ICS 680ES User manual
© 2017 ICS- Blount Inc Specications and pricing are subject to change without notice. P/N 598000 REV072717
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680ES
SERVICE MANUAL
© 2017 ICS- Blount Inc Specications and pricing are subject to change without notice. P/N 598000 REV072717
2
680ES SERVICE MANUAL
SECTION SECTION TITLE PAGE NUMBER
SERVICE MANUAL USE 2
1TOOLS 5
2POWER CUTTER SPECIFICATIONS 6
3SERIAL NUMBER LOCATION 7
4SPARE PARTS DIAGRAM 8
5AIR INTAKE 21
6SPARK PLUG 22
7 CLUTCH & RIM SPROCKET 24
8STARTER SYSTEM 28
9WALLWALKER® 29
10 CYLINDER COVER 35
11 MUFFLER 38
12 CARBURETOR 40
13 CYLINDER & PISTON 42
14 WATER HOSE & CAP 51
15 IGNITION COIL 53
16 FLYWHEEL 55
17 BOTTOM GUARD 57
18 FRONT HANDLE 58
19 FUEL TANK 59
20 CRANKCASE 61
21 BAR STUDS & BAR PAD 68
22 CHAIN TENSIONER 69
23 CARBURETOR TUNING 70
24 IDLE SPEED ADJUSTMENT 73
25 DIAGRAMS 74
26 FUEL SYSTEM LEAKS 76
27 CRANKCASE LEAKS 78
SPARK PLUG REFERENCE GUIDE 79
TABLE OF CONTENTS
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© 2017 ICS- Blount Inc Specications and pricing are subject to change without notice. P/N 598000 REV072717
680ES SERVICE MANUAL
SERVICE MANUAL USE
Service Manual Use
This manual contains all the technical information necessary for carrying
out repairs on the 680ES power cutter For safe, efficient work, it is of prime
importance that the values indicated be adhered to. Routine periodic
maintenance is covered in the operator’s manual included with each power
cutter.
General Shop Rules
• Always use the right tools for the job, otherwise components may be
damaged.
• Use a plastic dead blow mallet to separate parts attached solidly to each
other.
• Mark mating parts as a reassembly reference.
• Keep component parts together as a group. Assemble screws and nuts
into appropriate subgroups.
• When reassembling, clean all parts carefully, lubricate moving parts and
replace all oil seals, o-rings, gaskets, washers and self-locking nuts.
• For best results, use only original ICS®replacement parts.
General Recommendations
• Some procedures in this manual require the use of special tools. A
complete tool kit for the 680ES is available from ICS®.
• Detailed carburetor maintenance and overhaul information is available in
Walbro’s Diaphragm Carburetor Service Manual. Walbro can be contacted
at http://www.walbro.com or by calling 1.520.877.3000.
© 2017 ICS- Blount Inc Specications and pricing are subject to change without notice. P/N 598000 REV072717
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© 2017 ICS- Blount Inc Specications and pricing are subject to change without notice. P/N 598000 REV072717
680ES SERVICE MANUAL
1. TOOLS
Key # Part No. Description
1 71521 Scrench 13-19 mm
2 71541 Pressure Gauge Bulb
3 71542 Coil/Flywheel Timing Shim
4 71543 Cylinder Assembly Clamps & Piston Stop
5 71544 Manifold Assembly Tool
6 71546 Shock Absorber Tool
7 71547 Spark Tester
8 71548 Flywheel Disassembly Tool
9 71565 Electronic Tachometer
10 71569 Induction Seal Flange with Screws
11 71570 Exhaust Seal Flange with Screws
12 71573 Tuning Screwdriver
13 73461 Flywheel Puller
14 73462 Main Bearing Driver Tool
15 571227 2-Stroke Oil, 50:1 Mix, 2.6 oz (77 ml) (6-Pack)
15 571228 2-Stroke Oil, 50:1 Mix, 2.6 oz (77 ml) (24-Pack)
Not Shown 71734 Gasket Set
Not Shown 70249 14T Bar Nose Sprocket Repair Kit
© 2017 ICS- Blount Inc Specications and pricing are subject to change without notice. P/N 598000 REV072717
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680ES SERVICE MANUAL
2. SPECIFICATIONS
Engine Type 2-stroke, Air Cooled
Displacement 76.5 cc (4.7 cu-in)
Horsepower 3.7 kW (5 hp) @ 9,500 rpm
Torque 4.1 Nm (36.3 in-lbs) @ 6,500 rpm
Engine Speed 11500 +/- 500 rpm (max)
2,800 - 3,200 rpm (idle)
Chain Speed at Maximum Power 34.5 m/s (6800 ft/min)
Weight 9.5 kg (21 lbs) powerhead only
Powerhead Dimensions 46 cm (18 in) length 29 cm (11.5 in) height
25 cm (10 in) width
Air Filter Water resistant polyester
Carburetor Walbro WJ-136
Starter Dust and water resistant
Ignition Special water resistant electronic ignition
Clutch Centrifugal, three shoe, single spring
Fuel ratio 2% (50:1) 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 Ear, LpA (1) 101.0 dB(A) (K = 2.0 dB(A))
Vibration, ahv, eq Concrete Cutting (2) 7.2 m/s2(K=1.0 m/s2) Front Handle
8.5 m/s2(K=1.0 m/s2) Rear Handle
Engine Break-in Period One tank, without cutting, cycling throttle
Spark Plug NGK BPMR8Y or Champion RCJ7Y
Electrode gap 0.5 mm (0.020 in)
(1) Measured in accordance with ANSI S12.51-2012/ISO3741:2010
(2) Measured in accordance with ISO5349-1:2001 and ISO22867:2011
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© 2017 ICS- Blount Inc Specications and pricing are subject to change without notice. P/N 598000 REV072717
