Diamond Products CC3500J Manual de usuario

Operator’s Manual

CC3500J Concrete Saw

Part Number: 1802696

(800) 321-5336

www.diamondproducts.com

‘Whatever It Takes’

Table of Contents

Safety Precautions................................................. 1

Safety Alerts................................................................1

Proposition 65.............................................................1

Spark Arrester Requirement.......................................1

Respiratory Hazards...................................................1

General Safety............................................................2

Battery and Electrical Safety.......................................2

Blade Safety................................................................3

Blade Guard Safety.....................................................3

Fuel Safety..................................................................3

Engine Safety..............................................................3

Cutting Safety .............................................................4

Hydraulic Safety..........................................................4

Belt Safety...................................................................4

Transporting Safety.....................................................4

Lifting Safety...............................................................5

Introducing the CC3500J....................................... 7

Components................................................................7

Controls.......................................................................8

Dimensions.................................................................9

Specifications............................................................10

Operating the CC3500J....................................... 11

Spotlight (Optional)...................................................11

Standard Spotlight ........................................................11

Magnetic Spotlight ........................................................11

Handlebars................................................................11

Adjusting the Handlebars..............................................11

Control Grip Pushbuttons .........................................11

Blade Lowering Speed (Optional).............................11

Fuel System..............................................................12

Adding Fuel...................................................................12

Blade Guard..............................................................12

Installing the Blade Guard.............................................12

Removing the Blade Guard...........................................13

Flange Guard............................................................13

Installing the Flange Guard...........................................13

Removing the Flange Guard.........................................13

Diamond Blades........................................................13

Inspecting the Blade .....................................................13

Blade Speed.................................................................13

Wrench .........................................................................13

Installing the Blade........................................................14

Removing the Blade......................................................15

Engine.......................................................................15

Vernier Throttle.............................................................15

Tasks Prior to Starting the Engine ................................16

Starting the Engine .......................................................16

Stopping the Engine......................................................16

Transmission Lever...................................................16

Engaging the Transmission ..........................................16

Disengaging the Transmission......................................16

Speed Control Lever.................................................16

Water Supply ............................................................17

Using the Water Supply................................................17

Cutting Guides..........................................................17

Adjusting the Front Pointer...........................................17

Adjusting the Rear Pointer(s)........................................18

Concrete Cutting.......................................................18

Helpful Hints Prior to Cutting ........................................18

Tasks Prior to Cutting...................................................18

Making a Cut ................................................................18

Making a Cut Using the Blade Depth Stop ...................19

Continuing a Partial-Cut................................................19

Finishing a Cut..............................................................19

Maintaining the CC3500J.....................................21

Maintenance Overview.............................................21

Daily .............................................................................21

40 Hours.......................................................................21

100 Hours.....................................................................21

250 Hours.....................................................................21

Part Lubrication ........................................................21

Inner Blade Flange...................................................21

Installing the Inner Blade Flange..................................21

Removing the Inner Blade Flange................................21

Drive Alignment........................................................21

Wheels......................................................................22

Replacing the Front Wheels .........................................22

Replacing the Rear Wheels..........................................22

Battery ......................................................................23

Battery Type.................................................................23

Servicing the Battery ....................................................23

Speed Control Lever.................................................23

Adjusting the Speed Control Lever Linkage..................23

Adjusting the Speed Control Lever Friction ..................23

Magnetic Sensor (Optional)......................................24

Adjusting the Magnetic Sensor.....................................24

Replacing the Magnetic Sensor....................................24

Electrical System......................................................24

Transmission............................................................24

Cooling Fan..................................................................24

Adding Fluid..................................................................24

Tightening the Rear Drive Chain ..................................24

Hydraulic System......................................................25

Adding Fluid to the Hydraulic Lift Pump........................25

Belt Sheaves ............................................................25

Changing the Belt Sheaves..........................................25

Aligning the Belt Sheaves.............................................26

Belt System ..............................................................26

Tensioning/Replacing the Blade Drive Belts.................26

Tensioning/Replacing the Jackshaft Belts....................27

Replacing the Transmission Drive Belt.........................27

In-Line Fuel Filter......................................................27

Engine ......................................................................28

Cleaning the Engine.....................................................28

Storing ......................................................................28

Disposal....................................................................28

References...........................................................29

Appendix A...............................................................29

Serial Tags ...................................................................29

