Ics 680gc User manual

680GC

OPERATOR’S MANUAL

Serial numbers starting with 977

TITLE680GC OPERATOR’S MANUAL

TABLE OF CONTENTS

SYMBOLS & LABELS 4

SAFETY 5

TECHNICAL SPECIFICATIONS 8

SET-UP 9

OPERATION 12

MAINTENANCE 17

TROUBLESHOOTING 24

REFERENCE 25

INTRODUCTION

This manual outlines the maintenance and operation of ICS® manufactured products.

This is a professional tool and is soley intended for use by trained and experienced operators.

To get the maximum benefit from your saw, and ensure maximum safety, be sure to read this manual

thoroughly, and periodically review safety instructions.

TITLE 680GC OPERATOR’S MANUAL

SYMBOLS & LABELS

THE FOLLOWING SYMBOLS & DEFINITIONS ARE FOUND THROUGHOUT THIS MANUAL AND

ARE DESIGNED TO MAKE YOU AWARE OF POTENTIAL HAZARDS OR UNSAFE PRACTICES.

A potentially hazardous situation exists which, if not avoided,

could result in death or serious injury.

A potentially hazardous situation exists which, if not avoided,

may result in minor or moderate injury or property damage.

A potential situation exists which, if not avoided, may result in

product or property damage.

THE FOLLOWING SYMBOLS & LABELS MAY BE FOUND IN THIS MANUAL OR ON THE SAW

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

IMPORTANT

WARNING

CAUTION

TITLE680GC OPERATOR’S MANUAL

SAFETY

WARNING

THE FOLLOWING SYMBOL APPLIES TO ALL THE ITEMS LISTED ON THIS PAGE

A potentially hazardous situation exists which, if not avoided,

could result in death or serious injury.

Chain breakage can result in high-speed ejection of parts, which can result in death or

serious personal injury to operators or bystanders. The items listed below are critical to

minimizing the risk of diamond chain breakage and injury.

• DO NOT operate a concrete chain saw with a damaged, modified, broken, or missing side

cover, bottom guard, or guard flap. The side cover, bottom guard, and guard flap provide

protection against contact with moving parts, ejected debris, broken diamond chain,

thrown water and concrete slurry.

• DO NOT operate saw with loose, missing, damaged or improperly repaired parts.

• DO NOT insert saw into a slot narrower than the diamond chain segments. Rapid

pushback might occur. Reference: Most diamond segments are .225 inches (5.72 mm)

wide.

• DO NOT use damaged, modified or improperly repaired diamond chain.

• DO NOT run saw upside-down. Concrete debris can fly back into the operator’s face.

• DO NOT cut ductile iron pipe with a concrete chain saw. Segment loss or diamond chain

breakage may occur.

TITLE 680GC OPERATOR’S MANUAL

SAFETY

CAUTION

THE FOLLOWING SYMBOL APPLIES TO ALL ITEMS LISTED ON THIS PAGE

A potentially hazardous situation exists which, if not avoided,

may result in minor or moderate injury or property damage.

• Always turn a concrete chain saw OFF when performing maintenance on the saw

including diamond chain tensioning.

• Never use equipment that is not functioning properly.

• Have the saw repaired only by qualified service personnel.

• Turn engine OFF before refueling. Keep away from open flame. Always provide adequate

ventilation when handling fuel. Move saw at least 10 feet (3 m) away from refueling area

before starting.

• SealPro®diamond chains require a minimum water pressure of 20 psi (1.5 bar).

Insufficient water supply may result in excessive wear to the diamond chain, which

can lead to loss of strength and diamond chain breakage, and/or damage to the guidebar

nose sprocket.

• Never start saw unless the guidebar, diamond chain

and side cover are properly installed.

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 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.

TITLE680GC OPERATOR’S MANUAL

SAFETY

IMPORTANT

THE FOLLOWING SYMBOL APPLIES TO ALL ITEMS LISTED ON THIS PAGE

A potential situation exists which, if not avoided, may result

in product or property damage.

Note: The concrete chain saw is equipped with a two-stroke engine and must always be run

using a mixture of gasoline and ICS®two-stroke engine oil, or other high quality 2-stroke

oil that has been formulated for air cooled power equipment. 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.

• This engine is designed to be operated on premium unleaded gasoline.

• Use high quality, unleaded gasoline with a minimum octane rating of 90. If lower octane

gasoline is used, engine temperature will increase which will result in a piston seizure

and damage to the engine.

