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ICS 680GC Operator's Manual
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ICS 680GC Operator's Manual

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680GC
OPERATOR'S MANUAL
1-800-882-4959
F/N 525746 Jan 09
© 2009 ICS, Blount Inc.

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Summary of Contents for ICS 680GC

  • Page 1 680GC OPERATOR’S MANUAL 1-800-882-4959 F/N 525746 Jan 09 © 2009 ICS, Blount Inc.

  • Page 3: Table Of Contents

    680GC OPERATOR’S MANUAL TITLE TABLE OF CONTENTS SYMBOLS & LABELS SAFETY TECHNICAL SPECIFICATIONS SET-UP OPERATION MAINTENANCE TROUBLESHOOTING REFERENCE F/N 525746 Jan 09 © 2009 ICS, Blount Inc.

  • Page 4: Symbols & Labels

    Read the operator’s manual carefully and understand the contents before you use this equipment. Always use: • Protective helmet • Ear protection • Protective glasses or full face protection Wear hand protection © 2009 ICS, Blount Inc. F/N 525746 Jan 09...

  • Page 5: Safety

    DO NOT run a chain-based cut-off saw upside-down. Concrete debris can fly back into the operator’s face. • DO NOT cut ductile iron pipe with a chain-based cut-off saw. Segment loss or diamond chain breakage may occur. F/N 525746 Jan 09 © 2009 ICS, Blount Inc.
  • Page 6 GENERAL SAFETY PRECAUTIONS • Always wear protective clothing, including hard hat, eye protection, hearing protection, and gloves. • Avoid loose fitting clothing. • Perform safety checks before starting each day. • Always operate tool with solid footing and with both hands on cut-off saw. • Remove or control slurry to prevent slippery conditions while cutting. • Be sure there are no obstructions (plumbing, electrical conduit, air ducts) and no unnecessary people present. • Set up a well-marked safety zone with a roped boundary and clear signs. • Provide adequate ventilation when working in an enclosed area. Breathing exhaust gases is dangerous. • To avoid electrocution, check for live electrical wiring near cutting area. © 2009 ICS, Blount Inc. F/N 525746 Jan 09...
  • Page 7 IMPORTANT in product or property damage. Note: The chain-based cut-off saw is equipped with a two-stroke engine and must always be run using a mixture of gasoline and ICS two-stroke engine oil. It is important to accurately ® measure the amount of oil to be mixed to ensure that correct mixture is obtained. When mixing small amounts of fuel, even small inaccuracies can drastically affect the ratio of the mixture.

  • Page 8: Technical Specifications

    11.5 inches (29cm) height 10 inches (25cm) width Air Filter Dry nylon Walbro WJ85B, throttle shaft sealed, Carburetor pressure compensating Starter Dust and water shielded Special water resistant electronic Ignition ignition Clutch Three-weight, single spring Fuel ratio 25:1 gasoline-to-oil 0.23 gal (.88 liter) Fuel Capacity 15-18 minutes run time per tank Water Supply Minimum 20psi (1.5 bar) Noise Level 101dB at 3 ft (1m) Vibration Level 10.5 m/s (front handle) One tank, without cutting, cycling Engine Break-in Period throttle Spark Plug NGK BPMR8Y © 2009 ICS, Blount Inc. F/N 525746 Jan 09...

  • Page 9: Set-Up

    680GC OPERATOR’S MANUAL TITLE SET-UP GUIDE BAR AND DIAMOND CHAIN INSTALLATION STEP 4 Mount the diamond chain on the guide bar STEP 1 starting at the drive sprocket and continue Loosen side cover nuts and remove side over the guide bar nose. cover. Install the diamond chain correctly. If using a single bumper chain, the bumper must always lead the segment into the cut as shown here. STEP 2 Remove shipping spacer. STEP 3 Place bar onto studs and chain adjustment pin. STEP 5 Install the side cover. F/N 525746 Jan 09 © 2009 ICS, Blount Inc.
  • Page 10 STEP 6 All chains have a tendency to stretch Make sure all the drive links are inside when used. Diamond chains stretch more the guide bar groove then lift the bar nose than wood cutting chains because of the and tension the chain by turning the screw abrasive materials they are cutting. When clockwise. a chain stretches to a point where the drive links are hanging approximately 1/2” (12 mm) to 3/4” (18 mm)** below the bar, it’s time to tension the chain. See Note 2. STEP 7 If the chain is too loose, it could come off the bar, or it will allow the drive sprocket to spin without turning the chain, which can chew up the chain drive links. If the chain is too tight, a lot of the saw’s power goes into turning the chain rather than into the STEP 9 Before cutting, check for proper tension by cut. In extreme over-tightened cases, the pulling the chain around the bar by hand. If saw may not be able to turn the chain at you cannot easily pull by hand, the chain is all. In addition, damage can occur to the bar nose and premature stretch may occur. too tight and needs to be loosened a little. See Note 3. See Note 1. © 2009 ICS, Blount Inc. F/N 525746 Jan 09...
  • Page 11 680GC OPERATOR’S MANUAL TITLE SET-UP GUIDE BAR AND DIAMOND CHAIN INSTALLATION STEP 10 Continue to lift up on the nose of the guide bar and firmly tighten the side cover nuts. NOTE: To prevent chain tensioner breakage, be sure the side cover nuts are tightened to approximately 20 ft-lbs (27 Nm). STEP 11 Attach to water source with pressure of not less than 20 psi (1.5 bar). Note 1: Be aware that the guide bar rails may develop sharp edges over time so always pull the diamond chain by the diamond segments. Note 2: Do not “over tension” the diamond chain. Loss of power will result. It is normal for the drivelinks to hang underneath the guide bar. The diamond chain should be tight but be able to be pulled around the guide bar by hand. Note 3: To prevent chain tensioner breakage, be sure the side cover nuts are tightened to approximately 20 ft-lbs (27Nm). F/N 525746 Jan 09 © 2009 ICS, Blount Inc.

