ICS 890F4 Operator's Manual

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890F4

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 re, serious injury, or death.

SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE

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890F4 OPERATOR MANUAL

ENGLISH

This instruction manual contains translations of a manual drafted in English and are provided to assist those who do not speak English as their rst 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.

Specications subject to change without notice. For most up-to-date version of this manual, please visit:

https://icsdiamondtools.com/customer-service-support/.

Introduction

TABLE OF CONTENTS

SAFETY RULES SYMBOLS AND LABELS ICS 890F4 NAMES AND TERMS PRODUCT IDENTIFICATION UNPACKING AND ASSEMBLY OPERATION MAINTENANCE TROUBLESHOOTING TECHNICAL SPECIFICATIONS SERVICE CENTERS

8 10 12 14 21 29 33 34 35

INTRODUCTION

The 890 power cutter is designed to cut concrete, stone, and masonry when used with the appropriate genuine ICS Diamond Chain. Ductile iron pipe may

also be cut but ONLY if using PowerGrit® Utility Chain. This is a professional tool and is solely intended for use by trained and experienced operators. A rst time operator should obtain practical instruction before using the power cutter, as well as reading and understanding this Operator’s Manual.

Local legislation and/or workplace standards may regulate the use of this power cutter. Determine what regulations are applicable in the place you work before using the power cutter.

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890F4 OPERATOR MANUAL

ICS | BLOUNT, EUROPE SA. | Rue Emile Francqui 5 | 1435 Mont- Siant- Guibert, Belgium

EECC DDEECCLLAARRAATTIIOONN OOFF CCOONNFFOORRMMIITTYY

Manufacturer:

BLOUNT INC. DECLARES THE FOLLOWING PRODUCT(S) COMPLY WITH ALL RELEVANT EUROPEAN DIRECTIVES

Machinery: ICS 890F4 Hydraulic Saw

EUROPEAN DIRECTIVES AND STANDARDS

CLARIFICATION OF PRODUCT CLASS: The ICS 890F4 Hydraulic Saw, using the appropriate genuine ICS Diamond

Chain, is designed to ONLY cut concrete or designated materials other than wood . The cutting means is by grinding through the work-piece, using a continuous water supply as a coolant and lubricant. This product is not intended

for use with conventional wood cutting saw chain.

By design, this product is not intended to comply with the definition of a chain -saw as described by ISO 6531 – “Machinery for Forestry – Portable hand-held chain-saws – Vocabulary”:

ISO6531-1999; Clause 2.2.1; chain-saw: “power driven tool designed to cut wood with a saw chain and consisting of an integrated compact unit of handles, power source, and cutting attachment, designed to be supported with two hands”

Corporate Contact: European File Location:

John DeHaven

Product Safety & Compliance Manager Blount International Inc. Phone: 001.503.653.4273 Fax: 001.503.653.4701

Place: Portland Oregon, USA Date: 16 December 2013

Machinery Directive 2006/42/EC:2006

Safety of machinery - Basic Concepts, general principles for design; Basic terminology and methodology

EN ISO 12100-1;-2:2009

Mechanical vibration – Measurement and evaluation of human exposure to hand-transmitted vibration

EN ISO 5349-1;-2:2001

Acoustics – Sound power using sound pressure EN ISO 3744:2009

Portable Chainsaws – Chain Catcher, Dimensions & Mechanical Strength ISO 10726:1992

Blount International, Inc.

4909 SE International Way Portland, Oregon 97222 USA

Phone: 001.800.321.1240

Blount Europe S.A.

Rue Emile Francqui, 5 1435 Mont-Saint-Guibert

Belgium

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890F4 OPERATOR MANUAL

ENGLISH

Safety Rules

SAFETY RULES

To get the maximum benet from your power cutter, and assure maximum safety, be sure to read this manual thoroughly and follow the safety instructions

provided.

EXPLANATION 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 power cutter or property.

Indicates a hazard with a high level of risk which, if not avoided, will result in

death or serious injury.

WARNING

CAUTION

DANGER

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890F4 OPERATOR MANUAL

Safety Rules

HANDLING HYDRAULIC FLUID SAFELY

Check for hydraulic leaks before starting the hydraulic power source.

Visually check for leaks from the hydraulic ttings, and lines and do not use if

any leaks are found.

Hydraulic uid is combustible or can become combustible.

Consult the SDS (Safety Data Sheet) for the hydraulic uid being used for ash point and auto ignition temperature ranges. When these uids discharge under pressure in a ne mist, they ignite easily, burn rapidly, and emit large quantities of heat. In fact, their heats of combustion, which are over 18,000 BTU/lb (2327 kJ/kg), are comparable to fuel oil.

WARNING

CAUTION

WORK AREA SAFETY

Keep bystanders away from work area.

Set up a well-marked safety zone with a roped boundary and clear signs to keep bystanders at least 6 m (20 ft) away.

Remove or control slurry to prevent slippery conditions while cutting. This power cutter uses water and can cause slippery surfaces due to the slurry

produced and/or freezing temperatures.

Drugs or alcohol can impair vision, dexterity, and judgment.