680ES SERVICE MANUAL
3. SERIAL # LOCATION
3 This section shows the two locations of the serial number.
© 2017 ICS- Blount Inc Specications and pricing are subject to change without notice. P/N 598000 REV072717
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680ES SERVICE MANUAL
4. SPARE PARTS DIAGRAM
Starter Assembly
Key # Part No. Description
A1 73230 Bolt
A2 530208 Starter Rope Handle
A3 73904 Starter Rope
A4 531103 Starter Coil Spring & Housing
A5 71451 Starter Case Plate
A6 505380 Recoil Housing Screw
A7 528661 Starter Rope Pulley
A8 73905 Starter Pulley Washer
A9 73907 Starter Pulley Screw
A10 528637 Starter Cover Assembly
A11 530367 Starter Assembly Washer
A12 532026 Spring Housing Washer
A13 508853 Starter Assembly Cap
A1
A2
A3
A4
A12
A13A8A7
A11
A6
A12
A6
A5
A9
A10
9
© 2017 ICS- Blount Inc Specications and pricing are subject to change without notice. P/N 598000 REV072717
680ES SERVICE MANUAL
Starter Assembly
4. SPARE PARTS DIAGRAM
Key # Part No. Description
B31 531109 Flange, starter pulley 680
B45 528651 Flywheel 680
B48 73891 Nut, M8x1
B51 73911 Washer
B57 73912 Washer
B71 509163 Starter Pawl Assembly
Not Shown 71734 Gasket Set
B48
B31
B57
B51
45
B71
Flywheel and Starter Pawl Assembly
© 2017 ICS- Blount Inc Specications and pricing are subject to change without notice. P/N 598000 REV072717
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680ES SERVICE MANUAL
Key # Part No. Description
C20 576463 Ground Cable, 680ES
C21 73914 Screw m4x20
C22 73285 Wave Washer, 4.5mm
C23 73890 Washer
C24 73241 Spark Plug cap and spring kit
C25 73917 Spark Plug Spring
C26 576437 Ignition Coil 680ES
C21
C26
C25
C24
C23
C22
C20
Ignition Assembly
4. SPARE PARTS DIAGRAM
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© 2017 ICS- Blount Inc Specications and pricing are subject to change without notice. P/N 598000 REV072717
680ES SERVICE MANUAL
Key # Part No. Description
C20 576463 Ground Cable, 680ES
C21 73914 Screw m4x20
C22 73285 Wave Washer, 4.5mm
C23 73890 Washer
C24 73241 Spark Plug cap and spring kit
C25 73917 Spark Plug Spring
C26 576437 Ignition Coil 680ES
Ignition Assembly
Cylinder & Intake Assembly
Key # Part No. Description
D1 505469 Wallwalker® Sidearm Screw
D2 73897 Washer
D3 71735 Intake Manifold
D4 73901 Intake Manifold Flange Screw
D5 73947 Intake Manifold Flange
D6 73888 Carburetor Spring
D7 545877 Carburetor Pulse Tube
D8 577754 Carburetor, Walbro WJ-136 680ES
D9 517547 Screw Guide
D10 576462 Multifunction Actuator for 680ES
D11 73866 Screw
D12 576435 Carburetor Support Bracket for 680ES
D13 73868 Intake Manifold
D14 545870 Intake Manifold Clamp
D15 514770 Spark Plug
D16 73874 Cylinder Bolt & washer
D17 545874 Gasket, Base
D18 548084 Complete Piston/Cylinder Assembly
D19 73869 Wrist Pin Needle Bearing
D20 577630 Screw, 680ES Motor
D21 577629 Washer, 680ES Motor
D22 577631 Detent Spring, 680ES Motor
D1
D17
D10
D8 D9
D14
D11
D15 D16
D5
D19
D18
D22
D21
D6
D4
D3
D2 D7
D20
D13
D12
4. SPARE PARTS DIAGRAM
© 2017 ICS- Blount Inc Specications and pricing are subject to change without notice. P/N 598000 REV072717
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680ES SERVICE MANUAL
Key # Part No. Description
E1 545875 Cylinder to Muer Gasket
E2 545872 Muer Assembly
E3 73327 Washer, serrated
E4 73883 Muer Mounting Screw
