Diamond Products EZ-RIDER CC7800 User manual

DIAMOND
PRODUCTS
CONCRETE SAW
OWNERS MANUAL
MODEL:
CC7800 EZ-RIDER
(September 2007)
PART#: 1801107

2
WARNING
The engine exhaust from this product
Contains chemicals known to the
State of California to cause cancer,
birth defects or other reproductive harm.

3
Table of Contents
Table of Contents ........................................................................................................3
Shipping Papers and Information ................................................................................4
Safety Notes................................................................................................................5
Operating Procedures..................................................................................................6
Controls and Their Functions.......................................................................................7
Controls and Their Functions (continued)....................................................................8
Controls and Their Functions (continued)....................................................................9
Break-in Period and Fluid Capacities.........................................................................10
PTO:.......................................................................................................................10
Engine:...................................................................................................................10
Hydraulics: .............................................................................................................10
Engine Oil: .............................................................................................................10
Fuel:.......................................................................................................................10
Hydraulic Oil:..........................................................................................................10
Blade Mounting Instructions ......................................................................................11
Adjusting Blade RPM.................................................................................................12
Starting the Engine....................................................................................................13
EZ Direction Control Lever/Pump Neutral Adjustment...............................................14
Using the Direction Control Lever ..........................................................................14
Using the Blade Elevation Switch...........................................................................14
Neutral Adjustment.................................................................................................14
Control Lever Switch Installation ...............................................................................15
Switch Replacement and Wire Harness Replacement...........................................15
Control Lever Cable Adjustment................................................................................16
Installation of new speed control cable ..................................................................16
Flow Control Adjustment............................................................................................17
Using the Flow Control...........................................................................................17
EZ Saw Guide Installation and Alignment..................................................................18
EZ Water Hook up.....................................................................................................19
Hooking up Water to Saw ......................................................................................19
Adjust Water Flow to Joint Cleaner and Blade.......................................................19
Using the Blade Safety Switch (optional)...................................................................20
Lubrication and Replacement Filters .........................................................................21
Maintenance..............................................................................................................22
Scheduled Maintenance.........................................................................................22
Inspect and adjust Blade Drive Belts.........................................................................23
Maintenance..............................................................................................................24
Inspect and Adjust Alternator and Hydraulic Pump Drive Belt ...............................24
Bushing Removal and Installation .............................................................................25
Seat Switch Operation...............................................................................................26
Wiring Diagram..........................................................................................................27
Hydraulic Schematic..................................................................................................28

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Shipping Papers and Information
A packet containing IMPORTANT INFORMATION has been enclosed with your saw.
This packet contains:
1. Operation Instructions
2. Parts List
3. Warranty Information
4. Manufacturer's Documents
a. Engine
b. Hydraulic Power Unit
IMPORTANT: This manual contains the basic information required to operate, maintain,
and repair the DIAMOND PRODUCTS saw you have purchased. The use of this
manual insures accurate adjustments, operation, and proper lubrication of your
equipment. Please keep it handy.
Any parts orders or service problems relating to DIAMOND PRODUCTS equipment
should be directed to the DIAMOND PRODUCTS Parts Department at either (440) 323-
4616 or [phone]. When ordering parts, please have the following information
available:
SerialNumber:
Model Number:
Engine Model (H.P.):
Engine Manufacturer: Deutz
Replacement Part Number(s):

5
Safety Notes
PLEASE READ AND UNDERSTAND ENTIRE OPERATORS MANUAL BEFORE
PROCEEDING
WARNING: Protective clothing must be worn. Refer to ANSI Regulations.
1. Wear long pants.
2. Wear heavy leather boots or shoes.
3. Wear a protective face shield.
4. Wear a respirator.
5. Wear ear protection.
6. Never leave a saw unattended while the engine is running.
7. Remove objects from, and never stand in path of blade while
starting or operating the machine.
8. Never run wet cut blades without sufficient water.
9. Do not use excessive force or side pressure during sawing operations.
10.Never stand on any part of machine.
11.Never allow another person to adjust or operate the controls while you are operating
unit.
12.Never transport the saw with the engine running or with the front of the blade guard
in the up position.
13.Allow hydraulic lines to cool before disconnecting hoses or fittings.
14.Be cautious when getting on or off saw due to slippery conditions caused by wet
sawing.
15.Do not touch exhaust or engine parts until cooled down.
WARNING: Never exceed maximum RPM stamped on blade.

