ICS 660GC User manual

ICS
Brand
ICS
Model
660GC
Category
Power chainsaws
Type
User manual
©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011
660GC
SERVICE MANUAL
©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011
660GC SERVICE MANUAL
1
SECTION SECTION TITLE PAGE NUMBER
SERVICE MANUAL USE 2
1 TOOLS 3
2 SAW SPECIFICATIONS 4
3 SERIAL NUMBER LOCATION 5
4 SPARE PARTS DIAGRAMS
(TORQUE SPECS & LOCTITE
®
APPLICATION) 6
5 AIR INTAKE 19
6 SPARK PLUG 21
7 CLUTCH & RIM SPROCKET 23
8 STARTER SYSTEM 27
9 WALLWALKER
®
33
10 CYLINDER COVER 35
11 MUFFLER 39
12 CARBURETOR 41
13 CYLINDER & PISTON 43
14 WATER HOSE 52
15 IGNITION COIL 53
16 FLYWHEEL 55
17 FRONT HANDLE 57
18 FUEL TANK 58
19 CRANKCASE 60
20 BAR STUDS & BAR PAD 68
21 CHAIN TENSIONER 69
22 CARBURETOR TUNING 70
23 IDLE SPEED ADJUSTMENT 74
24 TROUBLESHOOTING DIAGRAMS 75
25 TROUBLESHOOTING FUEL SYSTEM LEAKS 77
26 TROUBLESHOOTING CRANKCASE LEAKS 80
APPENDIX
1. SPARK PLUG REFERENCE GUIDE 81
©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011
660GC SERVICE MANUAL
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ServiceManualUse
Thismanualcontainsallthetechnicalinformationnecessaryforcarryingoutrepairsonthe
660GCsaw.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saw.
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ICS
®
saws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1.989.872.2131.
SERVICE MANUAL USE
©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011
660GC SERVICE MANUAL
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Key # Part No. Description MSRP
1 71521 Scrench13-19mm $10.55
2 71541 PressureGaugeBulb $47.40
3 71542 Coil/FlywheelTimingShim $5.25
4 71543 CylinderAssemblyClamps&PistonStop $10.55
5 73462 MainBearingDriverTool $38.65
6 71546 ShockAbsorberTool $22.15
7 71547 SparkTester $46.35
8 71548 FlywheelDisassemblyTool $31.45
9 71550 LimiterCapPuller $89.25
10 71565 ElectronicTachometer $240.00
11 71573 TuningScrewdriver $10.55
NotShown 71625 CarburetorTuningKit $99.95
NotShown 505882 2-StrokeOil,25:1Mix,5.2oz(158ml)(6-Pack) $18.00
NotShown 505883 2-StrokeOil,25:1Mix,5.2oz(158ml)(24-Pack) $55.00
1. TOOLS
©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011
660GC SERVICE MANUAL
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EngineType 2-strokeSingleCylinderAirCooled
Displacement 3.9cu-in(64cc)
Horsepower 4.2HP(3.1kw)@9,500RPM
Torque 32in-lbs(3.6Nm)@6,000RPM
EngineSpeed
11,500+/-500rpm(max)
2,800-3,200rpm(idle)
Weight
18.2lbs(8.3kg)withoutguidebarand
diamondchain
CutDepth Upto10inches(25.4cm)
Dimensions
17inches(44cm)length
10inches(25.5cm)height
11.6inches(29.5cm)width
AirFilter WaterResistantPolyester
Carburetor WalbroHDA225
Starter DustandWaterresistant
Ignition
Specialwaterresistantelectronic
ignition
Clutch Centrifugalthreeshoe,singlespring
FuelMixratio 25:1(4%)
FuelCapacity 0.26gallons(1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
6.2m/s
2
(fronthandle)
7.3m/s
2
(rearhandle)
EngineBreak-inPeriod
Onetank,withoutcutting,cycling
throttle
SparkPlug
ChampionCJ7Y,BoschBWS7F,or
NGKBPMR7A.
Electrodegap.020in(0.5mm)
SPECIFICATIONS
2. SPECIFICATIONS
©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011
660GC SERVICE MANUAL
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3 660GCserialnumberseries.
3. SERIAL # LOCATION
©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011
660GC SERVICE MANUAL
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4 Thissectioncoverstorque,Loctite
®
,andlubricationrequirementsoftheindividual
components.Thekeynumbersusedarenotrelatedtothekeynumbersinthe
660GCReplacementPartsPriceList.