E5 73866 Screw, starter cover, lower muer
E1
E2 E3 E4
E5
Muffler Assembly
4. SPARE PARTS DIAGRAM
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© 2017 ICS- Blount Inc Specications and pricing are subject to change without notice. P/N 598000 REV072717
680ES SERVICE MANUAL
Crankshaft Assembly
Key # Part No. Description
E1 545875 Cylinder to Muer Gasket
E2 545872 Muer Assembly
E3 73327 Washer, serrated
E4 73883 Muer Mounting Screw
E5 73866 Screw, starter cover, lower muer
Key # Part No. Description
F1 73877 Crankshaft Seal Flywheel Side
F2 73878 Crankshaft Flywheel Woodru Key
F3 71410 Crankshaft Assembly
F4 73209 Crankshaft Seal Clutch Side
F5 71452 Crankshaft Bushing
F1
F2
F3
F4
F5
4. SPARE PARTS DIAGRAM
© 2017 ICS- Blount Inc Specications and pricing are subject to change without notice. P/N 598000 REV072717
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680ES SERVICE MANUAL
Key # Part No. Description
G1 73931 Sprocket Sealing Ring
G2 73949 Outer Crankcase Seal Body
G3 73940 Pump Body Bolt
G4 73285 Wave Washer, 4.5 mm
G5 73945 Clutch Spacer Washer
G6 70949 680/695 Drive Sprocket
G6 525496 680PG Drive Sprocket
G7 73939 Clutch Needle Bearing
G8 71520 Clutch Cup (includes p/n 73939)
G9 73941 Clutch Spacer Washer, Inside
G10 71419 Clutch Assembly
G11 73943 Clutch Spring
G1
G9
G8
G6
G7
G5
G4
G3
G2
G11
G10
Clutch Assembly
4. SPARE PARTS DIAGRAM
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© 2017 ICS- Blount Inc Specications and pricing are subject to change without notice. P/N 598000 REV072717
680ES SERVICE MANUAL
Key # Part No. Description
H1 73390 Fuel Line Grommet, Crankcase
H2 545967 Crankcase Assembly
H3 73281 Crankcase Dowel Pin
H4 545969 Crankshaft Bearing
H5 545968 Crankcase Gasket
H6 531107 Crankcase Grommet, Right Side
H7 73897 Washer
H8 73930 Crankcase Bolt, m5x22
H9 528657 Chain Guard, 680
H10 73397 Cover Guard Mounting Bolt
H11 73379 Screw
H12 73933 Bar Mounting Stud
H13 71740 Bar Mount Pad Spacer
H14 71738 Bar Mount Pad Cover Plate
H15 73935 Premium Tensioner Kit
H16 73936 Tensioner Screw Retainer
H1
H11
H7
H16
H15
H13 H14H12
H10
H7
H9
H8
H7
H6
H5
H4
H3
H2
H4
Crankcase Assembly
4. SPARE PARTS DIAGRAM
© 2017 ICS- Blount Inc Specications and pricing are subject to change without notice. P/N 598000 REV072717
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680ES SERVICE MANUAL
Key # Part No. Description
I1 528655 Fuel Tank, 680
I2 531105 Rear Handle Half, Black
I3 73976 Rear Handle Screw
I4 530479 Throttle Lever Assembly
I5 530471 Fuel Cap , 680
I6 73448 Fuel Cap O-Ring
I7 73459 Fuel Filter
I8 532028 Trigger Lockout Lever
I9 73988 Trigger Lockout Lever Spring
I10 73897 Washer
I11 73982 Screw
I12 73980 Shock Absorber
I13 71588 Clip, Fuel Filter
I14 73375 Fuel Line
I15 73270 Bumper, Shock Absorber, Fuel Tank Top
I16 73983 Front Handle Bolt
I17 545971 Front Handle
I18 71748 Fuel Breather Complete
I19 71766 Water Deector, Bottom
I20 71751 Breather Tube Body
I21 71759 Breather Tube Elbow
I22 71761 Fuel Breather, Remote
I23 71777 Breather Tube Extension
I24 71760 Tube Clamp
I25 581117 Plug, Fuel Tank and Handle Assembly for 680ES
I26 577628 Throttle Rod Assembly, 680ES Fuel Tank
I5
I22
I26
I2
I3
I6
I4
I9 I8
I12
I12
I25
I15
I1I12
I13
I23
I24
I21I20
I12
I14
I13
I7
I18
I16 I16
I16
I19
I11
I10
Fuel Tank
& Handle
Assembly
4. SPARE PARTS DIAGRAM
