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Related Manuals for Diamond Products CC5049D
Summary of Contents for Diamond Products CC5049D
- Page 1 CORE CUT OPERATOR’S MANUAL CC5049D Rev.: 21-00 Part #: 1802721...
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Page 3: Table Of Contents
TABLE OF CONTENTS Table of Contents Introduction ............................. 7 CC5049D Controls ..........................8 CC5049D Dimensions .......................... 10 CC5049D Specifications ........................11 Safety ..............................12 Safety Alerts ............................12 Proposition 65 ........................... 12 Spark Arrester Requirement ......................12 Respiratory Hazards ......................... 12 General Safety .......................... - Page 4 TABLE OF CONTENTS Bogie Wheel (Optional) ........................28 Bogie Wheel - Locked Sideways Motion ..................28 Bogie Wheel - Free Wheel Motion ....................29 Fuel System ............................29 Adding Fuel ........................... 29 Blade Guard ............................29 Installing the Blade Guard ......................29 Removing the Blade Guard ......................
- Page 5 TABLE OF CONTENTS Air Pre-Cleaner Upgrade (Optional) ....................38 Onboard Blade Storage (Optional) ....................38 Pointer Rope Recoil (Optional) ......................38 Maintenance ............................39 General ............................. 39 Maintenance Tools ..........................39 Pre Maintenance Preparations ......................39 Rear Cover Screen ........................... 39 Removal of Rear Cover Screen .....................
- Page 6 Appendix A ............................61 Troubleshooting ..........................61 Appendix B ............................63 CC5049D RPM Chart ........................63 CC5049D Blade Size Conversion Chart ................... 64 Appendix C ............................65 Additional Resources ........................65 Appendix D ............................66 Model and Serial Numbers ........................ 66...
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Page 7: 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 8: Cc5049D Controls
INTRODUCTION CC5049D Controls... - Page 9 INTRODUCTION 1. Engine Display Panel – Monitors and 13. Tilt Handlebar Button (Optional) – Allows displays various engine and machine adjustment of handlebars up or down to parameters. desired angle. 2. Ignition Switch – Starts the engine and 14. Water On/Off Control Valve - Turns water provides power to certain components.
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Page 10: Cc5049D Dimensions
INTRODUCTION CC5049D Dimensions CC5049D Dimensions Inches Millimeters Saw Height 1321 Saw Length - Min. 57-1/2 1461 Saw Length - Max. 3404 Handle Extension - Max. Frame Length 47-1/2 1207 Wheel Base Length Saw Width Rear Frame Width Front Wheels Inside Width... -
Page 11: Cc5049D Specifications
INTRODUCTION CC5049D Specifications... -
Page 12: Safety
4442, maintained in effective, working order or the engine Refer to the Diamond Products Parts List for is constructed, equipped, and maintained additional information and part diagrams. Refer... -
Page 13: General Safety
SAFETY PRECAUTIONS DO NOT: General Safety Assume the equipment will remain still • • Read and understand all safety, when in neutral 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 14: 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 15: Fuel Safety
SAFETY PRECAUTIONS • • Make sure the equipment is in neutral Always pivot the front of the blade guard 180° (fully upward) when starting the engine. so the guard does not swing • Fill the fuel tank and check the oil level down unexpectedly, causing prior to starting the engine. -
Page 16: Hydraulic Safety
SAFETY PRECAUTIONS • Transporting Safety DO NOT allow any person, animal, and/or objects in and around the work area while • Remove the blade prior to transporting the cutting. equipment. • DO NOT install a blade on the machine • Make sure the truck/trailer is in good, until it is in the cutting area. -
Page 17: Display Panel Controller
DISPLAY PANEL Display Panel Controller The display panel is a rugged Controller Area Network or CAN. This is a means of linking all of the electronic systems within the saw together allowing them to communicate with each other. This section explains the functions of the unit, describes the display screens and gives details about the configuration. - Page 18 DISPLAY PANEL There is a large digital gauge located in the center of the display. This gauge can be toggled through using the function keys to show blade speed, engine speed, and engine torque. Directly above the large center gauge is the dashboard warning icon display area. When certain conditions arise, there are seven icons that will be displayed in this area.