Do not operate the power cutter when tired or under the inuence of any substance.

WARNING

CAUTION

Following are the basic instructions for work area safety.

Do not operate this product during severe inclement weather.

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Safety Rules

PERSONAL SAFETY

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 hat and steel toed shoes may also

be required. Avoid loose tting clothing.

This power cutter can generate hazardous dust and vapors.

Determine the nature of the material you are going to cut before proceeding with the job. Be especially aware of cutting materials containing silica and asbestos as inhaling dust can result in respiratory disease. Be sure to use appropriate respiratory protection designed to lter out microscopic particles.

Be sure to use recommended water pressure to minimize dust generation.

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 ngers, hands or wrists, stop using the power cutter immediately. If the problem persists, seek medical attention.

Following are the basic instructions for personal safety.

WARNING

Long-term exposure to noise can result in permanent hearing impairment.

Always wear approved hearing protection.

Fluids escaping under pressure can penetrate skin and cause severe personal injury.

Do not use hands to search for leaks. Before disconnecting lines, be sure to relieve all pressure. Do not apply pressure to damaged lines, hoses or ttings. If any uid is injected into the skin, seek medical attention immediately to prevent gangrene. Consult supplied hydraulic uid SDS for additional

information regarding proper handling and use instructions.

TRANSPORTING & STORING

WARNING

Hydraulic hoses are charged with uid when the power cutter is shipped.

See the icsdiamondtools.com website for SDS information on

the hydraulic uid.

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890F4 OPERATOR MANUAL

Safety Rules

USING THE ICS POWER CUTTER SAFELY

Following are the basic instructions for safe use of the power cutter. Also read and understand additional safety precautions specic to the operation and

maintenance of the power cutter throughout this manual.

DO NOT operate the ICS power cutter with a saw chain or saw bar designed to cut wood. Using wood cutting saw chain on the ICS power cutter

could result in severe injuries to the operator or a bystander! Use ONLY the cutting attachments specied in this manual on this power cutter.

DO NOT operate the power cutter with damaged, modied, broken, or

missing components. Below safety features are designed to protect against contact with moving

parts, ejected debris, broken chain, thrown water, and concrete slurry.

• Side cover

• Bae drain

• Mud ap

• Mud ap bracket (Chain Catcher)

• Trigger interlock

Use only Genuine ICS replacement parts. Use of unauthorized aftermarket parts may result in injury or damage to the power cutter.

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 power cutter without an adequate water supply.

The integral water supply channels in the guidebar act to cool and lubricate the cutting system as well as to suppress dust and debris generated during cutting. Assure that the water supply is capable of delivering 1.5 bar (20 psi) pressure to the power cutter at a minimum ow rate of 4 lpm (1 gpm).

WARNING

DANGER

Never attempt to cut ductile iron pipe or similar pipe materials with the power cutter unless using PowerGrit® Utility Chain.

Using concrete cutting chain in these applications can cause the chain to snag abruptly in the cut which may result in chain breakage, pushback and/or kickback.

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ENGLISH

LABELS ON YOUR POWER CUTTER

NAMEPLATE LABEL

Symbols & Labels

SAFETY LABELS

� WARNING

• Do NOT operate power cutter without side cover.

• Do NOT operate power cutter without baffle drain.

• Do NOT use this power cutter cover on any other power cutter model.

• Failure to observe these precautions can result in serious injury.

� WARNING

• Do not exceed 8 GPM (30 LPM) hydraulic f low or 2500 psi (172.5 bar) hydraulic pressure

• Do NOT insert tool into slot narrower than chain.

• Do NOT run the power cutter backwards. The

chain should travel away from the operator on

the top of the bar and return on the bottom of the bar.

• Do NOT operate tool without solid footing and

firm hand grip.

• Failure to observe these precautions can result in serious injury. Fluids escaping under

pressure can penetrate the skin.

� WARNING

• Do not exceed 12 GPM (45 LPM) hydraulic flow or 2500 psi (172.5 bar) hydraulic pressure

• Do NOT insert tool into slot narrower than chain.

• Do NOT run the power cutter backwards. The

chain should travel away from the operator on

the top of the bar and return on the bottom oF the bar.

• Do NOT operate tool without solid footing and

firm hand grip.

• Failure to observe these precautions can result in serious injury. Fluids escaping under pressure

can penetrate the skin.

8 GPM POWER CUTTER 12 GPM POWER CUTTER

ZZZZ = Saw number within production batch in sequential order beginning with 00001

YY = Month of Manufacture (ie. 07)XX = Year of Manufacture (ie. 15)

Model 890 F4 Serial# XXYYZZZZZ

Blount, Inc.

4909 SE International Way

Portland, OR 97222 USA

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890F4 OPERATOR MANUAL

SYMBOLS AND LABELS

THE FOLLOWING SYMBOLS ARE FOUND THROUGHOUT THIS MANUAL

AND/OR ON THE POWER CUTTER AND ARE DESIGNED TO MAKE

YOU AWARE OF POTENTIAL HAZARDS OR UNSAFE PRACTICES.