  • Page 12: Operation

    • Always provide adequate ventilation when handling fuel. • Use caution when handling gasoline. Avoid direct contact with skin or inhaling fuel vapor. FUEL MIXING • Always mix gasoline and oil in a clean container intended for use with fuel. • Keep fuel container closed tightly to prevent moisture from getting into the fuel. • Always begin mixing fuel by adding half the amount of gasoline to be used. Then add the correct amount of two-stroke oil for 25:1 mixture and finish filling the container with gasoline. • Do not mix more than one month’s supply of fuel. This helps prevent the separation of the two-stroke oil from the gasoline (varnishing). • If the cut-off saw is not used for an extended period of time (3 months) the fuel tank should be emptied and cleaned. FUELING • Always shut off the cut-off saw before fueling. • Before fueling, clean the area around fuel cap to prevent dirt from contaminating the fuel. Contamination of the fuel tank can lead to cut-off saw malfunction. • Thoroughly mix the fuel in it’s container before fueling. • Slowly open the fuel cap to release any pressure that may have built-up in the tank. • After adding fuel, tighten the fuel cap carefully and secure with a wrench. © 2009 ICS, Blount Inc. F/N 525746 Jan 09...
  • Page 13 10. Pull the starter cord (hard, fast, short pulls) until engine fires or "pops" - should be 1 to 7 pulls. 11. Push the choke lever in. 12. Check decompression valve. Press if necessary. 13. Pull the starter cord until engine starts - should be 1 to 2 pulls. 14. When the engine starts, allow the engine to idle. Pull on the Figure 2: Decompression valve throttle trigger several times to help warm up the engine. 15. Open the water valve completely. WARM ENGINE STARTING PROCEDURE 1. Use the same procedure as starting cold engine, but DO NOT pull choke lever out. If choke is used, the carburetor will flood with gas. 2. If the engine does not start in 3 hard, fast pulls with the throttle locked, unlock the throttle and pull the starter cord 3 more times. Note: To hold the trigger fully open it may be necessary to insert right foot into rear handle opening and twist. F/N 525746 Jan 09 © 2009 ICS, Blount Inc.
  • Page 14 • Ensure all safety devices are properly mounted and functional and that all controls are in proper working order. • Be sure there are no obstructions (plumbing, electrical conduit, air ducts) and no unnecessary people present. • Always wear protective clothing, including hard hat, eye protection, hearing protection, non-slip safety boots, and gloves. Avoid wearing loose fitting clothing. • Diamond chains with SealPro require a minimum water pressure of 20 psi (1.5 bar). ® PLANNING THE CUT • Outline the cut with a permanent marker for a visual cutting guide. • Avoid pinching the guide bar and diamond chain. Always cut the bottom of an opening first, then top, and then the sides. Save the easiest cut for last. • For the straightest cuts use the “Step Cut” method. First score the entire cut line approximately a half-inch deep using the nose of the guide bar. Next, deepen the cut by about two inches. Then plunge all the way through and complete the cut using the Wallwalker ® • Be sure cut concrete cannot fall and injure operator or bystanders. Concrete is very heavy, one cubic foot = 12”x12”x12” = 150 lbs. (30cm x 30cm x 30cm = 68kg). • Check for live electrical wiring near the cutting area or in the concrete to avoid electrocution. © 2009 ICS, Blount Inc. F/N 525746 Jan 09...
  • Page 15 680GC OPERATOR’S MANUAL TITLE OPERATION CUTTING WITH THE 680GC CUT-OFF SAW To start a cut, hold trigger on full throttle and slowly plunge the nose of the guide bar straight into the wall. Lengthen the cut and engage the point of the fixed Wallwalker . Use the fixed Wallwalker as a ® ® pivot point and pull up on the rear handle to rotate the guide bar into the cut. CUTTING TIPS • Always operate the chain-based cut-off saw at full throttle. Apply enough feed force so that the free running RPM drops 20 to 30%. If too much force is applied, the cut-off saw will lug or stall. The diamond chain will not have enough speed to cut effectively. If too little feed force is applied, the diamonds will skid and glaze over. • For straighter cuts use the “step cut” method. First score the entire cut line with the nose of the guide bar approximately 1/2 inch (12mm) to 1 inch (25mm) deep. Next, deepen the cut by about 2 inches (50 mm). This groove will help guide the guide bar for a straight cut. Then plunge all the way through and complete the cut using the fixed Wallwalker ® • Plunge cut instead of starting at the top of the wall. This will reduce chatter, extend diamond life, create a straighter cut and more quickly enable the use of the Wallwalker ® • Use the fixed Wallwalker to help cut more efficiently ® and reduce operator fatigue. The fixed Wallwalker ®...
  • Page 16 OPERATION TITLE 680GC OPERATOR’S MANUAL SYSTEM CLEAN-UP • After cutting, run the saw for at least 15 seconds with the water on to flush slurry and debris from diamond chain, guide bar and drive sprocket. • Wash concrete slurry from cut-off saw assembly. • Avoid getting any water in the carburetor or exhaust system. If water enters exhaust port, point the guide bar tip down and pull the starter handle several times to expel water from muffler. • Remove guide bar and diamond chain. Flush out the chain tensioner with high water pressure and lubricate with grease. • After cleaning the cut-off saw, spray the entire saw body, diamond chain, guide bar, and drive sprocket with lightweight oil. Using lightweight oil on the cut-off saw will minimize rust and help reduce slurry build up. © 2009 ICS, Blount Inc. F/N 525746 Jan 09...