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Page 19: Function Keys
DISPLAY PANEL Function Keys When pressed, the function keys correspond to soft key commands and allow selections to be made accordingly. The soft key selections will appear at the bottom of the display. Soft Key Commands A horizontal row of commands located at the bottom of the display screen can be selected by pressing the function key directly below it. -
Page 20: Main Menu Key
DISPLAY PANEL Soft Key Description Select – Enters the action item highlighted on the screen Left Arrow – Moves cursor to the left Right Arrow – Moves the cursor to the right Up Arrow – Moves the cursor up Down Arrow – Moves the cursor down Plus –... -
Page 21: Engine Diagnostics
DISPLAY PANEL Engine Diagnostics The engine diagnostics screen displays the following items: 1. Recall Active Faults 2. Stored Faults Recall Active Faults This screen displays active faults or warnings from the Electronic Control Unit (ECU). Each diagnostic is shown with the appropriate Suspect Parameter Number (SPN), Failure Mode Indicator (FMI), Text Description (if available) and the source of the device that transmitted the diagnostic message. -
Page 22: User Settings
DISPLAY PANEL Stored Faults This screen displays the non-active faults or warning from the ECU. Each diagnostic is shown with the appropriate Suspect Parameter Number (SPN), Failure Mode Indicator (FMI), Text Description (if available) and the source of the device that transmitted the diagnostic message. User Settings The user setting is a series of two screens that display the following items: 1. -
Page 23: Utilities
DISPLAY PANEL Language This option allows the operator the ability to select the desired language utilized on the display. There are three languages choices: • English • Spanish • French Units This option allows the operator to choose between standard (US) and metric units. Set Clock This option allows the operator to set and update (save setting) the time on the clock display. -
Page 24: Operation
DISPLAY PANEL System Information The system information screen is informational only. The screen displays the following settings: 1. Engine Make 2. Engine Model 3. Engine Serial Number 4. Rated Power 5. Rated Speed 6. Software Revision Operation Blade Size Selection When the ignition switch is turned to ON, the display will begin to boot up. -
Page 25: Zero The Blade
DISPLAY PANEL To select the proper blade size: 1. Scroll through the available blade sizes using the function keys associated with the right and left arrow soft key commands located on the lower right side of the display panel. 2. When the proper size appears on the screen, press the select function key (middle key) to accept the blade size and this will bring up the “Main”... -
Page 26: 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 27: Manually Adjusting The Handlebars
OPERATING NOTE: The button only works with the ignition key at the ON position. 4. To reposition adjustment lever, pull out and move to desired lever position. Speed Control Lever The speed control lever is a part of an electro- hydraulic assembly that allows the operator to raise and lower the machine, move the machine in a forward or reverse direction, or... -
Page 28: Moving The Machine Forward / Reverse With The Engine Running
OPERATING WARNING Do not turn on the free wheel switch or attempt to manually push the machine while it is on a grade or slope. The operator could lose control of the machine causing serious injury to the operator or damage to the machine. -
Page 29: Bogie Wheel - Free Wheel Motion
OPERATING Bogie Wheel - Free Wheel Motion Adding Fuel To unlock the bogie wheel and allow it to move 1. Lower the saw to level the frame. freely: 2. Turn off the engine and let the saw cool down. 1. Fully pull the ring on the detent pin. 3. -
Page 30: Removing The Blade Guard
OPERATING Slurry Shield Flange Guard Frame Base Tapered Mount 2. Insert the lock pin through the hole on the Install the flange guard over the blade flange tapered frame mount to secure the guard. that is not in use. 3. For guards 36” and larger, place a lock Installing the Flange Guard washer and then a flat washer onto the blade guard screw. -
Page 31: Diamond Blades
OPERATING Diamond Blades NOTE: 125 ft-lb is equivalent to applying 125 pounds at the end of a 12” wrench. WARNING DO NOT exceed the blade’s maximum recommended speed when cutting. Excessive blade speeds can cause blade breakage, resulting in serious injuries and/or death. -
Page 32: Removing The Blade
OPERATING prior to pivoting the front of the blade guard 9. Place the wedge lock washer onto the 180° (fully upward). blade shaft bolt and insert the bolt into the blade shaft through the center of the outer flange. 10. Tighten the bolt by hand. Slowly lower the saw, if necessary, until the blade just touches the ground. -