• Fuel mixture: 25:1 (4%) gasoline/oil mixture. Incorrect fuel mixture is the number one

cause of piston seizure.

• Use ICS®brand two-stroke engine oil, or other high quality 2-stroke oil that has been

formulated for air cooled power equipment.

• Never use two-stroke oil formulated for water-cooled two-cycle engines, such as

outboard motor oil.

• Never use motor oil intended for four-stroke engines.

• Use of water is required to cool bar and chain during break-in period.

ENGINE BREAK-IN

• It is very important to break-in a new engine to “seat” all moving parts, especially the

piston rings.

• To break-in the engine, run one full tank of 25:1 (4%) fuel at idle, cycling the throttle every

5 to 10 minutes to prevent loading.

• Failure to break-in an engine may result in piston seizure.

• Failure to break-in an engine at altitude will result in up to 50% loss of power output for

the first hour of operation making the initial cutting experience unsatisfactory.

• Proper chain tension, especially for first cut, is extremely important. Over-tensioning of

bar and chain, especially at altitude, could result in severe loss of power output making

initial cutting experience unsatisfactory.

TITLE 680GC OPERATOR’S MANUAL

TECHNICAL SPECIFICATIONS

Engine Type 2-stroke Single Cylinder Air Cooled

Displacement 4.7 cu-in (76.5 cc)

Horsepower 5 hp (3.7 kW) @ 9,500 rpm

Torque 36.3 in-lbs (4.1 Nm) @ 6,500 rpm

Engine Speed 11,500 +/- 500 rpm (max)

2,800-3,200 rpm (idle)

Weight 21 lbs (9.5 kg) without guidebar and

diamond chain

Dimensions

18 inches (46cm) length

11.5 inches (29cm) height

10 inches (25cm) width

Air Filter Water resistant polyester

Carburetor Walbro WJ122B

Starter Dust and water resistant

Ignition Special water resistant electronic ignition

Clutch Centrifugal, three shoe, single spring

Fuel ratio 25:1 (4%) gasoline-to-oil

Fuel Capacity 0.23 gal (.88 liter)

Water Supply Minimum 20 psi (1.5 bar)

Water Flow Minimum: 2 gpm (8 lpm)

Noise Level 101 dB at 3 ft (1m)

Vibration Level 7.2 m/s2 (front handle)

8.5 m/s2 (rear handle)

Engine Break-in Period One tank, without cutting, cycling throttle

Spark Plug NGK BPMR8Y

Electrode gap .020 in (0.5 mm)

TITLE680GC OPERATOR’S MANUAL

SET-UP

STEP 1

Loosen side cover nuts and remove side

cover.

GUIDEBAR AND DIAMOND CHAIN INSTALLATION

STEP 4

Mount the diamond chain on the guidebar

starting at the drive sprocket and continue

over the guidebar nose.

STEP 2

Remove shipping spacer. STEP 5

Install the side cover and nuts. Do not

fully tighten side cover nuts until chain is

properly tensioned.

STEP 3

Place guidebar onto studs and chain

adjustment pin.

TITLE 680GC OPERATOR’S MANUAL

SET-UP

GUIDEBAR AND DIAMOND CHAIN INSTALLATION

CORRECT CHAIN TENSION

All chains have a tendency to stretch

when used. Diamond chains stretch more

than wood cutting chains because of the

abrasive materials they are cutting.

If the chain is too tight, a lot of the saw's

power goes into turning the chain rather

than into the cut. In extreme over-tightened

cases, the saw may not be able to turn the

chain at all. In addition, damage can occur

to the bar nose and premature stretch may

occur.

STEP 7

Before cutting, check for proper tension by

pulling 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.

CHAIN TOO LOOSE

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 drive links.

When a chain stretches to a point where

the drive links are hanging approximately

1/2 in (12 mm) to 3/4 in (18 mm) below the

bar, it is time to tension the chain.

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 screw

clockwise.

CHAIN TOO TIGHT CHAIN TOO LOOSE

TITLE680GC OPERATOR’S MANUAL

SET-UP

GUIDEBAR AND DIAMOND CHAIN INSTALLATION

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 sure the side cover nuts

are tightened to approximately 20 ft-lbs

(27 Nm).

STEP 9

Attach to water source with pressure of not

less than 20 psi (1.5 bar).

TITLE 680GC OPERATOR’S MANUAL

OPER ATION

CAUTION

FUEL HANDLING

FUEL MIXTURE: 25:1 (4%) gasoline/oil mixture.

