Diamond Products CC1600 User manual

DIAMOND

P R O D U C T S

WALL SAW

OPERATOR’S MANUAL

MODEL

CC1600

Part #: 1800745

Table of Contents

Description Page No.

Chapter 1 – Safety ………………………………………………………………………….. 3

Personal Safety………………………………………………………………………. 3

Blade Safety…………………………………………………………………………… 3

General Saw Safety…………………………………………………………………. 4

Cutting/Work Area Safety…………………………………………………………. 4

Chapter 2 – Technical Data………………………………………………………………… 5

Dimensions……………………………………………………………………………. 5

Weight…………………………………………………………………………………… 5

Blade Drive…………………………………………………………………………….. 5

Hydraulic System…………………………………………………………………….. 6

Maximum Cutting Depth…………………………………………………………… 6

Chapter 3 – Wall Saw Set Up Instructions…………………………………………….. 7

Mounting the Track…………………………………………………………………. 7

Mounting the Saw…………………………………………………………………… 7

Mounting a Standard Blade………………………………………………………. 8

Mounting a Flush Cut Blade……………………………………………………… 9

Chapter 4 – Operating the Saw…………………………………………………………… 10

Standard Cutting……………………………………………………………………. 10

Horizontal Bottom Cut……………………………………………………………… 11

Chapter 5 – Troubleshooting……………………………………………………………… 12

Chapter 6 – Maintenance………………………………………………………………….. 14

Daily…………………………………………………………………………………….. 14

Weekly………………………………………………………………………………….. 14

Annually……………………………………………………………………………….. 14

Miscellaneous…………………………………………………………………………. 14

List of Tables

Table 1 – Suggested Blade Speeds………………………………………………………… 6

Table 2 – Maximum Cutting Depth………………………………………………………. 6

Table 3 – Anchor Bolt Distances…………………………………………………………… 7

Table 4 – Capacities and Recommended Specifications……………………………… 15

Chapter 1

SAFETY

Your Diamond Products CC1600 wall saw has been designed to be as safe and efficient

as possible. However, wall sawing can be hazardous if proper safety precautions are not

taken and operating instructions are not followed carefully. Study this manual and

remember all warnings, cautions, and tips. Keep a copy of the manual near the job site

to allow the operator to review any section as needed.

SAFETY WARNINGS

PERSONAL SAFETY

• Read and understand instructions before operating saw.

• Wear proper safety clothing, including hardhat, respirator, gloves, and safety glasses.

Avoid loose fitting clothing.

• Sturdy boots with non-skid soles aid in providing proper footing. Steel-toed safety

boots are recommended.

• Cutting steel reinforcing bar produces sparks, avoid clothing of flammable material.

• Know how to stop the saw quickly in an emergency.

• Noise levels can be very high. Wear OSHA-approved hearing protection at all times

while the saw is operating.

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

• Be sure that the blade guard is the correct type (flush cut or standard), is set to

protect the operator, and is mounted securely on the saw.

• Do not operate the wall saw if you are under the influence of drugs or alcohol.

BLADE SAFETY

• Inspect the blade carefully before use. The blade should have no cracks, nicks, or

flaws. The arbor hole should be undamaged. Use only steel centered wet cutting

diamond blades manufactured for use on wall saws and recommended for your saw.

• Do not use dry cutting diamond blades, high-speed steel blades, carbide tipped

blades, or abrasive blades.

• Only use blades marked with a maximum operating speed higher than the blade shaft

speed.

• Cut only stone, concrete, reinforced concrete, and masonry materials. Do not cut

materials such as wood, glass, or plastic.

• Inspect flanges for damage, excessive wear, and cleanliness before mounting the

blade. The blade should fit snugly on a clean, undamaged shaft.

• Hydraulic power units are designed with the ability to vary the blade speed. Never

operate the saw at a speed higher than the maximum safe allowable speed indicated

on the blade. If you are unsure of the operating speed, contact the manufacturer or

Diamond Products.

• Always keep the blade guard in place, seated firmly on the blade guard support.

• Avoid getting in direct line with the blade.

GENERAL SAW SAFETY

• Never leave the saw unattended while running.

• Do not exceed the rated pressure of hydraulic components. If you are unsure, contact

the manufacturer or Diamond Products.

• Ensure that the track is securely mounted to the wall, with the track stop bolts in

place, before starting the saw. (Track assemblies with stiffener only)

• Verify that the saw is operating properly before cutting. The track rollers must be

adjusted properly and rotating freely. The motor must be connected to the power unit

to rotate the blade in a clockwise direction (facing the saw from the blade). The blade

must be properly mounted in the flanges. The guard must be in place and set to

protect the operator. All saw functions should be checked before mounting the blade.

• Set the blade guard to give maximum protection for the operator. Inspect the blade

guard frequently for damage, cracks, and wear.

• Never operate the saw without sufficient water flow to cool the blade and flush out

cutting debris.

• Always disconnect the power unit before servicing the saw.

• Never try to connect or disconnect the power unit while the power unit is running

and/or the hoses are under pressure.

