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.

2. All cuts must be made in steps. The first cut should be 2-3” deep. Each following
cut can add up to 6” depth until the wall is cut through or the next size blade is
needed.
• If the cut runs lengthwise through a reinforcing bar, cut completely through it in
one pass to prevent the blade from deviating in the cut and jamming.
• Attempting to cut too deep in one pass will result in a poor quality cut and may
cause the blade to jam.
• When the blade diameter exceeds 36”, you will have to mount the blade on the saw
off the track, or place the blade in the cut then flex it slightly to fit it over the saw
arbor.
3. At the end of the cut, rotate the arm deeper into the cut or take it out of the cut
while the blade is still running. Do not stop the blade in the cut.
4. When the cut is complete, rotate the arm away from the cut and shut off the power
unit and water supply. Remove the blade guard and blade from the saw if
required. Take the saw off the track by pushing the removable rollers to the “out”
position, being careful it does not fall when the last roller is released. Set the saw
in a safe place while you move the track for the next cut.
5. When the final cut is complete, turn off the power unit and water supply, relieve
the pressure in the hoses, and disconnect the hoses from the saw. Wash down the
saw to remove all concrete slurry. Remove the blade guard and blade and store
everything in a secure location.
HORIZONTAL BOTTOM CUT
1. If a horizontal bottom cut is needed, you should make it first and drive in shims to
support the slab while the other cuts are made. This will prevent the slab from
pinching the blade during this cut.
2. As you make additional cuts, add shims or restraining bars to keep the slab in
place.
3. When making the final cut, the track should be mounted on the surrounding wall,
rather than the section to be removed. If this is not possible, shims and retaining
bars must be used to hold the slab in position.
4. When the final cut is complete, turn off the power unit and water supply, relieve
the pressure in the hoses, and disconnect the hoses from the saw. Wash down the
saw to remove all concrete slurry. Remove the blade guard and blade and store
everything in a secure location.

Chapter 5
TROUBLESHOOTING
1. If your saw does not operate properly, the following table may be used as a guide in
diagnosing and eliminating the problem. If you cannot fix it using this table, call our
service representative.
2. Before calling, be sure you can describe the problem clearly so our representative can
help you. Have this manual at hand.
TROUBLE CAUSE REMEDY
Saw does not move or
moves erratically.
Rollers or slides out of
adjustment.
Rack is dirty.
Loose nut on Blade
Depth Control
Assembly
Loose nut on Manual
Travel Assembly
Travel Transfer
Assembly worm gear
mis-aligned.
Adjust rollers and
slides.
Clean rack.
Remove assembly and
tighten nut using
loctite 262
Same as above
Remove assembly,
slide worm gear
against bearing and
tighten setscrew.
Blade drive pressure
fluctuates.
Speed of motor is too
low.
Power unit is defective.
Change to a smaller
motor or increase
GPM.
Check power unit.
Blade does not rotate
when valve is opened.
Blade is jammed in
cut.
Power unit is defective.
Remove blade from cut
and try again.
Check power unit.
Saw motor leaks. Motor seals are
defective.
Replace motor or
motor seal.
Coupling leaks. Coupling is defective. Replace coupling or
coupling seal.

Saw does not move
past track joints.
Tracks are not aligned.
Tracks are warped.
Saw rollers too tight.
Mount tracks
correctly, using jack
screws to correct
alignment.
Readjust rollers until
saw travels past joint
properly.
No water at blade. Water valve is shut.
Water hose not
connected properly.
Low water pressure.
Check water supply.
Check hose
connections.
Check water pressure
(min. 15 psi)
Poor cutting
performance.
Defective saw motor.
Blade is glazed.
Defective power unit.
Replace saw motor.
Dress blade.
Check power unit.
Loss of gear oil or
water present in
pivoting arm
Defective seals in
support blade guard
mount
Replace water seals

Chapter 6
MAINTENANCE
Proper preventative maintenance is essential to ensure a long service life, minimize
downtime for repair and provide for safe, efficient operation. We recommend the
following service schedule.
WARNING!
Disconnect the power unit before servicing the saw.
DAILY
• Check roller and slide alignment and for flat spots on the rollers or other
conditions which might prevent free rotation. Grease rollers at least once a day.
• Check for smooth, free arm and travel motion.
• Check water flow.
• Check for hydraulic fluid leaks at the blade and travel motor connections.
• Check blade guards and flanges for damage. Replace if damaged.
WEEKLY
• Check hydraulic couplings for damage and replace if necessary.
ANNUALLY
• Major service to be carried out by Diamond Products or an authorized service
representative.
MISCELLANEOUS
• Periodically check for low gear oil in the pivoting gearbox assembly and add gear oil
in accordance with table 4 as required.
• Periodically check the lubrication of the main housing gears. If replacement is
necessary, wipe out the old lubricant and fill the gear cavity with new lubricant in
accordance with table 4 as required.

TABLE 4
CAPACITIES AND RECOMMENDED SPECIFICATIONS
Recommended
Specifications Capacities Location of Use
Motor Oil Mobile 10W30 3 oz. Pivoting Gearbox
Assembly
Grease Mobile AW2 28 oz. Main Housing gears
(Do not lubricate the
travel pinion)
Roller Bearings
Thread Locking
Compound
Loctite 262 High
Strength
(
Red
)
Loctite 242 Medium
Strength (Blue)
-
-
Miscellaneous
hardware
(See Parts List
Manual)

333 Prospect Street, Elyria, Ohio 44035
[phone] •[phone] •Fax [phone]
www.diamondproducts.com
Printed in U.S.A.
EQUIPMENT AND PARTS
WARRANTY
Diamond Products warrants all equipment manufactured by it against defects
in workmanship or materials for a period of one (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
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 engines, electric motors, batteries, transmissions,
etc., are excluded from this Warranty and are subject to the prime
manufacturer’s warranty.
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED
OR IMPLIED, AND ALL SUCH OTHER WARRANTIES ARE HEREBY
DISCLAIMED.