SAFETY ALERT

Indicates that the

text that

follows explains a

danger,

warning or caution.

READ

INSTRUCTIONS

The original instruction manual contains important

safety and operating

information. Read

and follow the

instructions carefully.

WEAR

PROTECTION

Wear eye , hearing

and respiratory

protection and a

protective helmet

when operating the

power cutter.

BEWARE OF

KICKBACK

Kickback can cause

severe injuries.

TWO-HANDED

HOLD

Operate the power

cutter with two

hands, securely

gripping both

handles

WEAR LONG

PANTS

Wear long pants

when operating the

power cutter.

WEAR FOOT

PROTECTION

Wear appropriate closed-toe boots

when operating the

power cutter.

WEAR HAND

PROTECTION

Wear hand

protection when

operating the power

cutter.

ONE-HANDED

HOLD

Do not operate the

power cutter with

only one hand.

DO NOT USE A

LADDER

Never stand on a

ladder when using

the power cutter.

KERF WIDTH

Do not insert tool

into slot

narrower than chain.

FLUIDS UNDER

PRESSURE

Fluids escaping

under pressure

can penetrate skin

and cause severe

personal injury.

SOUND POWER

Sound power level

is 107 dB(A).

FIRE DANGER

Risk of re if

warnings not

followed.

SLIPPERY

SURFACE

Unsure footing can

lead to

accidents.

Symbols & Labels

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890F4 OPERATOR MANUAL

ENGLISH

Names & Terms

ICS 890F4 NAMES AND TERMS

Bae Drain

A device for controlling slurry and cutting debris in the side cover to reduce chain stretch and protect the operator from other projectiles.

Bar retaining plate

The plate between the guidebar and side cover that clamps the guidebar

to prevent movement during operation.

Bar slot

The slot feature on the guidebar that ts over the bar studs.

Bystander safety zone

A 6 m (20 ft) circle around the operator that must remain free from bystanders, children and pets.

Chain catcher

A device for retaining the chain if it breaks or derails.

Chain pitch

The distance between any three consecutive rivets 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 power cutter

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 backward and/or upward motion of the guidebar, occurring when the chain near the top area of the nose of the guidebar contacts a foreign object or snags in the workpiece.

Mud ap

A barrier to deect slurry, cutting debris and other projectiles from

operator.

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890F4 OPERATOR MANUAL

Names & Terms

ICS890 NAMES AND TERMS

Powerhead

A power cutter without the chain or guidebar.

Pushback

The rapid backward motion of the guidebar, occurring when the chain on the top straight portion of the guidebar contacts a foreign object or

snags in the workpiece.

Rear handle

The support handle located at or toward the rear of the power cutter

intended to be gripped by the right hand.

Rear hand guard:

A structural barrier at the bottom of the rear handle to protect the operator in case the chain breaks or derails. Does not meet ISO 14982 Requirements.

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, bar retaining plate and guidebar.

Trigger lock-out

A device that prevents the unintentional operation of the throttle trigger until

manually released.

Trigger

A mechanism that controls motor operation.

WallWalker®

A device used as a fulcrum to provide mechanical advantage during cutting.

Water shut-o valve

A mechanism that controls water delivery and ow to the guidebar and chain.

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ENGLISH

Product Identication

PRODUCT IDENTIFICATION

Chain tensioning screw

Front handle

Rear handle

Water shut

off valve

Bar slot

Bar studs

Chain catcher

WallWalker®

Guidebar

Mud flap

Powerhead

Rear hand guard

Side cover

Side cover nuts

Trigger lock-out

Trigger

Bar retaining plate

Baffle drain

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890F4 OPERATOR MANUAL

Product Identication

Direction of hydraulic ow

Water hose

Hydraulic Supply Quick-Disconnect

Hydraulic Return Quick-Disconnect

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890F4 OPERATOR MANUAL

ENGLISH

BOX CONTENTS

Minimum contents for all packages shown. Some packages also contain guidebar and diamond chain.

See Z 34 for a list of compatible guidebars and diamond chain.

Unpacking & Assembly

GUIDEBAR AND DIAMOND CHAIN INSTALLATION & TENSIONING

Following are the basic instructions for guidebar and diamond chain

installation and tensioning.

Never perform any maintenance or adjustments on the power cutter while the hydraulic power source is connected.

Improper chain tension can lead to failure of the chain or derailing of the

chain o of the guidebar.

Check tension frequently and adjust if drive links of chain hang 18 mm (3/4 in) or more below the guidebar groove

Always wear gloves when handling the bar and chain. These components can develop sharp edges and cause cuts.

WARNING

CAUTION

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890F4 OPERATOR MANUAL

GUIDEBAR AND DIAMOND CHAIN

INSTALLATION & TENSIONING

Unpacking & Assembly

STEP 2

Loosen the side cover nuts and remove the side cover and bar

retaining plate.

STEP 3

Turn the chain-tensioning screw counterclockwise until the pin comes to a stop.

STEP 1

Disconnect hydraulic power supply.