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Operating Procedures
Note: This is a systematic guideline. You MUST read the entire manual and understand
the procedures before operating.
Prior to start up: Read the Deutz Engine Manual
Check all fluid levels before starting engine.
1. Route water hose through hose support and connect to water inlet coupling.
2. Turn on water and check for flow through all blade guard tube-ports.
3. Mount blade(s)
4. Align front blade guide with blade.
5. Check to make sure speed control lever is in the neutral (center) position.
6. Be sure blade is unobstructed and not resting on the ground.
7. Turn blade safety switch to the "off" position for starting engine.
8. Start the engine according to the Deutz and DIAMOND PRODUCTS manuals.
9. After the Engine is warmed up, set the engine to the proper RPM for the blade you
are using.
10.Travel to the desired sawing position by positioning the speed control lever in the
direction you wish to travel. The saw will turn in the same direction you turn the
steering when moving forward.
11.Turn the water supply.
12.If equipped, place the blade safety switch in the "on" position.
13.Lower the blade into the cut and adjust the stop to the desired depth.
14.Slowly move the lever forward to begin the sawing.
NOTE: Avoid excessive steering while sawing. Proper blade selection and sawing
speed will determine the required amount of over steer required for proper tracking.
15.At the end of the cut, be sure the blade is completely out of the pavement before
turning off the water and proceeding to the next location.
16.Be aware of the hose location before moving to prevent running over or sawing
through the hose.

7
Controls and Their Functions
1. Switches:
Blade Safety Switch (optional): This switch can be used to override the low water
safety feature. "ON" to activate low water safety, "OFF" for starting and to override
low water safety.
Light Switch: Toggle to turn on front or rear lights, toggle to turn lights off.
2. Key Switch with Indicator Lights:
Key Switch Positions: 0 - OFF
1- RUN
2- START
3. Temperature Gauge: Provides visual indication of engine temperature.
4. Tachometer/Hour Meter: Tachometer indicates engine RPM in a 1 to 1 Ratio
(Engine RPM equals blade RPM). Hour Meter indicates total hours of engine
operation (activates when key switch is in the run position).
5. Fuel Level Gauge: Indicates fuel level and is marked in 1/4 tank increments
6. Indicator Lights: Indicates low oil pressure, high engine temperature, and low water
pressure for blade. In case of an automatic fault shutdown, the light(s) that remain lit
will indicate the problem.
7. Emergency Stop: Provides an means to shutdown saw in an emergency situation.

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Controls and Their Functions (continued)
8. Steering Wheel: When driving saw forward, turn wheel clockwise to turn saw to the
right - turn wheel counter-clockwise to turn saw to the left. Wheel is mounted on
pivoting mount. To adjust angle of wheel, loosen handle bolt, move up/down, then
retighten handle bolt. Be sure handle bolt is tight and steering wheel is secure
before operation.
9. Water On/Off Valve: Used to quickly turn water on or off for both joint cleaner and
blade. Push handle forward to turn water off. Pull handle back to turn water on. To
adjust the flow to the joint cleaner and the blade, use the Independent Flow Control
Valves mounted under the seat.
10.Independent Flow Control Valves: Adjust the desired flow to the blade and to the
joint cleaner independently from completely closed to wide open. Turn valve
clockwise to decrease flow and counter-clockwise to increase flow.
11.Throttle: Pull "T" handle to increase engine speed and rotate to lock.
12.Arm Rest: To adjust armrest up or down, loosen two handle bolts, move to desired
position and tighten handle bolts.
13.Direction Control Lever: move lever forward to drive saw forward, back to drive in
reverse. To go faster, move lever further.

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Controls and Their Functions (continued)
14.Blade Elevation Switch: A thumb controlled switch on the top of the Direction Control
Lever. Move the switch to the right to lower the blade, to the left to raise it. Adjust
the rate of descent with the Flow Control Valve.
15.Flow Control Valve: Located in box under operator's left arm. Turn valve CW to slow
rate of descent, CCW to speed up rate of descent.
16.Depth Stop: The depth stop limits the depth of cut. To set depth stop, lower blade to
desired height, then rotate clockwise until it bottoms out against frame.
17.Footrest Height Adjustment: Back handle out until footrest will slide, move seat to
the predrilled hole closest to the desired height and retighten.