  • Page 17: Maintenance

    680GC OPERATOR’S MANUAL TITLE MAINTENANCE Follow these simple maintenance guidelines and the 680GC Cut-Off Saw will keep running at its very best. AFTER EACH USE 1. Rinse the saw, guide bar and diamond chain with water. 2. Follow instructions on the Daily Maintenance Label, located on the air filter cover. 3. Inspect and tighten all fasteners as necessary. 4. Inspect drive sprocket for tooth wear and replace if tooth tips are pointed. 5. Inspect the starter cord. Replace if frayed. 6. Clean air filter. Inspect the air filter for holes. Replace as necessary. 7. Spray saw, guide bar, and chain with lightweight oil. 8. Grease the chain tensioner.
  • Page 18 It is common for concrete slurry to get inside the starter housing IMPORTANT assembly during cutting. This can cause the starter pawls to stick and not engage when the rope is pulled. • After each usage, thoroughly flush the starter housing assembly with water. (Figure 3) • Lubricate the starter pawls by spraying light weight oil into the starter housing through the vents. (Figure 3) • Check the starter cord for fraying, replace if necessary. Figure 3 © 2009 ICS, Blount Inc. F/N 525746 Jan 09...
  • Page 19 TENSIONING THE RECOIL SPRING • Lift the starter cord up into the notch on the starter pulley (Figure 3) and wind the pulley clockwise 5 full turns. Remove the cord from the pulley notch while pinching the pulley. Release the pulley slowly allowing it to wind the rope counterclockwise onto the pulley. • When completed, the starter handle should be pulled back in the starter housing under it’s own tension. • To check that the starter pulley was assembled correctly, pull the cord completely out of the housing, grip the pulley and turn Figure 2 clockwise another 1/2 turn. If the pulley turns another 1/2 turn it is correctly assembled. STARTER HOUSING ASSEMBLY • To reattach the starter housing, first pull the starter cord out, then hold the starter housing against the crankcase (Figure 3). Slowly release the starter cord to enable the pulley to fit between the pawls. • Insert and tighten the screws. Use blue Loctite #242. ® Figure 3 F/N 525746 Jan 09 © 2009 ICS, Blount Inc.
  • Page 20 The needle bearing inside the splined adapter should be greased IMPORTANT regularly and should be replaced with each new clutch cup. A rim sprocket system (Figure 2) consists of a clutch cup Clutch Splined Adapter Sprocket w/ splined adapter and a rim sprocket. When the rim sprocket wears out, it is the only part that needs to be replaced. The clutch cup with splined adapter is a wear item that needs replacement after 3 to 5 rim sprockets have been used. • Inspect the rim sprocket for wear. Replace the rim sprocket if the drive teeth become pointed. • Check the drive sprocket bearing by spinning clutch cup. Replace the bearing if it is worn out. • The needle bearing on the drive shaft must be greased Figure 2 regularly, use high quality water-resistant bearing grease. © 2009 ICS, Blount Inc. F/N 525746 Jan 09...
  • Page 21 DRIVE SPROCKET REMOVAL • Remove the side cover, guide bar, 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. (Figure 1) Use a 19mm wrench to turn the clutch clockwise and remove. • Slide the clutch cup/drive sprocket assembly off the shaft. Remove the needle bearing and inspect for heavy wear or damage. Figure 1 DRIVE SPROCKET INSTALLATION • Slide the rim sprocket onto the splined adapter, either side out. • Apply a liberal amount of grease to the needle bearing. • Place the thin metal washer onto drive shaft. Slide the needle bearing and clutch cup w/rim sprocket onto shaft (Figure 2). • Install the clutch by turning it counter clockwise on the drive shaft and firmly tighten. Replace the clutch slurry shield. Installation of drive sprocket assembly is now complete. Figure 2 F/N 525746 Jan 09 © 2009 ICS, Blount Inc.