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890F4 OPERATOR MANUAL

ENGLISH

Unpacking & Assembly

GUIDEBAR AND DIAMOND CHAIN INSTALLATION & TENSIONING

STEP 4

Place the bar onto the studs

without engaging tensioner pin.

Assure bar is in contact with the

drive sprocket.

STEP 5

Install the chain around the drive sprocket and then around the nose

sprocket before inserting into the bar groove.

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890F4 OPERATOR MANUAL

GUIDEBAR AND DIAMOND CHAIN

INSTALLATION & TENSIONING

Unpacking & Assembly

STEP 6

Engage the tensioner pin into the

bar. Make sure all of the drive links are inside the top and bottom bar

grooves, then pre-tension the chain.

STEP 7

Install the bar retaining plate over the bar studs. Assure plate is properly oriented so "FRONT" is

facing outward (as shown).

STEP 8

Install the side cover over the

bar studs and finger tighten side

cover nuts.

FRONT

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890F4 OPERATOR MANUAL

ENGLISH

Unpacking & Assembly

GUIDEBAR AND DIAMOND CHAIN INSTALLATION & TENSIONING

CHAIN TOO TIGHT CHAIN TOO LOOSE

CORRECT CHAIN TENSION

STEP 9

Continue to lift up on the nose

of the bar and firmly tighten the

side cover nuts using the scrench

(approximately 20 -25 ft. lbs (27-33 Nm). Improper torque can cause the bar to slip.

STEP 9

Lift up on the nose of the bar and

tension the chain. Do not over

tension the diamond chain. Loss of

power will result.

chain tensioner

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890F4 OPERATOR MANUAL

CHECKING & ADJUSTING CHAIN TENSION

Unpacking & Assembly

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.

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 guidebar groove, it is

time to tension the chain.

A tight chain may rob power reducing cutting performance and increasing

chain friction, resulting in chain stretch. If the tension is set too loose the chain

could be thrown o of the bar or allow the sprocket to turn without turning the

chain which will damage the drive links.

IMPORTANT

WARNING

Improper chain tension can lead to breakage of the chain or derailing of the

chain o of the guidebar.

Check chain tension frequently and adjust if drive links of chain hang 18 mm (3/4 in) or more below the guidebar.

CONNECTING TO HYDRAULIC SUPPLY

Assure hydraulic hoses are connected to power cutter with the proper ow direction. The chain should travel away from the operator on the top of the bar and return on the bottom of the bar. If hydraulic motor does not turn when trigger is depressed, this may be an indication that the hydraulic ow direction

is likely reversed. Refer to diagram on page 13 for more details.

hydraulic ow direction

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890F4 OPERATOR MANUAL

ENGLISH

Unpacking & Assembly

CONNECT TO WATER SUPPLY

Following are the basic instructions for correct water supply to the

power cutter.

Inadequate water can result in increased potential for harmful airborne particulates.

ICS® power cutters require a continuous water supply to the guidebar and chain for the key purposes of cooling, lubrication and dust suppression. The potential for airborne particulates depends on many factors including, but not limited to, the material being cut, application and cutting environment.

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.

Insucient water supply will result in excessive chain stretch and may

cause chain breakage, damage to the guidebar, nose sprocket and drive sprocket.

Never operate the power cutter with insucient water supply. In all cases, assure that the water supply is delivering 1.5 bar (20 psi) pressure to the power cutter at a minimum ow rate of 4 lpm (1gpm).

CAUTION

Attach to water supply capable of delivering 1.5 bar (20 psi) pressure to the power cutter at a minimum flow rate of 4 lpm (1 gpm). The single most important factor an operator can control to increase chain life is to use adequate water pressure.

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890F4 OPERATOR MANUAL

Operation

OPERATION

Never start the power cutter without the bar, chain and side cover properly assembled.

Unintentional contact with moving chain or components may occur.

DO NOT operate the power cutter with loose, missing, damaged or improperly installed or repaired parts.

Check that the components shown below are intact, undamaged, and installed

correctly:

• Side cover nuts torqued down properly. Loose or improperly torqued side

cover nuts can lead to chain tensioner breakage

• Side cover not damaged and bae drain not plugged

• Handles not loose, gripping areas are clean and undamaged

• Mud ap is not ripped, torn or missing and is fully attached to the power cutter

• 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 or drive link damage or missing diamond segments

• Chain tensioner mechanism functions properly and pin is not bent or broken

• Drive sprocket not excessively worn

• Check alignment of drive sprocket and guidebar

• Assure proper chain tension: The chain should be easily pulled around the

guidebar by hand

• Assure all safety devices are properly mounted and functional and that all controls are in proper working order

• Adequate water supply and pressure

Minimum flow: 1 gpm (4 lpm) Minimum water pressure: 20 psi (1.5 bar)

• Proper hydraulic supply to the power cutter: Maximum flow: 8 gpm (30 lpm) or 12 gpm (45 lpm), depending on power

cutter model

Maximum hydraulic pressure: 2,500 psi (172.5 bar)

Following are the basic instructions for safe operation of the power cutter.

WARNING

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890F4 OPERATOR MANUAL

ENGLISH

PRE-OPERATION SAFETY CHECKS

Operation

• Assure proper chain tension: The chain should be easily pulled around the guidebar by hand.