GASOLINE OIL

Gallon

Fl oz

1 5.2

2 1/2 12.8

5 25.6

GASOLINE OIL

Liters ml

1 40

5 200

10 400

20 800

• Use premium unleaded gasoline with a minimum octane rating of 90. If lower octane gasoline

is used, engine temperature will increase which can result in a piston seizure and damage to

the engine.

• 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 (4%) 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 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 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 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.

TITLE680GC OPERATOR’S MANUAL

COLD ENGINE STARTING PROCEDURE

1. Toggle the ignition switch to the "ON" position and pull the

choke lever out.

2. Lock the throttle in the start position by depressing the trigger

(A) and trigger interlock (B) at the same time.

3. Depress and hold throttle lock button (C) while releasing the

trigger and trigger interlock in succession.

4. Open the water valve 1/4 turn.

5. Place the saw on stable ground making sure the chain

is free of any obstructions.

6. Place foot on the base of the rear handle, and place one hand

on front handle.

7. With opposite hand, slowly pull starter handle until the

starter pawls engage.

8. Pull the starter cord (hard, fast, short pulls)

until engine initially fires or "pops".

Could be as many as 10-15 pulls.

9. Push the choke lever in.

10. Pull the starter cord until engine starts. Could be as many as

5 to 7 pulls.

11. When the engine starts, allow the engine to idle. Pull on the

throttle trigger several times to help warm up the engine.

12. Open the water valve completely.

CAUTION

OPER ATION

STARTING AND STOPPING A CONCRETE CHAIN SAW

Never start a concrete chain saw without the guidebar, diamond

chain and side cover properly assembled. Failure to do so may

result in serious injury.

Always move saw at least 10 feet (3 m)

away from the fueling area before starting.

Place the saw on clear ground. Ensure that secure footing is

established and diamond chain is not contacting any objects.

IMPORTANT

WARNING

WARM ENGINE STARTING PROCEDURE

1. Use the same procedure as starting a 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 to open fully,

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.

A: Trigger

B: Trigger interlock

C: Throttle lock button

TITLE 680GC OPERATOR’S MANUAL

OPER ATION

PRE-CUT CHECKLIST

• Proper Diamond Chain Tension: The diamond chain should be tight but easily pulled around

the guidebar by hand.

• 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 guidebar 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 guidebar. 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 in x 12 in x 12 in = 150 lbs. (30 cm x 30 cm x 30 cm = 68 kg).

• Check for and remove any obstructions (plumbing, electrical conduit, air ducts, etc,) that may

interfere with the cut.

The single most important factor an operator can control to

increase chain life is to use adequate water pressure. Insufficient

water supply will result in excessive wear to the chain, which can

lead to loss of strength and chain breakage, and/or damage to the

guidebar nose sprocket.

IMPORTANT

TITLE680GC OPERATOR’S MANUAL

OPER ATION

CUTTING WITH THE 680GC CONCRETE CHAIN SAW

To start a cut, hold trigger on full throttle and slowly plunge the nose of the guidebar straight into the

wall. Lengthen the cut and engage the point of the WallWalker®. Use the WallWalker® as a pivot point

and pull up on the rear handle to rotate the guidebar into the cut.

CUTTING TIPS

• Always operate the concrete chain 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 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

guidebar approximately 1/2 in (12 mm) to 1 in (25 mm) deep. Next, deepen the cut by about 2

in (50 mm). This groove will help guide the guidebar for a straight cut. Then plunge all the way

through and complete the cut using the WallWalker®.

• Plunge cut instead of starting at the top surface 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 WallWalker® to help cut more efficiently

and reduce operator fatigue. The WallWalker® is

a fulcrum that can be used to apply additional force

when cutting. To use correctly, plunge into the wall

and simply engage the point of the WallWalker®

into the cut and pry upward with the rear handle.

• As the saw begins to rotate up, feed force is

developed down the line of the intended cut.

Once the saw is fully rotated upwards, pull the saw

out of the cut a few inches and re-engage the pick

into the cut and repeat.

• 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 diamond chain life when

cutting heavy rebar.

• Expect more diamond chain stretch when making nose buried cuts for extended periods of time,

as the diamond chain does not have a chance to “throw” the slurry away from the nose of the

guidebar.

• If the saw begins to cut consistently crooked, turn the guidebar over and use the other side.

Dress worn rails with belt sander. Note: The normal life of a guidebar is 2 to 3 diamond chains.

Heavy rebar can shorten guidebar life.