Appendix B................................................................30

Daily Maintenance Task Chart......................................30

Appendix C ...............................................................31

Belt Tension Settings....................................................31

Appendix D ...............................................................32

Troubleshooting............................................................32

Appendix E................................................................33

Additional Resources....................................................33

CC3500J Concrete Saw Manual 1

Safety Precautions

Operate the CC3500J Concrete Saw and all of its

components according to this manual. Failure to comply

with and understand the following safety, operations,

and maintenance instructions can result in serious

injuries and/or death. All operators must be properly

trained or supervised by experienced personnel prior to

using this saw and should understand the risks and

hazards involved. Diamond Products discourages

improper or unintended saw usage and cannot be held

liable for any resulting damages.

Saw modifications should be made by Diamond

Products to ensure safety and design. Any modifications

made by the owner(s) are not the responsibility of

Diamond Products and void all saw warranties if a

problem arises as a result of the modification.

Refer to the CC3500J Parts List for additional

information and part diagrams. Refer to the engine

manual and manufacturer as the primary source for all

safety, operations, and maintenance instructions

regarding the engine. Prior to operating, record the

saw’s serial number, and the engine’s model and serial

numbers in Appendix A.

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

WARNING

Engine exhaust and some of its

constituents are known to the State of

California to cause cancer, birth defects,

and/or other reproductive harm.

Spark Arrester Requirement

WARNING

In the State of California it is a violation of section

4442 or 4443 to use or operate the engine on any

forest-covered, brush-covered, or grass-covered

land unless the engine is equipped with a spark

arrester, as defined in section 4442, maintained in

effective, working order or the engine is

constructed, equipped, and maintained for the

prevention of fire pursuant to section 4443.

Respiratory Hazards

WARNING

Concrete cutting produces dust and fumes known

to cause illness, death, cancer, respiratory

disease, birth defects, and/or other reproductive

harm. Safety protection techniques include, but are

not limited to:

Wearing gloves.

Wearing safety goggles or a face shield.

Using approved respirators.

Washing work clothes daily.

Using water when wet cutting to minimize

dust.

Washing the hands and face prior to

eating/drinking.

For additional safety and self-protection

information contact your employer, the

Occupational Safety and Health Administration

(OSHA), and/or The National Institute for

Occupational Safety and Health (NIOSH).

General Safety

Read and understand all safety, operations, and

maintenance instructions provided in this manual

prior to operating or servicing the saw.

Keep saw components clean and free of slurry,

concrete dust, and debris.

Inspect water hoses prior to operating the saw.

Clean, repair, or replace damaged components.

Raise the saw to a proper height for access when

working underneath the saw. Use chocks to block

the wheels, and fit blocks or jacks under the frame

edges at the front and back of the frame for

additional support.

When using a jack to raise the saw, place the jack

against a solid, flat area under the frame base to

properly support the saw.

Repair the saw immediately when a problem arises.

Replace saw decals if unreadable.

Dispose of all hazardous waste materials according

to city, state, and federal regulations.

Always have a phone nearby, and locate the nearest

fire extinguisher and first aid kit prior to operating the

saw.

Operate the saw wearing flame resistant clothing.

Always wear safety glasses when removing retaining

rings.

Persons under the statutory age limit should not

operate the saw.

Keep all body parts away from rotating machinery.

Replace all guards and access panels (unless stated

otherwise) prior to operating the saw.

Always pivot guards fully to avoid serious injuries.

DO NOT assume the saw will remain still when in

neutral or when parking/stopping the saw on a

slope. Chock the wheels to help prevent

unnecessary movement.

DO NOT:

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 saw without using the appropriate

safety equipment required for the work task.

Operate or service the saw with any clothing, hair, or

accessories that can snag in the machinery, which

could lead to serious injuries or death!

Operate the saw using attachments not associated

with or recommended for the saw.

DO NOT (cont.):

Operate the saw around combustible materials or

fumes to prevent fires/explosions.

Operate the saw with anyone near the work area or

within the direct line of the blade.

Operate the saw until all unnecessary materials

have been removed from the work area.

