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680ES OPERATOR MANUAL

change without notice. REV071315 F/N 577451

TABLE OF CONTENTS

SYMBOLS AND LABELS

ICS 680ES NAMES AND TERMS
PRODUCT IDENTIFICATION
INTRODUCTION
SAFETY RULES
UNPACKING AND ASSEMBLY

FUELING

OPERATION

TRANSPORTING & STORING
MAINTENANCE
TROUBLESHOOTING
REFERENCE
EMISSIONS
TECHNICAL SPECIFICATIONS
SERVICE CENTERS
DECLARATION OF CONFORMITY

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Table of Contents

Summary of Contents for 680ES

Page 1: ... F N 577451 680ES OPERATOR MANUAL WARNING READ AND UNDERSTAND ALL SAFETY WARNINGS AND ALL INSTRUCTIONS BEFORE YOU USE THIS EQUIPMENT Failure to follow the warnings and instructions may result in fire serious injury or death SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE Original Document ...

Page 2: ...ual drafted in English and are provided to assist those who do not speak English as their first language Being a technical writing some terms may not have a like or equivalent meaning as translated Therefore you should not rely on this translation and should cross reference the English version where relying on the translated instructions could result in harm to your person or property ...

Page 3: ...CONTENTS SYMBOLS AND LABELS ICS 680ES NAMES AND TERMS PRODUCT IDENTIFICATION INTRODUCTION SAFETY RULES UNPACKING AND ASSEMBLY FUELING OPERATION TRANSPORTING STORING MAINTENANCE TROUBLESHOOTING REFERENCE EMISSIONS TECHNICAL SPECIFICATIONS SERVICE CENTERS DECLARATION OF CONFORMITY 4 7 9 10 11 15 22 25 36 37 45 46 47 49 50 51 Table of Contents ...

Page 4: ...STRUCTIONS The original instruction manual contains important safety and operating information Read and follow the instructions carefully WEAR LONG PANTS Wear long pants when operating the saw WEAR FOOT PROTECTION Wear appropriate closed toe boots when operating the saw WEAR HAND PROTECTION Wear hand protection when operating the saw KERF WIDTH Do not insert tool into slot narrower than chain VENT...

Page 5: ...WARE OF POTENTIAL HAZARDS OR UNSAFE PRACTICES SOUND POWER Sound power level is 117 dB A Symbols Labels DO NOT USE A LADDER Never stand on a ladder when using the saw FIRE DANGER Risk of fire if warnings not followed SLIPPERY SURFACE Unsure footing can lead to accidents ONE HANDED HOLD Do not operate the saw with one hand BEWARE OF KICKBACK Kickback can cause severe injuries TWO HANDED HOLD Operate...

Page 6: ...er within production series WW Week number within the year Y Last Digit of the year the saw was built LABELS SHOWN FOR REFERENCE ONLY ICS Blount Inc 4909 SE Int Way Portland OR 97222 USA IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS U S EPA EXH REGS FOR 2015 MY EMISSIONS COMPLIANCE PERIOD 50 HOURS REFER TO OWNER S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS MADE IN ITALY MANUFACTURED FA...

Page 7: ...ivets on the chain divided by two Chain tensioning screw An adjustment screw used to set proper tension on the chain and compensate for chain stretch from normal use Front handle The support handle located at or toward the front of the saw intended to be gripped by the left hand Guidebar A railed structure that supports and guides the chain Sometimes simply called the bar Kickback The rapid backwa...

Page 8: ...d guard A structural barrier at the bottom right side of the rear handle to protect the operator in case the chain breaks or derails Side cover The component on the powerhead that covers the drive sprocket and directs debris away from the operator during use Side cover nuts The components on the side cover that secure the side cover and guidebar Throttle trigger lock out A device that prevents the...

Page 9: ...ntification PRODUCT IDENTIFICATION Chain tensioning screw Front handle Fuel filler cap Multi function lever Rear handle Starter handle Water shut off valve Air box intake Bar slot Bar stud Chain catcher WallWalker Guidebar Mud flap Powerhead Rear hand guard Nameplate label Side cover Side cover nuts Throttle trigger lock out Throttle trigger ...