• Assure 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, etc.) and no unnecessary people present

• Always wear protective clothing, including hard hat, eye protection, hearing protection, non-slip safety boots, gloves. Avoid wearing loose

fitting clothing.

• Adequate water supply and pressure Minimum flow: 1 gpm (4 lpm) Minimum water pressure: 20 psi (1.5 bar)

• Proper hydraulic supply to the power cutter: Maximum flow: 8 gpm (30 lpm) or 12 gpm (45 lpm),

depending on power cutter model

Maximum hydraulic pressure: 2,500 psi (172.5 bar)

The single most important factor an operator can control to increase chain life is to use adequate water pressure. Insufficient water supply may 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

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890F4 OPERATOR MANUAL

PRECUT CHECKLIST

Operation

Sudden contact of the guidebar nose with a foreign object may generate kickback.

Remove and/or avoid any obstructions (plumbing, water supply hoses, electrical conduit, air ducts, etc.) that may interfere with the cut.

Always operate the power cutter with solid footing and both hands on the power cutter.

Keep your left hand on the front handle and your right hand on the rear handle. Wrap your thumbs around the handles to assure you maintain a secure grip on both handles.

To avoid electrocution, check for live electrical wires.

Wires may be hidden within or behind walls and/or laying around the workspace. Assure that any ancillary electrical equipment (fans, pumps, vacuums, etc.) are properly grounded and certied 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 hat, steel toed shoes and a

respirator may also be required. Avoid loose tting clothing. Follow all local regulations regarding PPE.

WARNING

Cutting with the power cutter may generate sparks, especially when cut-

ting through metal (such as rebar), and may start a re in combustible

materials such as dry grass, wood and fuel.

Be sure to use adequate water pressure and have re ghting equipment readily available.

Be sure that no part of the cutting system is contacting a solid object when starting the power cutter.

The power cutter may react unexpectedly if the chain contacts a solid object.

WARNING

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890F4 OPERATOR MANUAL

ENGLISH

Operation

CUTTING WITH THE POWER CUTTER

DO NOT insert the guidebar into a slot narrower than the width of the chain.

Rapid pushback, kickback and/or chain breakage could result.

Slippery or unstable surfaces such as ladders may cause a loss of balance or control of the power cutter.

Always keep proper footing and operate the power cutter only when standing on xed, secure and level surface.

Unexpected loss of control of the power cutter and loss of balance can result in injury.

Do not overreach and do not cut above 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 rst and assure workpiece is secure and does

not shift during cutting operations. Do not operate power cutter upside down.

Cutting debris can be directed back towards the operator.

Always operate power cutter at full throttle.

For best results, always operate the power cutter at full power.

Take special precautions when cutting in horizontal orientation.

Be aware that debris may be ejected dierently than when cutting in a vertical

position.

Be sure cut concrete cannot fall and injure the operator or bystanders.

Assure cut piece is controlled and does not fall unexpectedly.

NOTE: Concrete is very heavy; one cubic foot = 30 cm x 30 cm x 30 cm = 68 kg (12 in x 12 in x 12 in = 150 lbs).

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890F4 OPERATOR MANUAL

Operation

To assure the best performance from your ICS power cutter, follow all safety precautions and recommended techniques. Additional helpful information can be obtained at icsdiamondtools.com.

CUTTING WITH THE POWER CUTTER

CONCRETE/MASONRY CUTTING Planning the Cut

1. Select the proper chain type for the material being cut. Refer to the chain selection guide in this manual (page 32).

2. Outline the cut with a permanent marker for a visual cutting guide.

WARNING

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 rst, then

top or sides. Save the easiest cut for last. (see image at right)

4. Be sure cut concrete cannot fall and injure the operator

or bystanders. As the cut is being completed, assure that appropriate bracing is in place to control the cut section

of the workpiece. Concrete is very heavy,

one cubic foot = 30 cm x 30 cm x 30 cm = 68 kg (12 in x 12 in x 12 in = 150 lbs)

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890F4 OPERATOR MANUAL

ENGLISH

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,

to rotate the nose down

4. Rotate rear handle down, to rotate the nose up.

1. Plunge in

Page 27

890F4 OPERATOR MANUAL

Operation

CUTTING TIPS

• 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® as a pivot point and pull on the rear handle to rotate the bar into the cut.

• When the WallWalker is extended in the mechanical mode, the Wall Walker provides a 4:1 mechanical advantage.

• Always operate the concrete power cutter at full throttle. If too much force is applied, the power cutter will lug or stall. The chain will not have enough

speed to cut eectively. If too little feed force is applied, the diamonds will

skid and glaze over.

• 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.

• When cutting heavy rebar, slowly “rock” the power cutter 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 extende periods of time, as the chain does not have a chance to “throw” the slurry away from the nose of the guidebar (use step cut method).

• If the power cutter begins to cut consistently crooked, stop the power cutter, remove the bar and chain and turn the bar over and use the other side. Dress worn rails with a belt sander, at le or bar rail dresser.