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© 2017 ICS- Blount Inc Specications and pricing are subject to change without notice. P/N 598000 REV072717
680ES SERVICE MANUAL
Key # Part No. Description
J1 576438 Cylinder Cover for 680ES (incl J6, J11, J15, J17, J19)
J2 71752 Air Filter Canister, Polyester
J3 530473 Air Filter Cover
J4 73992 Filter Cover Screw
J5 73338 Air Filter Mount
J6 71756 Filter Cover Gasket
J7 71771 Screw, Cylinder Cover, Long, Socket Head
J8 73336 Internal Screen
J9 71758 Air Filter Mount Screw
J10 73337 Filter Support Screw
J11 73335 Filter Canister Gasket
J12 71472 O-Ring
J13 71760 Tube Clamp
J14 505382 Compensator Tube
J15 576459 Screw, Torx T27
J16 577628 Throttle rod assembly for 680ES
J17 576461 Support Bushing, Multifunction lever
J18 73897 Washer
J19 576460 Multifunction lever, 680ES
J4
J3
J7
J18
J6
J19
J17
J15
J2
J16 J14
J13
J12
J9
J8
J1
J11
J10
J5
Air Intake Assembly
4. SPARE PARTS DIAGRAM
© 2017 ICS- Blount Inc Specications and pricing are subject to change without notice. P/N 598000 REV072717
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680ES SERVICE MANUAL
Carburetor Repair Kit
Key # Part No. Description
K1 576680 Mud Flap Replacement Kit, 680
K2 71532 WallWalker® Lever Arm
K3 71531 Guard Flap Clamp
K4 505469 Screw & Washer
K5 71479 WallWalker® Flap Screw
K6 73951 Washer
K8 71469 Water Hose Gasket
K9 545975 Fitting
K10 545976 Clip
K11 71457 Ring Nut
K12 71468 Water Hose O-Ring
K13 71458 Water Shut-O Valve
K14 71454 Barb Fitting, 1/4 male thread
K15 71455 Tube
K16 71465 Hose Clamp
K17 71461 Hose Hanger
K18 71464 Water Hose Cover
K19 71463 Water Hose Screw
K20 71453 Fitting
K21 71456 Copper Washer
K22 73923 Water Tank Cap
K23 73448 Fuel Cap O-Ring
K24 71459 Tube
K25 71470 Fitting
K26 71471 Fitting
K27 71472 O-Ring
K20
K13
K16 K17
K16
K18
K15
K14
K9
K12
K27
K25
K26
K24
K22 K23
K21K19
K8
K10
K11
K3
K6
K2
K4
K4
K1
K5
K20
K13
K16 K17
K16
K18
K15
K14
K9
K12
K27
K25
K26
K24
K22 K23
K21K19
K8
K10
K11
K3
K6
K2
K4
K4
K1
K5
K20
K13
K16 K17
K16
K18
K15
K14
K9
K12
K27
K25
K26
K24
K22 K23
K21K19
K8
K10
K11
K3
K6
K2
K4
K4
K1
K5
4. SPARE PARTS DIAGRAM
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© 2017 ICS- Blount Inc Specications and pricing are subject to change without notice. P/N 598000 REV072717
680ES SERVICE MANUAL
L9
L6
L5
L10
L8
L2
L7
L4
L14
L13
L11
L12
L3
L1
Key # Part No. Description
L1 71743 Side Cover Insert, Top
L2 73958 Side Cover Nut
L3 71462 Chain Cover Cap
L4 73367 Nut
L5 71533 WallWalker Side Arm
L6 73951 Lock Washer
L7 507355 WallWalker Side Arm Screw
L8 71487 Screw
L9 71447 Side Cover Plate
L10 73957 Lower Guard
L11 73972 Deector, Lower
L12 73948 Deector, Upper
L13 73310 Rubber Bumper Cover
L14 528659 Side Cover Assembly, Complete
WallWalker & Water Delivery System
4. SPARE PARTS DIAGRAM
© 2017 ICS- Blount Inc Specications and pricing are subject to change without notice. P/N 598000 REV072717
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680ES SERVICE MANUAL
Key # Part No. Description
M1 577754 Carburetor, Walbro WJ-136
M2 73996 Carburetor Repair Kit
M3 577633 Needle Screw High, 680ES Carburetor
M4 577635 Limiter Cap
M5 577634 Needle Screw Low, 680ES Carburetor
M2
M2
M2
2
M2
M4 M5
M3
M1
CARBURETOR REPAIR KIT
4. SPARE PARTS DIAGRAM
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