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Break-in Period and Fluid Capacities
PTO:
Lubricate with a high-temperature grease (synthetic recommended) after every 25 hours
of operation.
Engine:
After 50 hours of operation you must change oil, oil filter and fuel filter. Also, check v-
belt tension, valve clearance, engine mounting, and check for oil leaks. Refer to page
3.1 of Deutz engine manual for more details.
Hydraulics:
After approximately one hour of operation, check hydraulic fluid level and check for any
hydraulic leaks.
After 50 hours of operation, change the hydraulic return filter element.
Engine Oil:
Use a CD/SE or CD/SF oil. Refer to the viscosity chart on page 4.1 of the Deutz
manual for proper oil selection. Always check dipstick to verify correct oil volume.
Fuel:
Use fuel meeting ASTM D 975-1:1-D and 2-D specifications. Refer to page 4.2 of the
Deutz manual for details. Fuel tank capacity is 19 gallons.
Hydraulic Oil:
Use a high quality MV32 or ISO 68 hydraulic oil. The hydraulic reservoir capacity is 10
gallons; however, the hoses and components will hold an additional amount. Check
level by removing filler cap. The oil level should be approximately 1/2 to 3/4 the way up
the mesh strainer in the tank.

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Blade Mounting Instructions
NOTE: Before mounting the blade, clean the blade collars and stub shaft.
EZ ARBOR Shaft Blade Mounting Instructions:
1. Remove blade guard - loosen retaining screw on the side of the blade guard and you
will be able to lift the blade guard from the saw.
2. Remove bolt (A). This bolt has right hand threads (to remove turn
counterclockwise).
3. Pull off outside collar (B) and the stub shaft (C), wipe collar and blade. Install a new
blade. If blade pin (D) is removed, it must be reinserted in the outside collar to go
through the blade and the inside collar (E).
WARNING: Observe rotation arrow on blade and do not exceed maximum RPM
stamped on blade. To set proper RPM, consult the table.
4. Reinstall outside collar, stub shaft and secure with bolt. Strike wrench with hammer
to secure tightly.
5. Reinstall blade guard and secure retaining screw.
NOTE: For wider cutting applications Items A and C are available in longer sizes.
WARNING: Max blade capacity for the EZ Rider saw is 20” Diameter.

12
Adjusting Blade RPM
WARNING: When you change the blade size on your saw, it is important to check the
blade for the recommended blade RPM, which is stamped on the blade.
The RPM's should be adjusted according to Table 2 below:
NOTE: This chart is for reference only. Always check the RPM stamped on the
blade and adjust sheave sizes and engine RPM to required settings.
Consult DIAMOND PRODUCTS for assistance if necessary.

13
Starting the Engine
WARNING: Be sure blade is unobstructed and not resting on the ground before
starting engine.
Note: Read the engine instruction manual before starting.
Make sure directional control lever is in neutral.
Pull throttle handle out about halfway and turn to lock in place.
Make sure shutdown lever is in operating position (refer to illustration). When working
properly, the lever is spring loaded to the operating position.
Start engine by rotating the ignition key to the right.
Note: DO NOT crank engine for more than 20 seconds at a time. If engine fails to
start, wait 1 minute before attempting to start the engine again. If engine
does not start after 2 attempts, refer to the diagnosis chart in the engine
manual.
Note: Allow engine to warm up a few minutes before applying load. DO NOT race
or gun the engine to hurry warm-up.
When the engine is warm, pull the throttle out, adjust to proper RPM, and lock in
position by turning the handle to the lock position.
Note: Refer to Engine RPM Table to find proper RPM for specific blade size.
To stop the engine, return engine to idle for 1-2 minutes then rotate the ignition key to
the left or "off" position.

14
EZ Direction Control Lever/Pump Neutral Adjustment
Using the Direction Control Lever
The Direction Control Lever (A) is used to control the
direction and speed of the saw. It is spring loaded to the
neutral position. Moving the lever forward propels the saw
forward 0-350 FPM. Pulling the lever back from neutral
propels the saw in reverse from 0-350 FPM. The further the
control is stroked, the faster the saw will travel.
Using the Blade Elevation Switch
The Blade Elevation Switch (B) is a thumb controlled switch
on the top of the Direction Control Lever. Move the switch to
the right to lower the blade, to the left to raise it. Adjust the
rate of descent with the Flow Control Valve.
Neutral Adjustment
If the unit creeps when lever (A) is in the neutral (center)
position, adjustments must be made. Loosen nuts (C) and
adjust as required.
Warning: Rear drive wheel must be jacked up off the ground
while adjusting.