Note: The normal life of a guidebar is two to three diamond chains (with rotation after every chain). Heavy rebar can shorten guidebar life.

• The guidebar is solely a guide track for the chain. Never use the guidebar to lift, twist or pry concrete material.

• When using a new chain, you can increase the initial cutting speed by

“opening up the diamonds”. This can be accomplished by rst making a few cuts in an abrasive material such as a cinder block or brick.

Page 28

890F4 OPERATOR MANUAL

ENGLISH

PIPE CUTTING USING POWERGRIT® UTILITY CHAIN

To assure the best performance from your ICS® power cutter when cutting

ductile iron pipe or similar pipe materials, follow all safety precautions and recommended cutting techniques.

Never attempt to cut ductile iron pipe or similar pipe materials with the power cutter unless using PowerGrit® Utility Chain.

Using concrete diamond chain in these applications can cause the chain to snag abruptly in the cut which may result in chain breakage, pushback and/or kickback.

Always assure that pipe is properly evacuated before cutting.

Pipes may contain sewage, gas or other hazardous materials.

Always support the pipe on both sides of the cut to assure the cut remains

open throughout the cutting operation, including when the cut is nished.

An improperly supported pipe can cause the cut to close, pinching the chain and guidebar which may result in chain breakage, pushback and/or kickback.

WARNING

1. Make a small plunge cut into the lower quadrant

of the pipe to relieve internal pressure and allow contents to drain from pipe in a controlled manner.

2. With pipe drained, cut from the top of pipe and continue through bottom of the pipe.

4. To assist with cutting, engage the WallWalker® in the cut when possible to provide additional leverage and alternate cutting between the near

and far side walls of the pipe.

3. To assure straightness of cut, guidebar should extend completely through the pipe during the cut.

Recommended Pipe Cutting Techniques

Operation

Page 29

890F4 OPERATOR MANUAL

MAINTENANCE

IMPORTANT

Maintenance

SYSTEM CLEAN-UP

• After cutting, run the power cutter for at least 15 seconds with the water on to flush slurry and debris from diamond chain, guidebar and drive sprocket.

• Wash concrete slurry and debris from power cutter assembly.

• Remove guidebar and chain. Flush out the chain tensioner and side cover with water. Lubricate tensioner with waterproof grease.

• After cleaning the power cutter, spray the entire power cutter body, chain, guidebar, and drive sprocket with lightweight oil. Using lightweight oil on the power cutter will minimize rust and help reduce slurry build up.

AFTER EACH USE

• Inspect drive sprocket for wear

• Inspect and tighten all fasteners as necessary.

• Flush and rinse the power cutter, guidebar and chain with water

• Check trigger function assembly

• Check mud ap for tears or damage

• Check guidebar and chain for damage or missing segments

• Check trigger cover bubble levels

• With power cutter disconnected from power source, check hose whips for leaks or damage.

• Inspect drive sprocket for wear.

• Replace when the drive teeth are worn more than half way through.

Page 30

890F4 OPERATOR MANUAL

ENGLISH

Maintenance

DRIVE SPROCKET

• The drive sprocket is a wear item and

should be replaced every two to three chains, or when the teeth become pointed

or if a groove cuts through top of tooth.

• Inspect the sprocket for wear.

• Inspect drive shaft for wear.

DRIVE SPROCKET ASSEMBLY REMOVAL/INSTALLATION

• Disconnect power cutter from the power source

• Remove the side cover, bar retainer plate,

guidebar and diamond chain

• Remove snap ring from shaft

• Slide drive sprocket off shaft

• Slide new sprocket onto shaft

• Replace snap ring onto shaft and assure complete engagement in shaft groove

• Installation of new drive sprocket is complete.

• Reinstall guidebar, diamond chain, bar retainer plate and side cover.

• Assure diamond chain and guidebar are in good, useable condition. Worn

or damaged guidebar and chain can damage the new drive sprocket.

Drive teeth

Snap Ring

Drive Sprocket

Snap Ring

Drive Shaft

Drive Sprocket

Page 31

890F4 OPERATOR MANUAL

Maintenance

CHAINS & GUIDEBARS

Inspect chain segments and drive links for damage or excessive wear. Chains with damage or excessive wear should not be used or repaired, they should be

replaced.

NOTE: Guidebars are designed to be used on both sides. If the cut is consistently leading to one side, turn the guidebar over. It is recommended to turn the guidebar over with every new chain.

• A table mounted belt, disc sander, at le or bar rail dressercan be 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 replaced by an Authorized Service Center.

• Periodically clean the water ports inside the groove of the guidebar using a small diameter piece of wire or pipe cleaner.

• The guidebar is solely a guide track for the chain. Never use the guidebar to lift, twist or pry concrete material.

• Prior to storage, spray the chain and guidebar with lightweight oil.

IMPORTANT

Chain Tensioner

CHAIN TENSIONER

The chain tensioner can become clogged with concrete slurry during cutting.

• After each use thoroughly ush the chain tensioner with water and apply a liberal amount of waterproof grease covering the chain tensioner screw.