Page 10: ...ornia legislation that was intended by its authors to protect California citizens and the State s drinking water sources from chemicals known to cause cancer birth defects or other reproductive harm and to inform citizens about exposures to such chemicals Proposition 65 requires businesses to notify Californians about significant amounts of chemicals in the products they purchase in their homes or...

Page 11: ...XPLANATION OF WARNING LEVELS IMPORTANT Indicates a hazard with a medium level of risk which if not avoided could result in death or serious injury Indicates a hazard with a low level of risk which if not avoided could result in minor or moderate injury Indicates a potential situation exists which if not avoided may result in damage to your saw or property Indicates a hazard with a high level of ri...

Page 12: ... the STOP position and allow the engine to cool a few minutes before fueling Do not smoke or refuel the saw in close proximity to any ignition sources Move the saw at least 3 m 10 ft from the fueling area before restarting it WARNING CAUTION WORK AREA SAFETY Keep children and bystanders away from work area Set up a well marked safety zone with a roped boundary and clear signs to keep bystanders at...

Page 13: ...iratory protection designed to filter out microscopic particles Be sure to use adequate water pressure Over exposure to vibration can lead to circulatory and or nerve damage to the extremities especially in cold temperatures Reynaud s Disease If you experience tingling numbness pain or changes in skin color particularly in your fingers hands or wrists stop using the saw immediately If the problem ...

Page 14: ...wn water and concrete slurry Side cover Mud flap Mud flap bracket Chain Catcher Rear hand guard Throttle trigger interlock Use only Genuine ICS replacement parts Use of unauthorized aftermarket parts may result in injury or damage to the saw DO NOT insert the guidebar into a slot narrower than the width of the chain Rapid pushback kickback and or chain breakage could result DO NOT operate the saw ...

Page 15: ... are the basic instructions for guidebar and diamond chain installation and tensioning Never perform any maintenance or adjustments on the saw while the engine is running Be sure the multi function lever is set to the STOP position before proceeding Improper chain tension can lead to failure of the chain or derailing of the chain off of the guidebar Check tension frequently and adjust if drive lin...

Page 16: ...International Inc Specifications are subject to change without notice REV071315 F N 577451 GUIDEBAR AND DIAMOND CHAIN INSTALLATION TENSIONING Unpacking Assembly STEP 1 Loosen side cover nuts and remove side cover STEP 2 Remove shipping spacer ...

Page 17: ... change without notice REV071315 F N 577451 Unpacking Assembly GUIDEBAR AND DIAMOND CHAIN INSTALLATION TENSIONING STEP 4 Mount the diamond chain on the guidebar starting at the drive sprocket and continue over the guidebar nose STEP 3 Place guidebar onto studs and tensioning adjustment pin ...

Page 18: ...GUIDEBAR AND DIAMOND CHAIN INSTALLATION TENSIONING Unpacking Assembly STEP 5 Install the side cover and nuts Do not fully tighten side cover nuts until chain is properly tensioned STEP 6 Make sure all the drive links are inside the guidebar groove then lift the bar nose and tension the chain by turning the tensioning screw clockwise ...

Page 19: ...ulling the chain around the bar by hand If you cannot easily pull by hand the chain is too tight and needs to be loosened slightly CAUTION Be aware that the guidebar rails may develop sharp edges over time so always pull the diamond chain by the diamond segments STEP 8 Continue to lift up on the nose of the guidebar and firmly tighten the side cover nuts NOTE To prevent chain tensioner breakage be...

Page 20: ...l be used just to overcome friction In severe cases the chain may not turn at all and can lead to chain breakage If the tension is set too loose the chain could be thrown off of the bar or allow the sprocket to turn without turning the chain which will damage the drive links When a chain stretches to a point where the drive links are hanging approximately 12 mm 1 2 in to 18 mm 3 4 in below the gui...