• Before cutting, be sure that there are no electric, water, or gas lines in the area you

are working. Do not saw if you are unsure of the presence of utility lines in the work

area.

• The cut out section can be very heavy. (For example, a 3’ x 7’ door cut from a 12”

thick wall will weigh over 3000 lb.) Be sure that the slab is properly secured before

making the final cut.

CUTTING/WORK AREA SAFETY

• Never operate the saw in any application or job where you are not properly trained or

supervised.

• Operate only in well-ventilated areas.

• Place barricades or tape to block off the work area on both sides of the wall. Keep

bystanders, animals, and unnecessary equipment out the work area.

• Do not operate the saw near combustible material or fumes. Sparks occur during

sawing that may cause a fire or explosion.

FAILURE TO COMPLY WITH THE PRECEDING WARNINGS COULD

RESULT IN SERIOUS BODILY INJURY.

Chapter 2

TECHNICAL DATA

DIMENSIONS

15.8

18.4 6.4

1.0

3.66.4

17.3

16.8

11.4

WEIGHT

Saw only (1:1 blade drive ratio) 87 lb. (37.2 kg)

Saw + Lamina motor 90 lb. (38.5 kg)

P-T Saw + Cross motor 118 lb. (49.9 kg)

Track (With stiffener), per ft. 10.9 lb. ( 4.9 kg)

Track (Without stiffener), per ft. 4.9 lb. (2.2 kg)

BLADE DRIVE

Std. 3.8 hydraulic motor rated at 2500 psi (172 bar), wt 18 lb. (8.2 kg.)

Opt. 5.2 hydraulic motor rated at 2500 psi (172 bar), wt 19 lb. (8.6 kg.)

Travel: Hydraulic Travel motor rated at 1500 psi (103 bar)

WARNING!

Spinning the blade faster than the manufacturer’s recommended

speed can damage the blade and cause serious personal injury.

Some manufacturers mark the maximum safe RPM on the blade.

TABLE 1

SUGGESTED BLADE SPEEDS

BLADE

DIAMETER

OPTIMUM

RPM

MAX SAFE

RPM

(D-P

BLADES)

GPM

3.80

CU IN

MOTOR

GPM

5.20

CU IN

MOTOR

18” 2100 3400 30

24” 1600 2500 26

30” 1300 2000 21

36” 1100 1700 18 24

42” 900 1400 16 20

48” 800 1200 13 18

54” 700 1100 11 16

HYDRAULIC SYSTEM

Your CC1600 wall saw is designed to operate from a separate hydraulic power unit

providing up to 30 gpm at 2500 psi (up to 129 l/min at 172 bar). See blade speed table

above for flow requirements with a specific blade/motor combination.

MAXIMUM CUTTING DEPTH

The CC1600 saw will cut to within 2 3/4” of the blade center. For example, a 36”

blade has a radius of 18”. The maximum depth of cut is 18” - 2 3/4” = 15 1/4”.

TABLE 2

MAXIMUM CUTTING DEPTH

BLADE DIAMETER MAXIMUM CUTTING DEPTH

18” 6.3”

24” 9.3”

30” 12.3”

36” 15.3”

42” 18.3”

48” 21.3”

54” 24.3”

Chapter 3

WALL SAW SET UP INSTRUCTIONS

MOUNTING THE TRACK

1. Locate the cut line on the wall.

WARNING!

Before cutting or drilling, be sure there are no electric,

gas, or water lines in the area you are working. Cutting a

live wire could cause electrocution, injury or death.

2. Locate a second line from the cut line in accordance with table 3 and place 1/2”

anchors for the track feet on this line.

Table 3

Anchor Bolt Distances

Longyear Style with Non-

Stiffened Track All Other Styles

Anchor Bolt Distance from

Cut Line 8-1/2” 12-1/2”

3. Locate a second line 12-1/2” from the cut line, on the side you will cut from. Place

1/2” anchors for the track feet on this line. For Longyear style feet used with non-

stiffened track, the anchor bolt should be 8-1/2” from the cut.

4. Thru-bolt the mounting foot on brick or concrete block walls. Use a back-up plate

if needed to ensure a secure mounting. Read and follow the safety rules and

mounting procedure provided by the anchor manufacturer.

5. Use leveling screws to correct for unevenness in the walls and provide stability for

the mounting feet. The head of hex head leveling screws should be against the

wall to prevent damage to the screw threads.

6. Mount the track on the wall with the rack on the cut side. Normally, two track feet

will be sufficient on each track section however, with the non-stiffened track, a

third foot may be needed when mounting the 90” or 122” length to reduce flexing

when using large blades or cutting difficult materials. When using stiffened track,

attach the track stop bolt into the stiffener at the top end of the track. (This acts

as a safety stop in case the track slips.)

MOUNTING THE SAW

1. The saw rides the track on ten rollers, six fixed and four moveable. It is guided on

the track by two fixed rollers and two adjustable slides.