FRONT

Page 32

890F4 OPERATOR MANUAL

ENGLISH

Maintenance

890F4 CHAIN SELECTION GUIDE & CONSUMABLES

890 F4 Chain Selection Guide

Chain &

Applications

Soft Stone/

Abrasive/Brick

Natural Stone

Medium

Concrete/Light

Reinforcement

Hard

Concrete/ Heavy

Reinforcement

Ductile Iron/Cast

Iron/PVC/HDPE

FORCE4®

General Purpose

◊ ◊ ◊

FORCE4® Premium L

Longer Cutting Life

◊ ◊ ◊

FORCE4® Premium S

Faster Cutting Speed

◊ ◊

FORCE4®

Abrasive

Ideal for brick & block

◊

PowerGrit

For Utility Pipe

◊

890F4 Consumables

10 in (25 cm) 15 in (38 cm) 20 in (50 cm) 25 in (63 cm)

FORCE4® Diamond Chain p/n 531743 p/n 525342 p/n 531749 p/n 525345

FORCE4®

Premium L Diamond Chain p/n 531745 p/n 525343 p/n 531751 p/n 525346

FORCE4® Premium S Diamond Chain p/n 531739 p/n531735 p/n 531741 p/n 531737

FORCE4® Abrasive Diamond Chain p/n 531747 p/n 525344 p/n 531753 p/n 525347

PowerGrit

Diamond Chain p/n 537764 p/n 537765 p/n 545017

FORCE4® Guidebar p/n 529829 p/n 523080 p/n 529767 p/n 525320

Drive Sprocket 565065

Page 33

890F4 OPERATOR MANUAL

Troubleshooting

TROUBLESHOOTING

PROBLEM Possible Cause

POWER CUTTER WON'T REACH FULL RPM

Low hydraulic oil.

Worn hydraulic power cutter motor

Worn hydraulic valve assembly.

Worn powerpack pump

SLOW CHAIN SPEED

All of the above, plus chain tension too tight. Chain should always be able to be pulled around the guidebar by hand. It is normal for the drive links of the chain to hang below the guidebar. See pages 15-19 for chain

tensioning instructions.

POOR CUTTING SPEED

All of the above, plus diamonds may be glazed over. Make a few cuts in an abrasive material to expose the diamonds.

Chain or diamonds may be worn out.

Worn drive sprocket.

PREMATURE CHAIN STRETCH

Initial chain tension too tight.

Bar nose buried in cut.

Not enough water pressure. The minimum water pressure required is 1.5 bar (20 psi).

Chain comes in contact with ground, dirt, gravel and/or sand.

CHAIN TENSIONER BREAK AGE

Side cover nuts are not tight enough. Torque to 27-33 Nm (20 -25 ft-lbs).

Tensioning with side cover nuts already tight.

Tensioner pin not aligned and side cover tightened.

WATER NOT FLOWING

Water hose is kinked or water supply not turned on.

Water ports plugged with debris.

Damaged or worn water valve in power cutter.

MOTOR DOES NOT TURN

Hydraulic lines connected backwards or power pack is set to reverse.

Chain tension is too tight.

CHAIN BREAKAGE

Improper chain tension.

Insufficient water pressure.

Inserting power cutter into slot narrower than diamond chain segments.

Using chain that is already stretched beyond ability to tension.

Contact with exposed rebar or steel.

Page 34

890F4 OPERATOR MANUAL

ENGLISH

Technical Speccations

TECHNICAL SPECIFICATIONS

890 Series 8 gpm (30 lpm) 890 Series 12 gpm (45 lpm)

Weight w/out bar and

chain (1' hose whips)

23.5 lbs (10.6 kg)

Length 23 inches (58.5 cm)

Height 10.5 inches (26.5 cm)

Width 9.5 inches (24 cm)

Hydraulic Supply

8 gpm (30 lpm) @

2,500 psi (172.5 bar)

12 gpm (45 lpm) @

2,500 psi (172.5 bar)

Hydraulic Fluid

Requirements (Type)

PC HYDREX MV32 or equivalent

Water Pressure Minimum: 20 psi (1.5 bar)

Water Flow 1 gpm (4 lpm) minimum

Operating Speed

6,100 rpm (avg. free running)

5,500 sfm (avg. free running chain)

6,500 rpm (avg. free running)

5,800 sfm (avg. free running chain)

Torq ue* 7.0 ft-lbs (9.6 Nm) 10.0 ft-lbs (13.5 Nm)

Horsepower (1)* 6 hp (4.5 kW) 8 hp (6.0 kW)

Guaranteed Sound Power

Level Lwa (2)

107 dB(A) (K=0.2 dB(A))

Equivalent Sound Pressure

at the Operator's Ear L

(2)

98 dB(A) (K=0.7 dB(A))

Vibration a

hv, eq

Concrete

Cutting (3)

2.0 m/s2 (K=0.1 m/s2) Front Handle

6.0 m/s2 (K=1.4 m/s2) Rear Handle

Vibration a

hv, eq

PowerGrit

Cutting (3)

4.6 m/s2 (K=0.1 m/s2) Front Handle

4.8 m/s2 (K=0.3 m/s2) Rear Handle

* Output ratings based on maximum input conditions and eciency assumptions and may vary depending on power supply.