  • Page 22 • If cut-off saw has been running satisfactorily and there is a gradual decrease in power and drop in RPM at full throttle, the filter may have become dirty or saturated with water. © 2009 ICS, Blount Inc. F/N 525746 Jan 09...
  • Page 23 680GC OPERATOR’S MANUAL TITLE MAINTENANCE GUIDE BARS • The guide bar is designed to be used on both sides. If the cut is consistently leading to one side, turn the guide bar over to expose a new set of guide rails. • A table mounted belt or disc sander can be used to square the rails of a worn guide bar. A badly worn guide bar can quickly damage an expensive diamond chain. If the diamond chain is touching the bottom of the guide bar groove, replace the guide bar. • Check the guide bar for straightness. Minor adjustments can be made by bending the guide bar slightly. • Proper diamond chain tension will extend guide bar life. See page 9. • Under some circumstances, especially low water pressure, the sprocket nose can wear out before the guide bar body. Sprocket nose replacement kits may be purchased from an Authorized Dealer (part #70249). • Spray the diamond chain and guide bar with lightweight oil for storage. • Store guide bar with the sprocket nose up. • Periodically clean the water ports inside the groove of the guide bar using a small diameter piece of wire. • The guide bar is solely a guide track for the diamond chain. Never use the guide bar to lift, twist or pry concrete material. F/N 525746 Jan 09 © 2009 ICS, Blount Inc.

  • Page 24: Troubleshooting

    • DIFFICULT TO START – Possible flooded engine. Turn ignition switch on, push choke in, hold throttle on full with foot and pull starter cord until engine starts. • DIFFICULT TO START – Possible fouled spark plug. Remove spark plug, clean with wire brush and re-gap. • DIAMOND CHAIN BREAKAGE – Diamond chain installed backwards. Bumpers should lead segments into the cut. • DIAMOND CHAIN BREAKAGE – Not enough feed pressure while cutting. Avoid letting the cut-off saw bounce and chatter. Further questions? Call 1-800-321-1240 or visit our website at icsbestway.com © 2009 ICS, Blount Inc. F/N 525746 Jan 09...

  • Page 25: Reference

    680GC OPERATOR’S MANUAL TITLE REFERENCE APPROXIMATE CUTTING RATES Material Cutting Rate Hard aggregate & Steel 15-25 sq-in/min (90-160 sq-cm/min) Medium aggregates 20-30 sq-in/min (160-190 sq-cm/min) Masonry, Soft aggregates 30-50 sq-in/min (190-320 sq-cm/min) INCH-FOOT DEFINITION An in-ft is a measure of how much material is to be cut. An in-ft is defined as: depth in inches times length in feet. Note: 129 in-ft = 1m Example: How many in-ft are in this doorway? 1. Determine the depth of the cut in inches. For this example, 8 inches. 2. Determine the length of the cut in feet. 3+7+3+7=20 feet 3. Multiply the two numbers 8 in x 20 ft = 160 in-ft F/N 525746 Jan 09 © 2009 ICS, Blount Inc.
  • Page 28 680GC OPERATOR'S MANUAL ICS, Blount Inc. 4909 SE International Way Portland, OR 97222 Tel 800-321-1240 Fax 503-653-4393 icsbestway.com © 2009 ICS, Blount Inc. F/N 525746 Jan 09...