Operate the saw with loose nuts, screws, and bolts.

Operate the saw when ill or fatigued.

Operate the saw under the influence of drugs and/or

alcohol.

Operate the saw on steep slopes.

Cut concrete with guards and access panels

removed.

Grease the saw with the engine running (unless

stated otherwise).

Touch hot components when operating the saw.

Leave the saw unattended until the engine is off and

the blade has stopped spinning.

Place the saw into storage until it has cooled down.

Service the saw until it has cooled down.

Service the saw with the engine running (unless

stated otherwise).

Battery and Electrical Safety

Ignitable explosive gases are

emitted from the battery. DO NOT

expose the battery to sparks or open

flames.

Keep the area around the battery well-ventilated.

Keep the battery level when handling it.

Use protective eyewear or a face shield, and avoid

contact with the skin when handling/servicing the

battery.

Use a proper battery tester when testing the battery

strength.

Always be sure to connect the battery cables to the

proper terminal when reconnecting the cables.

Occasionally inspect the battery, cables, clamps,

and terminals for damages. Service components as

necessary.

Always keep the battery cable clamps away from the

battery terminals when the battery is disconnected to

avoid accidental connections while servicing.

Immediately rinse your clothing, skin, or eyes with

water if exposed to battery acid. Seek medical

attention immediately!

Disconnect the battery prior to servicing all saw

components (unless stated otherwise).

Remove the battery when storing the saw for longer

periods.

Always use the correct size fuses (amps) to prevent

fires.

CC3500J Concrete Saw Manual 3

Blade Safety

Always use reinforced abrasive blades or steel-

centered diamond blades.

Never use a wet cutting blade without an adequate

water supply to properly lubricate the blade.

Inspect all blades prior to usage and discard

damaged blades. Clean dirty blades as necessary.

DO NOT install or remove a blade with the engine

running.

Keep all body parts away from rotating blades.

Inspect the blade flanges for damages, wear, and

cleanliness. Clean or replace dirty/damaged

components immediately.

DO NOT expose yourself or anyone

else to the direct line of the blade when

operating the saw.

Always use an appropriate size blade and the

correct blade type based on the cutting task and the

type of material being cut.

The blade must always fit snug on the blade shaft,

outer flange, and/or inner flange.

Wear gloves and be alert to the surrounding

environment when handling blades.

When installing the blade, always point the arrow

printed on the blade in the direction of the blade

shaft’s rotation.

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!

DO NOT use damaged blades when cutting to avoid

harming yourself, others, or the saw.

DO NOT use a blade for cutting that requires a lower

speed than the blade shaft speed.

Always tighten the blade shaft bolt/screw as directed

to properly secure the outer flange and blade.

Failure to properly secure the outer flange and blade

may cause parts to loosen or fall off the saw,

resulting in serious injuries or death!

Let the blade cool prior to removal when dry cutting

(applicable models).

Blade Guard Safety

DO NOT operate the saw with the blade guard

raised or removed.

Blade exposure should not exceed 180° while

cutting.

When pivoting the front of the blade guard,

raise/lower it cautiously and slowly to avoid serious

injuries.

DO NOT pivot the blade guard front up or down

when installing/removing very large blades.

Attempting to pivot the front of a heavy guard when

the guard is positioned higher up for blade

installation/removal makes the guard difficult to lift

and/or lower. In this situation, install/remove the

blade guard front instead of pivoting it.

Always pivot the front of the blade guard

180° (fully upward) so the guard does

not swing down unexpectedly, causing

serious injuries.

Always secure the pivoted section of the blade

guard using the detent pin (guards 26” and up).

Use extreme caution when installing/removing parts

of a guard or the entire guard as guards can be

extremely heavy and may require

installation/removal at moderate heights.

DO NOT install or remove the blade guard with the

engine running.

Always use a blade guard that corresponds with the

blade size.

Inspect the blade guard and water tubes prior to

starting the saw. Clean or replace dirty/damaged

components immediately.

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 fuels.

Always use appropriate fuels in cold weather.

Move the saw away from the refueling area prior to

starting the engine.

DO NOT smoke or expose fuel to open

flames when filling the fuel tank or

working with fuel.