Page 33: Engine
OPERATING NOTE: If the outer flange is difficult to remove, Starting the Engine tighten screws into two of the holes on the Note: In an emergency, press the outer flange to help separate the outer flange emergency stop button to immediately stop from the blade. -
Page 34: Water Supply
OPERATING Water Supply Water Pump (Optional) The optional water pump directs water from the The water supply directs cooling water to the water source hose to the saw blade. fuel cooler and blade and minimizes dust when cutting. 1. Ensure all water supply lines are connected. -
Page 35: Adjusting The Front Pointer
9. Lift the frame off the ground when finished. will make the slurry look thick and pasty. 10. Tension the lanyard and secure it to the • Refer to the Diamond Products’ Guide for cable cleat. Professional Concrete Cutters for additional cutting tips and information. -
Page 36: Making A Cut Using The Blade Depth Stop
OPERATING Lower the blade to just above the cutting If you are cutting more than 2” deep, you surface and zero the blade by pressing the can finish the job in less time and effort by “Zero Blade” button on the display panel. step cutting in 2”... -
Page 37: Drive Alignment
OPERATING Drive Alignment Weight Bar (Optional) Adjusting the Drive Alignment The weight bar (optional) adds 56 lb. to the rear of the saw to improve the rear wheel Adjust the rear axle when the saw’s drive traction when cutting. alignment is off (saw will not cut in a straight line). -
Page 38: Led Light Bar (Optional)
For additional information 2. Tighten the bolts to secure. contact either your local Diamond Products 3. Turn the light bar switch on or off as representative or Customer Service. needed for additional area lighting. -
Page 39: Maintenance
MAINTENANCE Maintenance • Prior to any maintenance being performed, know the locations of all safety equipment General such as fire extinguishers, first aid kits, etc. • Failure to read and comply with the All maintenance shall be performed by maintenance instructions provided in this qualified personnel only. -
Page 40: Radiator
MAINTENANCE Radiator Part Lubrication Ensure that the radiator is cool prior to cleaning. Use compressed air or a power WARNING washer, set at 25° or larger, to clean the DO NOT grease parts with the radiator fins being careful not to damage the engine running. -
Page 41: 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 42: Daily Service
MAINTENANCE Daily Service Check Fuel Level Prior to checking the fuel level, ensure that Check Engine Oil Level there is no blade installed on the saw and that the saw frame is in a level position. Prior to checking the engine oil level, ensure that there is no blade installed on the saw and 1. -
Page 43: Check Hydraulic Fluid Level For Hydro Pump Assembly
MAINTENANCE Inspect all hydraulic hoses and fittings daily for 3. Remove the hydraulic pump breather cap. leaks. Remember to use cardboard or a piece 4. Using a funnel with flexible hose, add of paper when checking for leaks and replace SAE15W-40 oil or an equivalent to just damaged components immediately. -
Page 44: Check And Clean Blade Guard Spray Tubes
MAINTENANCE Check and Clean Blade Guard Spray Check Air Cleaner Restriction Indicator Tubes 1. Check the restriction indicator located on 1. Raise the front of the blade guard and pin it the outlet of the air cleaner. in place using the hinge detent pin if 2. -
Page 45: Lubricate The Pto Bearings
MAINTENANCE Lubricate the PTO Bearings Fuel/Water Separator Filter 1. Swing the cover plate on the belt guard Drain Water from the Fuel Filter away enough to expose the front face of Inspect the fuel filter and drain as necessary. the PTO. The unit is located between the upright and the 2. -
Page 46: Lubricate Front Axle Bearings
MAINTENANCE Lubricate Front Axle Bearings 250 Hour Service 1. Raise the saw to the full up position. Clean the Air Cleaner Element 2. Add no more than two pumps of grease to each of the two front axle bearings grease WARNING fittings located under the frame base on DO NOT operate the saw without the filter... -
Page 47: Replace Engine Oil And Filter
MAINTENANCE 5. Move away from the saw and clean the filter from the inside out. Use dry compressed air to clean the filter (a maximum of 30 psi or 2.1 bar) and rotate it while cleaning. 6. Inspect the inside of the air cleaner housing and the end cover for debris, and wipe them down with a damp cloth as necessary. -
Page 48: 500 Hour Service
MAINTENANCE 11. Replace the cap and tighten to secure. 11. Place a funnel with a flexible hose end into the oil fill tube on the engine. 12. Add oil in accordance with the manufacturer’s specifications and capacities. 13. Replace the engine oil fill cap. 500 Hour Service Replace Hydraulic Oil and Filter 1. -