((1)Measured using 18HP hydraulic power pack (8 gpm/30 lpm and 23HP hydraulic power pack (12 gpm/45 lpm) at 2000psi/138 bar. (2) Measured in accordance with ISO3744:2010 (3) Measured in accordance with ISO5349-1:2001

Page 35

890F4 OPERATOR MANUAL

Service Centers

AUTHORIZED SERVICE CENTERS

DEALER PHONE ADDRESS CITY STATE POSTAL CODE

KENNEDY EQUIPMENT CO INC 714.771.7324 748 N. LEMON ST ORANGE CA 92867

ABLE TOOL EQUIPMENT 860.289.2020 410 BURNHAM STREET SOUTH WINDSOR CT 06074

EQUIPSERV LLC 770.709.5101 6225 MABELTON PARKWAY SW MABLETON GA 30126

STAR EQUIPMENT 515.283.2215 1401 2nd AVE DES MOINES IA 50314

MCCANN INDUSTRIES, INC. 630.627.8700 543 SOUTH ROHLWING RD ADDISON IL 60101

CLEAN RITE TECH 504.468.7997 1332 FULTON ST KENNER LA 70062

ACE CUTTING EQUIPMENT 248.449.4944 25806 NOVI RD. NOVI MI 48375

CONCRETE CUTTING & CORING 952.882.0980 12690 CREEK VIEW AVE SAVAGE MN 55378

ACME ELECTRIC 218.628.3523 4332 GRAND AVE DULUTH MN 55807

MERLIN STELZER SALES CO., INC. 314.535.7540 4109 PAPIN ST ST. LOUIS MO 63110

ACME ELECTRIC 701.258.1267 3840 E. ROSSER AVE BISMARCK ND 58501

ACME ELECTRIC 701.746.6481 1705 12TH AVE NORTH GRAND FORKS ND 58203

ACME ELECTRIC 701.476.4600 920 36TH STREET S.W. FARGO ND 58103

ACME ELECTRIC 701.839.2263 700 20TH AVE S.E. MINOT ND 58701

ADMAR SUPPLY 585.272.9390 1950 BRIGHTON-HENRIETTA TL RD ROCHESTER NY 14623

ADMAR SUPPLY 315.433.5000 6014 DROTT DR EAST SYRACUSE NY 13057

ADMAR SUPPLY 518.690.0750 878 ALBANY SHAKER RD LATHAM NY 12110

ADMAR SUPPLY 607.754.4700 2305 OLD VESTAL RD VESTAL 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 LANE FORT MILL SC 29707

STAN HOUSTON EQUIPMENT 605.336.3727 501 SOUTH MARION ROAD SIOUX FALLS SD 57106

STAN HOUSTON EQUIPMENT 605.348.1155 1210 DEADWOOD AVENUE RAPID CITY SD 57702

LINCOLN CONTRACTORS SUPPLY 414.541.1327 11111 WEST HAYES AVE MILWAUKEE WI 53227

LINCOLN CONTRACTORS SUPPLY 608.249.6476 901 WALSH RD MADISON WI 53714

LINCOLN CONTRACTORS SUPPLY 715.359.6111 5207 WESTFAIR AVE SCHOFIELD WI 54476

LINCOLN CONTRACTORS SUPPLY 920.757.1901 5663 NUEBERT RD APPLETON WI 54913

LINCOLN CONTRACTORS SUPPLY 920.432.8697 1654 MORROW ST GREEN BAY WI 54302

LINCOLN CONTRACTORS SUPPLY 715.874.4100 7840 PARTRIDGE AVE EAU CLAIRE WI 54703

LEE JENSEN SALES CO, INC 815 459-0929 101 WEST TERRA COTTA CRYSTAL LAKE IL 60014

ROCK-CRETE EQUIPMENT LTD. 604 464-1448 50 BURBIDGE STREET COQUITLAM BC V3K 6B1

CONCUT DIAMOND PRODUCTS 561-989-8895 6500 W ROGERS CIRCLE SUITE 6000 BOCA RATON FL 33487

AUSTECH SUPPLIES PTY LTD 61298541200 UNIT 12, 197 POWER STREET GLENDENNING NSW 2761

HATCH BUILDING SUPPLY COMPANY 608 222-0011 5601 MANUFACTURERS DRIVE MADISON WI 53704

AMERICAN TOOL AND FASTENER 972-801-9909 1331 E PLANO PKWY STE #B PLANO TX 75074

HENARD UTILITY PRODUCTS, INC 501 268-1987 1920 S. MAIN STREET SEARCY AR 72143

Page 36

890F4 OPERATOR MANUAL

ICS, Blount, Inc.

4909 SE International Way

Portland, OR 97222, USA

Tel 800.321.1240 Fax 503.653.4393

ICS, Blount Europe S.A.

Rue Emile Francqui, 5

1435 Mont-Saint-Guibert, Belgium

Tel +32 10 301 251 Fax +32 10 301 259

icsdiamondtools.com