• When using a new diamond chain, you can increase the initial cutting speed by “opening up the

diamonds”. Make a few cuts in an abrasive material such as a cinder block.

WallWalker®point

TITLE 680GC OPERATOR’S MANUAL

OPER ATION

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, guidebar and drive sprocket.

• Wash concrete slurry from concrete chain saw body.

• Avoid getting any water in the carburetor or exhaust system. If water enters exhaust port, point

the guidebar tip down and pull the starter handle several times to expel water from muffler.

• Remove guidebar and diamond chain. Flush out the chain tensioner with high water pressure and

lubricate with grease.

• After cleaning the saw, spray the entire saw body, diamond chain, guidebar, and drive sprocket

with lightweight oil. Using lightweight oil on the saw will minimize rust and help reduce slurry build

up.

TITLE680GC OPERATOR’S MANUAL

MAINTENANCE

Follow these simple maintenance guidelines

and your saw will continue running at its very best.

AFTER EACH USE

1. Rinse the saw, guidebar 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, guidebar, and chain with lightweight oil.

8. Grease the chain tensioner.

AFTER 10 HOURS OF USE

1. Remove the starter cover and lubricate the starter recoil spring. Clean the flywheel fins

and the starter pawls with a wire brush, then grease the starter pawls.

2. Remove the spark plug and clean with a wire brush. Check the electrode gap.

The correct gap is 0.020 in (0.5mm).

AFTER 40 HOURS OF USE

1. Change the spark plug. Adjust the electrode to 0.020 in (0.5 mm).

2. Check the fuel filter located inside the fuel tank. Clean or replace if clogged.

TITLE 680GC OPERATOR’S MANUAL

MAINTENANCE

AIR FILTER

IMPORTANT

STARTER HOUSING ASSEMBLY

It is common for concrete slurry to get inside the starter housing

assembly during cutting. This can cause the starter pawls to stick

and not engage when the rope is pulled.

IMPORTANT

• After each usage, thoroughly flush the starter housing

assembly with water.

• Lubricate the starter pawls by spraying light weight oil into the

starter housing through the vents.

• Check the starter cord for fraying, replace if necessary.

The air filter is made from water resistant polyester and includes

internal spit-back screen. Both must be kept clean for the engine

to operate properly. If the saw is not reaching full RPM, most

likely one or both of the air filters are dirty.

• The air filter should be free of holes and white in color.

• Replace air filter when dirty.

• The spit-back screen should be free of holes and be

white in color. Clean with mild solvent or gasoline and dry

with high pressure air. If spit-back screen is dirty the saw

will not reach full RPM.

• During re-assembly, tighten air filter wing-nut "finger tight"

plus an 1/8 in of a turn with wrench.

TITLE680GC OPERATOR’S MANUAL

MAINTENANCE

TENSIONING THE RECOIL SPRING

• Lift the starter cord up into the notch on the starter

pulley 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 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. Slowly

release the starter cord to enable the pulley to fit between the

pawls.

• Insert and tighten the screws. Use blue Loctite® #242.

STARTER CORD REPLACEMENT

• Remove the 4 screws that attach the starter assembly to the

crankcase.

• Pull the cord out approximately 8 in and lift the cord

up into the notch in the pulley. Relax the recoil spring

by placing thumb on pulley and gently allow the pulley

to unwind entirely. Undo the screw in the center of the

pulley and remove the pulley.

• Thread the new cord through the starter cover and

fasten it to the pulley. Wind 4 turns of the starter cord

on to the pulley. Assemble the starter pulley against

the recoil spring so the end of the spring engages into

the backside of the pulley. Install the retaining screw

in the center of the pulley.

TITLE 680GC OPERATOR’S MANUAL

MAINTENANCE

DRIVE SPROCKET

The drive sprocket (rim sprocket) is a wear item and should be

replaced every 2-3 diamond chains.

IMPORTANT

The needle bearing inside the splined adapter should be greased

regularly and should be replaced with each new clutch cup.

IMPORTANT

A rim sprocket system consists of a clutch cup

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

regularly, use high quality water-resistant bearing grease.

Clutch

Cup

Splined

Adapter

Rim

Sprocket

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 grease.

IMPORTANT

Most Common Causes of Tensioner Damage:

• Side cover nuts are not tight enough. Side cover nuts

should be torqued to 20 ft-lbs (27Nm).

• Chain tensioning is attempted without loosening

the side cover nuts.

• Concrete debris in tensioner pocket.

Chain

Tensioner

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