Fuel Injection) May 2020 Rev.: 20-00 Part #: 1802723...
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Page 3: Table Of Contents
TABLE OF CONTENTS Table of Contents Introduction ............................. 6 CC3538JK Controls ..........................7 CC3538JK Dimensions ........................... 8 CC3538JK Specifications ........................9 Safety ..............................10 Safety Alerts ............................10 Proposition 65 ........................... 10 Respiratory Hazards ......................... 10 General Safety ..........................11 Battery and Electrical Safety ...................... - Page 4 TABLE OF CONTENTS Water Pressure Switch (Optional) ....................22 Water Pump (Optional) ........................22 Cutting Guides ..........................22 Adjusting the Front Pointer ......................22 Adjusting the Rear Pointer(s) ......................22 Concrete Cutting ..........................22 Helpful Hints Prior to Cutting ......................23 Tasks Prior to Cutting ........................
- Page 5 TABLE OF CONTENTS Regular Maintenance ..........................36 Drive Alignment ..........................36 Wheels .............................. 36 Replacing the Front Wheels ......................37 Replacing the Rear Wheels ......................37 Battery ............................... 37 Battery Type ..........................38 Servicing the Battery ........................38 Speed Control Lever ......................... 38 Adjusting the Speed Control Lever Linkage ..................
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Page 6: Introduction
Welcome to the Diamond Products family and thank you for choosing Diamond Products equipment. At Diamond Products we are driven to ensure you are completely satisfied with your product and continually strive to improve our product line so that we can offer you the best possible equipment in the industry. -
Page 7: Cc3538Jk Controls
INTRODUCTION CC3538JK Controls 1. Handlebars – Allows for manual 12. Water Pump Switch (Optional) – Activate maneuvering of the saw. water pump. 2. Handlebar Locking Knobs – Locks the 13. Water Pressure Switch (Optional) – handlebars in place. Indicates low water pressure to the blade. 3. -
Page 8: Cc3538Jk Dimensions
INTRODUCTION CC3538JK Dimensions CC3538JK Dimensions Inches Millimeters Saw Height 1092 Saw Length - Min. 46-3/4 1187 Saw Length - Max. 125-1/2 3188 Handle Extension - Max. Frame Length 39-3/4 1010 Wheel Base Length 18-1/4 Saw Width 30-1/4 Rear Frame Width 23-1/2 Front Wheels Inside Width 20-1/4... -
Page 9: Cc3538Jk Specifications
INTRODUCTION CC3538JK Specifications CC3538JK Specifications Saw Model CC3538JK-14 CC3538JK-20 CC3538JK-26 CC3538JK-30 Blade Guard Capacity 14" (350mm) 20" (500mm) 26" (700mm) 30" (800mm) Blade Cutting Depth Max 4.5" 7.5" 10.5" 12.5" Blade Shaft Speed 3000 rpm 2500 rpm 1900 rpm 1650 rpm Blade Flange Size 5"... -
Page 10: Safety
Safety protection Refer to the Diamond Products Parts List for techniques include, but are not limited to: additional information and part diagrams. Refer to the engine manufacturer as the primary •... -
Page 11: General Safety
SAFETY PRECAUTIONS DO NOT: General Safety Assume the equipment will remain still • • Read and understand all safety, when in STOP or when parking/stopping operations, and maintenance instructions the equipment on a slope. Chock the provided in this manual prior to operating or wheels to help prevent unnecessary servicing the saw. -
Page 12: Battery And Electrical Safety
SAFETY PRECAUTIONS Battery and Electrical Safety • DO NOT expose yourself or anyone else to the direct line of • Ignitable explosive gases are the blade when operating the emitted from the battery. DO equipment. NOT expose the battery to •... -
Page 13: Cutting Safety
SAFETY PRECAUTIONS Hydraulic Safety • Always pivot the front of the blade guard 180° (fully upward) • Turn off the engine prior to servicing so the guard does not swing hydraulic components. down unexpectedly, causing • Lower the equipment completely prior to serious injuries. -
Page 14: Transporting Safety
SAFETY PRECAUTIONS Transporting Safety • Place the equipment in STOP and turn off the engine once the equipment is loaded in • Remove the blade prior to transporting the the truck/trailer. equipment. • Chock the wheels and secure the saw in the •... -
Page 15: Operating
OPERATING Operating General Operating Precautions • Prior to operating the machine, read the operator’s manual thoroughly and ensure that you understand the safe and proper operation of the machine. • Use approved personal protective equipment at all times while operating the machine. -
Page 16: Blade Lowering Speed (Optional)
OPERATING Blade Lowering Speed (Optional) CAUTION Turn the Blade Lowering Speed valve • Clean up any spilled fuel prior to counterclockwise to increase the blade’s starting the engine. lowering speed and clockwise to decrease the • Fuel may seep out from the fuel cap blade’s lowering speed. -