Page 21: ...that the water supply is capable of delivering 1 5 bar 20 psi pressure to the saw at a minimum flow rate of 4 lpm 1gpm NOTE Local and or regional regulation can vary widely It is the responsibility of the operator to wear appropriate dust protection applicable in their area and suitable to the application Never operate saw with insufficient water supply Insufficient water supply will result in exc...

Page 22: ...el combined with ICS 2 stroke oil or other high quality 2 stroke oil specifically formulated for aircooled power equipment at a mixture of 4 25 1 Due to the heavy duty cycle ICS saws are subjected to in concrete cutting applications oil mixture and fuel quality are critical to the performance and life of the engine ALKYLATE FUELS Alkylate fuel i e Aspen 4 is an acceptable alternative to convention...

Page 23: ...l Do not mix more than one month s supply of fuel This helps prevent the separation of the 2 stroke oil from the gasoline varnishing Before fueling clean the area around fuel cap on the saw to prevent dirt from contaminating the fuel Contamination of the fuel tank can lead to saw malfunction Always begin mixing fuel by pouring half the amount of gasoline to be prepared into the mixing container Th...

Page 24: ... Pressure can build up in the fuel tank and container and possibly cause sudden release of fuel vapors when the tank is opened Open the fuel cap slowly and always provide adequate ventilation when handling fuel After adding fuel carefully install the fuel cap and tighten firmly by hand Tip the saw slightly to one side and check for leaks Should any fuel leaks be observed do not start the saw Custo...

Page 25: ... not loose gripping area is clean and undamaged Mud flap is not ripped torn or missing and fully attached to the saw Cylinder cover is properly secured in place Muffler not damaged and is adequately secured to cylinder Guidebar not bent or otherwise damaged such as rails dished and uneven Nose sprocket not excessively worn or broken and turns freely Diamond chain does not have loose rivets chassis...

Page 26: ...saw are functioning properly If any items are excessively worn or damaged replace before use With the multi function lever set to the STOP position without starting saw pull starter rope slowly and inspect for fraying wear and abrasion Assure vibration isolators are intact With engine running and without depressing thottle trigger lockout pull throttle trigger and assure continuous chain movement ...

Page 27: ...ow which may result in engine stall Be sure that no part of the cutting system is contacting a solid object when starting the saw When the multifunction lever is set to the choke and or throttle advance position for starting the chain may move and cause the saw to react if the chain contacts a solid object Move the saw at least 3 m 10 ft from the fueling area before starting it Assure that secure ...

Page 28: ...ndle until you feel the starter pawls engage 5 Pull the starter cord hard fast short pulls until engine initially fires or pops Do not exceed 5 pulls in this step 6 Move the multi function lever to the middle position which releases the choke but keeps the throttle in the advance position 7 Pull the starter cord until the engine starts should be 1 to 2 pulls 8 Release the throttle advance by pulli...

Page 29: ...on a warm engine the carburetor will flood with gas If this occurs see troubleshooting section 2 Open the water valve 1 4 turn 3 Place foot on base of rear handle and place one hand of front handle 4 With opposite hand slowly pull starter handle until you feel the starter pawls engage 5 Pull the starter cord hard fast short pulls until engine starts 6 Allow the engine to idle briefly then pull thr...

Page 30: ...walls and or laying around the workspace Assure that any ancillary electrical equipment fans pumps vacuums etc are properly grounded and certified for use in the intended environment Always wear protective clothing At a minimum always wear eye protection and or face shield hearing protection long sleeve shirt long pants closed toe shoes with non slip soles and gloves In many work situations a hard...

Page 31: ...bove shoulder height IMPORTANT WARNING CAUTION Do not allow workpiece to pinch the guidebar and chain or rapid pushback could result Always cut bottom of opening first and assure workpiece is secure and does not shift during cutting operations Do not operate saw upside down Cutting debris can be directed back towards the operator Always operate saw at full throttle For best results always operate ...