Clean up any spilled fuel prior to starting the engine.

Drain the fuel tank and fuel lines when storing the

saw for longer periods of time. Refer to the engine

manual for additional recommendations.

Engine Safety

Refer to the engine manual as the primary source

for engine safety.

Always know how to turn off the engine quickly for

emergency purposes.

Make sure the saw is in neutral when starting the

engine.

Fill the fuel tank and check the oil level prior to

starting the engine.

Keep all body parts away from

rotating saw parts with the engine

running.

DO NOT start the engine without the air filter(s)

installed.

DO NOT allow dust to enter the air intake tube when

cleaning/replacing air filter(s).

Replace damaged components immediately that

may allow dust to enter the engine.

DO NOT leave the engine running unattended.

Always operate the saw in well-ventilated

areas. Concentrated engine exhaust can

cause loss of consciousness and/or death.

DO NOT touch the engine/muffler assembly with the

engine running, and always let them cool down prior

to touching or servicing the saw.

Handle hot oil carefully when changing the oil.

Let the engine cool prior to removing pressurized

caps (applicable models).

DO NOT use any starter substances or starter fluids

(e.g., starter fluid sprayed into the air filter) when

starting the engine using a glow plug (applicable

models). These materials are extremely flammable

and explosive, and can melt parts or possibly

explode when used to help start the engine.

Cutting Safety

The direct work area should not contain buried or

embedded electrical, gas, or water lines that could

be damaged and/or cause personal injury while

cutting.

Turn off all electricity, gas, and water around the

direct work area prior to cutting.

DO NOT expose yourself or anyone else to the

direct line of the blade when operating the saw.

DO NOT allow any person, animal, and/or object in

and around the work area while cutting.

Hydraulic Safety

Turn off the engine prior to servicing hydraulic

components.

Lower the saw completely prior to servicing to

decrease the hydraulic pressure in the lines.

Always make sure any hydraulic components being

serviced are not supporting the weight of other saw

components. If a particular component is under

pressure when connection points are loosened, oil

may spray out forcefully.

Always place a piece of cardboard or

paper up against hydraulic components,

or use a leak detection fluid to check for

hydraulic fluid leaks. Keep all body

parts away from leaks and/or areas that may eject

hydraulic fluid. Pressurized hydraulic fluid can

penetrate the skin, causing serious injuries. Seek

medical attention immediately!

Belt Safety

Turn off the engine and let the belts cool down prior

to servicing them.

Regularly inspect the belts for fraying, stress cracks,

and/or breakage and replace immediately when

damaged. Always check the belt alignment prior to

operating the saw.

Use extreme caution when working with belts and

rotating machine parts to avoid entanglement.

Over-tensioning belts may damage the crankshaft.

Under-tensioning belts may cause slippage, shorter

belt life, and/or poor saw performance.

Squealing belts indicate looseness.

DO NOT use old and new belts together on the

same sheave.

Transporting Safety

Remove the blade prior to transporting the saw.

Make sure the truck/trailer is in good, working

condition and sufficient to transport the load. DO

NOT tow the saw behind a vehicle.

Close the fuel shutoff valve (applicable models)

when transporting.

Drain the fuel tank when transporting long distances.

Use heavy-duty ramps that will support the weight of

the saw and yourself when loading or unloading.

Raise the saw to avoid damaging components while

moving up and down ramps.

Use extreme caution when guiding the

saw up and down ramps. Slowly drive

the saw forward down the ramp.

Slowly back the saw in reverse up the

ramp. Avoid standing directly downhill from the saw

to prevent machine rollover.

Place the saw in neutral and turn off the engine once

the saw is loaded in the truck/trailer.

Chock the wheels and secure the saw in the

truck/trailer prior to transporting.

Refer to the Department of Transportation (DOT) for

additional transportation recommendations.

CC3500J Concrete Saw Manual 5

Lifting Safety

Move yourself and all others away from

the lifting area when hoisting the saw to

prevent being crushed.

Secure the appropriate hoisting cables, straps,

and/or chains to the saw’s designated lift points prior

to hoisting.

Never use the tie-down brackets (applicable models)

to lift the saw.

DO NOT attempt to lift the saw irresponsibly and/or

improperly.

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