Page 17: Installing The Blade Guard
OPERATING Installing the Blade Guard Installing the Flange Guard Always install the blade guard with the blade 1. Fit the tapered mount on the back of the off the saw. flange guard onto the tapered mount on either the frame base (right side of saw) or 1. -
Page 18: Blade Speed
OPERATING The blade can be installed on the right or left Blade Speed side of the saw. Install the blade on the side Refer to the CC3538JK RPM Chart, the blade, preferred or most appropriate for the cutting or the blade packaging information for the task. -
Page 19: Removing The Blade
OPERATING Note: The outer flange should fit snug with the Note: Failure to fully pivot and secure the front blade, inner flange, and blade shaft. of the guard may cause serious injuries. 8. Slightly rotate the outer flange and blade 3. -
Page 20: Vernier Throttle
OPERATING Vernier Throttle Starting the Engine Note: In an emergency, press the emergency stop button to immediately stop the engine and any saw movement! 1. Open the fuel shutoff valve. Insert the key into the ignition, turn it to START, and release when the engine starts. -
Page 21: Engaging The Transmission
OPERATING 1. Slowly push the lever toward FORWARD to move the saw forward and release when at the desired traveling speed. 2. Slowly pull the lever toward REVERSE to move the saw backward and release when at the desired traveling speed. 3. -
Page 22: Water Pressure Switch (Optional)
OPERATING Increase and decrease the water flow while Adjusting the Front Pointer cutting using the water valve lever on the 1. Remove the lanyard from the cable cleat. valve connected to the water supply hose. 2. Lower the front pointer frame to the ground. 7. -
Page 23: Helpful Hints Prior To Cutting
• Refer to the Diamond Products’ Guide for Professional Concrete Cutters for 7. Raise the blade out of the cut and additional cutting tips and information. -
Page 24: Making A Cut Using The Blade Depth Stop
OPERATING 12. Make another pass across the entire Making a Cut Using the Blade Depth Stop cutting line. 1. Align the blade and cutting guide(s) with 13. Continue the step-cut process using the the cutting line. Blade Depth Stop to reach the maximum 2. -
Page 25: Maintenance
MAINTENANCE Maintenance Rear Cover Screen General The rear cover screen is a versatile component in regards to maintenance of the machine. It Failure to read and comply with the can be removed to gain access to components maintenance instructions provided in this within the upright assembly. -
Page 26: Part Lubrication
MAINTENANCE Part Lubrication Post Cleaning • Lubricate the machine as required. WARNING • Dry all electrical components using DO NOT grease parts with the compressed air. engine running. • Do not start the machine until it has had time to thoroughly dry. Lubricate all necessary parts on schedule for maximum saw efficiency. -
Page 27: Service Schedule
MAINTENANCE Service Schedule The service schedule is based primarily on the standard operating time of the machine. The frequency of the maintenance tasks can be increased based on the working environments of the machine. -
Page 28: Daily Service
MAINTENANCE Daily Service Check Fuel Level Check Engine Oil Level Prior to checking the fuel level, ensure that there is no blade installed on the Prior to checking the engine oil level, ensure saw and that the saw frame is in a that there is no blade installed on the saw and level position. -
Page 29: Adding Fluid To The Hydraulic Lift Pump
MAINTENANCE Inspect all hydraulic hoses and fittings daily for 4. Using a funnel add Dexron 3 automatic leaks. Remember to use cardboard or a piece transmission fluid or equivalent to just of paper when checking for leaks and replace below where the fill port extends into the damaged components immediately. -
Page 30: Tensioning The Drive Belts
MAINTENANCE Inspect all belts daily for fraying, stress cracks, and/or breakage and replace immediately when damaged. Always re-tension new belts after the first four hours of use. DO NOT exceed the manufacturer’s recommended belt tension settings when tensioning belts. Note: Over-tensioning belts may damage the crankshaft. -
Page 31: 100 Hour Service
MAINTENANCE 3. Loosen the blade drive belts by loosening 100 Hour Service the nut on both drive belt tension bolts and Bearing Lubrication turning the tension bolts counterclockwise. 4. Loosen the two jackshaft mount bolts. Lubricate the Jackshaft Bearings There are four jackshaft bearings that need lubrication. -
Page 32: Lubricate The Front Axle Bearings
MAINTENANCE 3. Locate the two transmission jackshaft Lubricate the Front Axle Bearings bearing fittings and add no more than two 1. Raise the saw to the full up position. pumps of grease to each of the bearings grease fittings. Right and Left Front Axle Bearing Grease Fittings 2. -
Page 33: Lubricate The Front Wheels