Page 32: ... to the chain selection guide in this manual See page 44 2 Outline the cut with a permanent marker for a visual cutting guide 3 Avoid pinching the guidebar and chain by using shims or other anchoring devices to stabilize the workpiece Always plan to cut the bottom of an opening first then top or sides Save the easiest cut for last see image at right 4 Be sure cut concrete cannot fall and injure th...

Page 33: ...5 F N 577451 Operation CONCRETE MASONRY CUTTING Recommended Concrete Cutting Techniques 2 Cut down to open slot 5 Reengage WallWalker and repeat Steps 3 and 4 3 Insert WallWalker rotate rear handle up 4 Pull saw out rotate rear handle down press bottom of saw to leading edge of cut and rotate rear handle up 1 Plunge in ...

Page 34: ...e create a straighter cut and more quickly enable the use of the WallWalker When cutting heavy rebar slowly rock the saw so that you re always cutting concrete as well as steel This will help keep the diamonds exposed Also expect less chain life when cutting heavy rebar Expect more chain stretch when making nose buried cuts for extended periods of time as the chain does not have a chance to throw ...

Page 35: ...680ES OPERATOR MANUAL 35 2015 ICS Blount International Inc Specifications are subject to change without notice REV071315 F N 577451 This page intentionally left blank ...

Page 36: ...or personal injury Proper handling of the saw will reduce the likelihood of accidental contact with the guidebar and chain CAUTION ICS recommends mixing fuel in small batches to be used within 30 days Fuel stabilizers additives can prolong the life of the fuel but still should not be stored longer than 90 days WARNING Fuel and vapors are highly flammable When transporting or storing fuel always us...

Page 37: ...the saw spray the entire saw body chain guidebar and drive sprocket with lightweight oil Using lightweight oil on the saw will minimize rust and help reduce slurry build up 6 Inspect and tighten all fasteners as necessary 7 Inspect drive sprocket for wear Replace if tooth tips are pointed or if groove cuts through top of tooth 8 Check clutch cup needle bearing for wear Assure clutch cup spins free...

Page 38: ... for wear or damage Replace if damaged FUEL SYSTEM Clean area around fuel cap before removing Check the fuel cap and seal for damage Check the fuel line for damage Check fuel filter assure it is free of debris Replace fuel filter if it is stained dark or clogged fuel filter cannot be cleaned After each use After every 10 hours After every 40 hours External Cleaning Clean Starter Housing Replace Sp...

Page 39: ...lter section SPARK PLUG Clean the spark plug with a wire brush and check to assure the plug gap is 0 5 mm 0 020 in Inspect the spark plug boot replace if needed Inspect lead wire for wear or damage Replace if necessary lead wire cannot be replaced separately from ignition module Replace spark plug after 40 hours of use or if the electrode is corroded or eroded Always use a recommended spark plug r...

Page 40: ...hen the starter cord is pulled all the way out STARTER ROPE REPLACEMENT Loosen the four screws that attach the starter cover assembly to the crankcase and remove the starter cover assembly from the saw Remove starter cord shield screws Pull 10 15 cm 4 6 in of rope out Line rope up with notch on pulley Using your thumb on the pulley as a brake slowly rotate pulley counter clockwise until spring pre...

Page 41: ...he starter cord out then hold the starter recoil housing against the crankcase Slowly release the starter cord to enable the pulley to fit between the pawls Insert and tighten the screws Use blue Loctite 242 CHAIN TENSIONER The chain tensioner can become clogged with concrete slurry during cutting After each use thoroughly flush the chain tensioner with water and apply a liberal amount of waterpro...

Page 42: ...e sprocket bearing by spinning clutch cup Replace the bearing if it is worn out DRIVE SPROCKET ASSEMBLY REMOVAL INSTALLATION Remove the side cover guidebar diamond chain and clutch slurry shield Remove the spark plug and insert the piston stop supplied with each saw into the spark plug hole Pull the starter cord slowly until the piston stops Use a 19 mm wrench to turn the clutch clockwise and remo...