2. Before mounting the saw, be sure the moveable rollers are in the “out” position.

3. Place the saw on the track with the pinion on the saw engaging the rack.

4. Push the moveable rollers to the “in” position to lock the saw onto the track.

Check that the saw is secure and tight. If necessary, adjust the rollers or slides as

follows:

To adjust the rollers: loosen the set screw, rotate the roller assembly with a 1-1/2”

wrench until the roller is in contact with the track, then tighten the set screw. If the

rollers are too loose, the saw will not cut smoothly and may jam the blade. If a roller is

adjusted too tight, it will be difficult to pull out when removing the saw.

To adjust the slides: loosen the set screw, turn the adjusting shaft with a 1/2” wrench

until the slide is in contact with the track, then tighten the set screw.

WARNING!

Never try to connect or disconnect the hoses while the

power unit is running and/or the hoses are under

pressure.

5. Connect the hydraulic lines to the blade drive motor and travel motors (if used)

and the water line to the blade guard support.

6. Run the saw along the track and rotate the arm through a complete circle before

mounting the blade to be sure the setup is correct.

7. Check the hydraulic and water lines while doing this to be sure they will not

interfere with travel or be cut by the blade.

8. Before mounting the blade, be sure the blade shaft turns clockwise (looking

toward the saw at the blade). Incorrect blade rotation will cause increased wear,

damage the blade, and may blow out motor seals.

9. Select the correct blade, based on the depth to cut and the stage of cutting. (See

Table 2) Walls over 15” thick will need more than one blade, a starting blade up to

∅36” to start the cut and one or more larger blades to complete the cut.

10. Check blade speed, either with a shaft tachometer or by checking the hydraulic

fluid GPM rate and comparing it to Table 1 on page 6. Do not exceed the rated

blade speed.

11. The CC1600 wall saw can take a blade of ∅36” or less out of the cut. To use a

larger blade, you must first make a cut with a ∅36” or smaller blade.

MOUNTING A STANDARD BLADE

1. Be sure you have the correct diamond wall saw blade. Using a blade not

manufactured for wall saw use could result in serious bodily injury.

2. Inspect the flanges and clean or replace if necessary. Inspect the blade for damage

to the arbor hole before mounting the blade.

3. Place the blade over the arbor on the inner flange. Be sure the blade is mounted

correctly. The “tails” behind the diamonds should point opposite the blade

rotation. Reversing the blade will cause higher blade wear.

4. Place the outer flange over the arbor, making sure the waterways are clear.

5. Tighten the flange nut to lock the blade in place. (NOTE: This is a left-hand nut.)

MOUNTING A FLUSH CUT BLADE

NOTE

Always use a flush cut blade guard when flush cutting and a standard style blade guard

for all other cutting.

1. Remove the standard flange from the blade shaft.

2. Mount the flush cut flange to the blade shaft.

3. Place the blade on the flush cut flange. Be sure the blade is mounted correctly.

The “tails” behind the diamonds should point opposite the blade rotation.

Reversing the blade will cause higher blade wear.

4. Fasten the blade to the flange with six 5/16-18 x 1” flat head socket cap screws.

Chapter 4

OPEARATING THE SAW

NOTE

Ensure the saw is properly set up and ready for operation in accordance with

Chapter 3 of this manual.

CAUTION

To prevent seal damage, do not operate the saw without sufficient water flow. The water

also assists in cooling the blade and carrying away cutting debris.

STANDARD CUTTING

1. Two operating options are available: full manual, and power travel.

• FULL MANUAL – Open the inlet ball valve to start the blade rotation. Using the

15/16” socket and speed handle, turn the blade depth shaft to the desired cutting

depth. Feed the saw along the cut by turning the manual travel shaft with the

15/16” socket and speed handle. The pressure needed to drive the blade will

increase considerably when cutting steel, so resist forcing the saw and stalling the

blade. If the blade jams, back it up to free it. If this does not work, lift the blade

out of the cut until it starts turning again, then lower it back into the cut and

resume cutting.

• POWER TRAVEL USING STANDARD HYDRAULIC ASSEMBLY – Open the inlet

ball valve to start the blade rotation. Blade depth is set manually as above. To

feed the saw along the cut, set the flow control valve to “0”. Shift the directional

valve in the direction you want to travel then, slowly turn the flow control valve-

adjusting knob until the desired speed is attained. Continue to adjust the flow

control knob as necessary to maintain desired speed.

• POWER TRAVEL USING OPTIONAL HYDRAULIC ASSEMBLY – Open the inlet

ball valve to start the blade rotation. Blade depth is set manually as above. To

feed the saw along the cut, turn the adjusting knob counter-clockwise to the full

out position. Shift the directional lever in the direction you want to travel then,

slowly turn the adjusting knob clockwise until the desired speed is attained. If the

saw does not move, manual assistance using the speed handle may be required to

move the blade into the cut and build up enough back pressure to allow for saw

movement. Continue to adjust the control knob as necessary to maintain desired

speed. Feathering the directional lever toward the neutral position can attain some

speed control.

WARNING!

Never stand directly in line with a spinning blade. Severe

injury could result if a segment breaks off or the blade

fractures.

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