15
Control Lever Switch Installation
Switch Replacement and Wire Harness Replacement
Remove rubber boot (A)
Remove (6) screws that hold the plastic handle halves (B) together
Lay the unit on a flat surface and remove one of the halves.
Lift out switch (C) and replace with new one making sure it is wired as shown
Replace handle half and tighten. As the two halves are tightened, the switch will be
squeezed and held in place
Replace rubber boot (A)
NOTE! Numbers are printed on the individual wires.
NOTE! Reversing wires 2 and 3 will not harm the system. It will only reverse the two
functions of the switch.
If replacing wire harness, refer to the picture shown below:

16
Control Lever Cable Adjustment
Installation of new speed control cable
1. Slip the o-ring (A) over the cable and push it past the groove in the end cap.
2. Install hex nut (B) and lock washer (C) approximately 1/2" from end on the
cable’s threaded rod.
3. Install clevis (D) and clevis nut (B) on cable. The cable rod end should extend
beyond clevis nut as shown. Tighten the jam nut (B).
4. Slip the clevis (D) over the bell crank, install the clevis pin, and secure with cotter
pin.
5. Remove the "U" Bolt (E) from Housing.
6. Position the "O" ring (A) on the cable end cap so when the cable is brought down
in place, the "O" Ring fits in the groove in the housing.
7. Slip the "U" bolt (E) over the cable and through the housing.
8. Place the spacer (F) over the open end of the "U" bolt, install the lock-washer (G)
and nuts (H). Torque the nuts to 70-100 inch pounds.
9. Slip the cover in place and fasten with the four screws and CSK lock-washer.

17
Flow Control Adjustment
Using the Flow Control
The Flow Control Valve (C) is located in the box under the operator's left arm and is
used to regulate the rate of the blade descent into the cut.
WARNING: Excessive descent rates can damage diamond or abrasive blades and
lead to possible bodily harm.
To adjust the Flow Control Valve:
1. Raise the blade by moving the Blade Elevation Switch to the left.
2. Lower the blade by moving the Blade Elevation Switch to the right and observe
the rate of descent.
3. To increase the rate, turn knurled knob CCW until the desired rate is achieved.
To decrease the rate, turn the knob CW
The valve controls the amount of oil flow in the blade-lowering mode only. It has no
effect on the blade raising speed.

18
EZ Saw Guide Installation and Alignment
WARNING: Engine should be completely shut down before installing guide.
1. Remove saw guide (A) from left side of saw by loosening L-bolt (B) and lifting up
on saw guide.
2. Mount saw guide on frame on the right side of saw. Slide the square tube on the
bottom of the guide into the receiver on the frame and threaded stud on the back
of guide into "U" bracket. Tighten handle nut (C) on stud to hold guide in place.
WARNING: Be sure blade is unobstructed and not resting on the ground before
starting engine.
WARNING: Keep hands and feet clear of blade at all times.
WARNING: Stop engine. Engine should be completely shut down before aligning
indicator.
3. Loosen the handle nut (D) and rotate extension (E) until the pointer is near the
ground. Retighten handle nut (D).
4. Adjust Pointer by loosening handle nut and turning the threaded indicator to
move it left or right. Adjust the pointer so that it is directly in line with the blade.
Note: Make sure all three handle nuts are tight before operating saw.

19
EZ Water Hook up
Hooking up Water to Saw
Prior to starting the engine, you should attach the water hose and visually inspect to
make sure that water is flowing to the blade. Attach your hose to the coupling on the
back of the saw and turn on your water source. Then open the water valve below the
steering wheel.
Note: Water flow volume is metered with the flow control valves below the seat.
WARNING: Make sure that engine is completely shut down before removing blade
guard.
Visually inspect the water tubes to make sure that water is flowing from each of the six
water ports. To do this, the blade guard must be removed. If any of the holes are
blocked you can remove the water tube plugs and flush impurities from the tube.
Reinstall blade guard making sure L-bolt is secure.
Adjust Water Flow to Joint Cleaner and Blade
Note: The Water Valve (near the steering wheel) is an ON/OFF control, not a
metering device. Use the Flow Control Valves for flow adjustments.
The Flow Control Valves are located under the driver’s seat. They will independently
adjust the flow to the joint cleaner and the blade. Turn the flow control valves counter
clock wise to increase water flow – clock wise to decrease water flow.
By presetting the flow control valves, you only need to open the water valve when
approaching a cut. When beginning each cut there no need to adjust flow with the
water valve.

20
Using the Blade Safety Switch (optional)
The blade safety switch is a switch that stops the engine automatically when water
pressure drops below 4 PSI. The safety switch protects the blade should the water
supply become interrupted or inadequate. When water pressure is restored, the switch
is automatically reset.
To start the engine the blade safety switch must be in the "OFF" position, unless there
is adequate water pressure.
Leave in the "OFF" position for dry cutting with abrasive blades. NOTE: When the
water pressure drops, pressure switch (B) activates the Aux. terminal of Controller (C).
There is approximately a 5-second delay before the engine will shut down.