Page 43: ...used to square the rails of a worn guidebar A badly worn guidebar can quickly damage the chain If the chain is touching the bottom of the guidebar groove replace the guidebar Check the guidebar for straightness Proper chain tension will extend guidebar life Under some circumstances especially low water pressure the sprocket nose can wear out before the guidebar body Sprocket nose assemblies may be...

Page 44: ...tural Stone Medium Concrete Light Reinforcement Hard Concrete Heavy Reinforcement Ductile Iron Cast Iron PVC HDPE TwinMAX General Purpose TwinMAX Plus For harder materials TwinMAX Abrasive For brick block 3 8 Pitch Consumables 30 cm 12 in 35 cm 14 in TwinMAX Diamond Chain p n 71400 p n 71486 TwinMAX Plus Diamond Chain p n 71704 p n 71705 TwinMAX Abrasive Diamond Chain p n 71554 p n 71610 3 8 Pitch...

Page 45: ... supply may result in excessive wear to the chain which can lead to stretch and chain breakage CHAIN TENSIONER BREAKAGE Side cover nuts are not tight enough Torque to 27 Nm 20 ft lbs Tensioning with side cover nuts already tight WATER NOT FLOWING Water hose is kinked or water supply not turned on Water ports plugged with debris WON T START Aged or bad fuel Corroded or eroded spark plug Multi funct...

Page 46: ...680ES OPERATOR MANUAL 46 2015 ICS Blount International Inc Specifications are subject to change without notice REV071315 F N 577451 Reference This page intentionally left blank ...

Page 47: ... emission control system on your small non road engine for the period of time listed below provided there has been no abuse neglect or improper maintenance of your unit Your emission control system includes parts such as the carburetor and the ignition system Also included may be hoses connectors and other emission related assemblies Where a warrantable condition exists ICS will repair your saw en...

Page 48: ...improper maintenance unapproved modifications or the use of parts not made or approved by the original equipment manufacturer You are responsible for presenting your saw engine to an ICS authorized servicing dealer as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time typically not to exceed 30 days If you have any questions regarding your warranty rig...

Page 49: ... 136 Starter Dust and water resistant Ignition Special water resistant electronic ignition Clutch Centrifugal three shoe single spring Fuel ratio 4 25 1 gasoline to oil Fuel Capacity 0 88 liter 0 23 gallon Water Supply Requirement Minimum 1 5 bar 20 psi Water Flow Requirement Minimum 4 lpm 1 gpm Guaranteed Sound Power Level Lwa 1 117 dB A Kwa 3 0 dB A Equivalent Sound Pressure at the Operator s Ea...

Page 50: ...L NY 13850 ADMAR SUPPLY 716 873 8000 1394 MILITARY RD BUFFALO NY 14217 CESSCO INC 503 288 1242 4222 N E COLUMBIA BLVD PORTLAND OR 97218 TRI BORO CONST SUPPLIES 800 632 9018 435 LOCUST ST DALLASTOWN PA 17313 LEHIGH CONSTRUCTION SUPPLY CO 570 654 3981 295 SCHOOLEY AVE EXETER PA 18643 DRIVEKORE INC 717 766 7636 101 WESLEY DRIVE MECHANICSBURG PA 17055 ECKHART CONSTRUCTION 803 802 6635 1019 SOCIETY LAN...

Page 51: ...ation and Restriction of Chemicals REACh 1907 2006 Restriction of Hazardous Substances RoHS 2002 95 EC Noise Directive ODN 2000 14 EC according to ANNEX V see technical specifications EN ISO14982 2009 CISPR12 2007 AMD1 2009 CLARIFICATION OF PRODUCT CLASS The ICS 680GC Gas Saw using the appropriate genuine ICS Diamond Chain is designed to ONLY cut concrete or designated materials other than wood Th...

Page 52: ...ount International Inc Specifications are subject to change without notice REV071315 F N 577451 680ES OPERATOR MANUAL ICS BLOUNT INC 4909 SE International Way Portland OR 97222 USA 800 321 1240 icsdiamondtools com ...

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