Page 49: Replace The Fuel Filter
MAINTENANCE 3. Open the drain valve (6) and open vent 8. Install a new O-ring seal (4) and filter screw (1) and drain the filter. Close drain element (3). screw and vent screw when completed. 9. Reinstall the filter bowl (5) to the filter base (2) and hand tighten only. -
Page 50: 1000 Service Hours
MAINTENANCE 2. Disconnect wire harness from the spotlight if installed. 3. Place a drain pan under the radiator drain valve. 4. Slowly remove the radiator cap. CAUTION Remove the radiator cap only when it feels cool to the touch, and always open it slowly to relieve any built up pressure. -
Page 51: 1500 Service Hours
MAINTENANCE 11. Add a 50/50 mix of water and anti-freeze to 3. Unscrew the cap from the main body and lower it down and out from the engine. the “Cold Full” line. 4. Remove the filter element and O-ring seal 12. -
Page 52: Engine
MAINTENANCE Warning Never weld on the machine with the ECM connected to the wire harness. Engine Clamp Bolts Battery 3. On the front of the saw, locate the belt tension assembly located beneath the WARNING radiator. Ignitable explosive gases are emitted from the battery. -
Page 53: Battery Type
MAINTENANCE Battery Type Fuses 12 Volt, Group Size 24 The fuses are located in the power block assembly which can be accessed by removing Servicing the Battery the right hand panel on the display dash assembly. 1. Disconnect the negative cable lead from the negative terminal. -
Page 54: Speed Control Lever
MAINTENANCE Speed Control Lever Adjusting Speed Control Cable The forward and reverse functions of the speed control system are set at the factory. If additional adjustment is needed, there are two locations to accomplish this action. The first is located between the upright assembly and engine on the left side of the saw. -
Page 55: Inner Blade Flange
1. Raise the saw to gain access to the The handlebar lock cylinder must be serviced maximum cutting depth stop bolts by Diamond Products if the handlebars can be moved up or down in excess amounts when underneath the frame base. -
Page 56: Removing The Lock Cylinder
MAINTENANCE Removing the Lock Cylinder 5. Holding the cylinder, remove the upper hairpin cotter and clevis pin from the 1. Open the rear cover screen. handlebar tube. 2. Remove the round 1-5/8” hole plug located on the lower right hand side of the upright assembly. -
Page 57: Transporting
MAINTENANCE • Turn off all switches and controls. • Lower the saw completely to remove strain on the lifting mechanism. • Clean and wipe down the saw to remove dust, debris, and slurry from saw components (especially fans). • Remove the battery and store in a proper location, out of reach from children. - Page 58 REFERENCES...
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- Page 60 REFERENCES...
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Page 61: Troubleshooting
REFERENCES Appendix A Troubleshooting Troubleshooting the CC5049D Symptom Problem Solution Out of Fuel? Fill fuel tank. Fuel lines or fuel filter Unclog or replace fuel lines or fuel clogged? filter. Inspect, clean, and tighten battery Faulty battery connection? 1. Engine will not cables. - Page 62 REFERENCES Loose belts causing Check and adjust belt tension. slippage? Use straightedge to check blade shaft Sheaves misaligned? sheave alignment. Adjust as 8. Short belt life. necessary. Check for groove wear and replace Worn sheave grooves? sheaves when necessary. Replace with matched set of belts. DO Mismatched belts? NOT use old and new belts together.
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Page 63: Cc5049D Rpm Chart
REFERENCES Appendix B CC5049D 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. -
Page 64: Cc5049D Blade Size Conversion Chart
REFERENCES CC5049D Blade Size Conversion Chart WARNING: When changing blade size, use the chart below for selecting the correct items for the different configurations. Model CC5049D 14” 20” 26” 30” 36” 42” Blade Guard 6010950 6010952 6010954 6010956 6010958 6010960... -
Page 65: Additional Resources
REFERENCES Appendix C Additional Resources 1. Cat ( www.cat.com • Operation and Maintenance Manual (C1.7 and C2.2 Industrial Engines) 2. Diamond Products ( www.diamondproducts.com • CC5049 Concrete Saw Parts List • A Guide for Professional Concrete Cutters • Training Manual – Introduction to Diamond Blades, Bits, and Equipment •... -
Page 66: 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 (1) Note: This information can be viewed on the display panel under the “System Information”... - Page 68 (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...