MAINTENANCE 3. Locate the 7-3/4” linkage that connects the Lubricate the Front Wheels control lever assembly to the rear drive 1. Raise the saw to the full up position. assembly and add no more than one pump 2. Locate the grease fitting on the outside of of grease to each of the two rod ends. -
Page 34: 150 Hour Service
MAINTENANCE 4. Remove the 1/4” pipe plug from the end of 2. Check and clean the inlet screen. the drain hose and allow the oil to drain completely. 5. Remove the oil filter located on the right side of the engine. 6. -
Page 35: Replace The Fuel Filter
MAINTENANCE Replace the Fuel Filter 1. Lower the saw completely. 2. Close the fuel shutoff valve. 3. Place a drain pan under the hoses and in- line filter. 4. Remove the hose clamp from both sides of the filter. Air Filter Assembly 2. -
Page 36: Yearly Service
MAINTENANCE 5. Reinstall the plug wire ensuring that it is Yearly Service fully seated onto the plug. Replace and Gap Spark Plugs 6. Repeat steps 1 through 5 for the second plug. There are two spark plugs associated with the engine. -
Page 37: Replacing The Front Wheels
MAINTENANCE 2. Remove the three screws from the wheel. Replacing the Front Wheels 3. Remove the wheel mount washer and Replace the front wheels when damaged wheel from the rear axle. and/or affecting saw performance. 4. Place a new wheel onto the rear axle. 5. -
Page 38: Battery Type
MAINTENANCE 9. Re-secure the battery to the hold down top brace by reinstalling the lock nuts onto the two tie rod bolts and tighten them to secure. Speed Control Lever Adjusting the Speed Control Lever Linkage Adjust the speed control lever linkage when it is set incorrectly;... -
Page 39: Shaft Tachometer Magnetic Sensor (Optional)
MAINTENANCE 8. Retighten the jam nut down to the frame Shaft Tachometer Magnetic Sensor base to secure. (Optional) 9. Reconnect the tachometer sensor wire The magnetic sensor transfers the blade speed harness. to the blade shaft tachometer if installed. 10. Reconnect the battery. Adjust or replace the magnetic sensor if the 11. -
Page 40: Belt Replacement
MAINTENANCE 1. Loosen the four engine mount screws. Belt Replacement WARNING • Turn the engine off prior to servicing the belts • Use extreme caution when working with belts and rotating machine parts to avoid entanglement. Engine Mount Bolts (Left Side) CAUTION 2. -
Page 41: Replacing The Jackshaft Belts
MAINTENANCE 12. Test the belt tension and readjust the bolt Replacing the Jackshaft Belts as necessary. DO NOT exceed the manufacturer’s tension settings. 13. Tighten the nut on the jackshaft belt tension bolt. 14. Retighten the two jackshaft mount screws. 15. -
Page 42: Changing The Small Jackshaft Sheave (30" Saw), Blade Shaft Sheave, Transmission Sheave, And Engine Sheave
MAINTENANCE 5. Fit the appropriate size bushing and 2. Adjust either or both sheaves for alignment sheave together and slide them onto the and secure in place. jackshaft. Engine Note: Align the bushing with the jackshaft key in place on the shaft prior to installing, or drive WARNING the key into the key hole once the sheave and Let the engine cool down prior to... -
Page 43: Disposal
MAINTENANCE worth repairing or maintaining. Complete the • Refer to the engine manual for all engine tasks listed below when discontinuing usage: recommendations prior to storing. • Store the saw in a dry area, protected from • Remove the battery and bring to a outdoor elements and out of reach from recycling facility;... -
Page 44: Troubleshooting
REFERENCES Appendix A Troubleshooting Troubleshooting Symptom Problem Solution Out of fuel? Fill fuel tank. Emergency stop button down? Pull up emergency stop button. Fuel lines clogged? Unclog or replace fuel lines. Air in fuel lines? Bleed fuel lines. 1. Engine will not start. Worn-out battery? Charge or replace battery. -
Page 45: Cc3538Jk Rpm Chart
REFERENCES Appendix B CC3538JK RPM Chart WARNING: Do not exceed blade speed (RPM) shown for each blade size. Excessive blade speed could result in blade breakage and serious personal injury. CC3538JK Blade Size Conversion Charts WARNING: When changing blade size, use the chart below for selecting the correct items for the different configurations. -
Page 46: Additional Resources
REFERENCES Appendix C Additional Resources 1. Diamond Products ( www.diamondproducts.com • CC3500J Saw Parts List; #1801378 • A Guide for Professional Concrete Cutters • Training Manual – Introduction to Diamond Blades, Bits, and Equipment • Diamond Products’ Equipment Catalog •... - Page 47 REFERENCES...
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Page 50: Model And Serial Numbers
REFERENCES Appendix D Model and Serial Numbers Record the saw’s serial number below for future reference and customer service purposes. Serial Number Record the engine’s model and serial numbers below for future reference and customer service purposes. Model Number Serial Number... - Page 51 REFERENCES...
- Page 52 (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...