KEY DESCRIPTION
TORQUE LOCTITE
®
PART NUMBER
Nm in‑lbs. 242
1 SPARKPLUG 27.5 243 73199
2 CYLINDERBOLT 10.7 95 X 73874
3 DECOMPRESSIONVALVE 12.8 113 71642
4 CYLINDERBASEGASKET 505439
5 COMPLETECYLINDER&PISTONASSEMBLY 505428
6 WRISTPINNEEDLEBEARING 505403
CYLINDER&PISTONASSEMBLY
2
6
4
3
5
4. SPARE PARTS DIAGRAM
©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011
660GC SERVICE MANUAL
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KEY DESCRIPTION
TORQUE LOCTITE
®
PART NUMBER
Nm in‑lbs. 242
1 CRANKCASEPLUG 505407
2 TANKPLUG 512461
3 CRANKCASE 537665
4 CRANKCASEDOWELPIN 73281
5 FUELLINEGROMMET 505627
6 CRANKCASEGROMMET 505408
7 CRANKSHAFTBEARING 505375
8 BARMOUNTINGSTUD 509555
9 TENSIONER 505393
10 BARMOUNTPADCOVERPLATE 505467
11 SCREW,5X50mm 4.9 43 X 509709
12 WASHER 73897
13 CRANKCASEBOLT 7.9 69 X 73930
14 CRANKCASEGASKET 505440
15 CHOKELEVERBUSHING 73955
16 CHOKELEVER 505409
CRANKCASEASSEMBLY
2
6
5
8
8
7
4
3
9
10
16
15
14 13
12
11
7
4. SPARE PARTS DIAGRAM
©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011
660GC SERVICE MANUAL
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4. SPARE PARTS DIAGRAM
KEY DESCRIPTION
TORQUE LOCTITE
®
PART NUMBER
Nm in‑lbs. 242
1 CRANKSHAFTSEAL 505381
2 CRANKSHAFTBEARING 505375
3 CRANKSHAFTASSEMBLY 505397
4 WRISTPINNEEDLEBEARING 505403
5 CRANKSHAFTBUSHING X 509487
KEY DESCRIPTION
TORQUE LOCTITE
®
PART NUMBER
Nm in‑lbs. 242
1 CRANKSHAFTRETAINERSEAL 540139
2 CRANKCASESEALRETAINER 505423
3 WASHER 73285
4 BOLT 2.9 26 X 73940
5 CLUTCHSPACER 505421
6 CLUTCHBEARING 505378
7 8TRIMSPROCKETKIT 70949
8 CLUTCHCUPWITHSPLINEDADAPTOR 505422
9 CLUTCHSPACERINSIDE 505436
10 CLUTCH 33.3 295 505442
11 CLUTCHSPRING 505434
CLUTCH&CRANKCASEASSEMBLY
1
11
10
9
86
7
5
4
3
2
1
5
1
2
3
2
4
©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011
660GC SERVICE MANUAL
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4. SPARE PARTS DIAGRAM
KEY DESCRIPTION
TORQUE LOCTITE
®
PART NUMBER
Nm in‑lbs. 242
1 CYLINDER-TO-MUFFLERGASKET 505385
2 MUFFLER 537692
3 MUFFLERSCREW&WASHER 8.8 78 548518f
4 LOWERMUFFLERSCREW 5.8 52 73866
MUFFLERASSEMBLY
3
4
©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011
660GC SERVICE MANUAL
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4. SPARE PARTS DIAGRAM
KEY DESCRIPTION
TORQUE LOCTITE
®
PART NUMBER
Nm in‑lbs. 242
1 SCREW 4.9 43 505469
2 WASHER 73897
3 OUTERINTAKEMANIFOLD 507427
4 OUTERINTAKEMANIFOLDFLANGESCREW 4.9 43 X 73901
5 OUTERINTAKEMANIFOLDFLANGE 505384
6 COMPENSATORTUBE 505382
7 CARBURETORSPRING 73888
8 CARBURETOR,WALBRO 517742
9 PULSETUBE 71751
10 CARBURETORMOUNTINGBRACKET 505411
11 SCREW 4.0 35 X 73866
12 ADJUSTMENTGUIDE 505391
13 INTAKEMANIFOLD 505383
14 INTAKEMANIFOLDCLAMP 1.0 11 73867
CARBURETORASSEMBLY
1
9
7
8
6
4
5
2
3
10
14
13
12
11
©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011
660GC SERVICE MANUAL
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4. SPARE PARTS DIAGRAM
KEY DESCRIPTION
TORQUE LOCTITE
®
PART NUMBER
Nm in‑lbs. 242
1 REARHANDLEHALF 548392
2 SCREW 1.0 9 73976
3 THROTTLELEVER 71749
4 THROTTLELINKAGEASSEMBLY 71750
5 TRIGGERLOCKOUTLEVERSPRING 73988
6 TRIGGERLOCKOUTLEVER 73987
7 SHOCKABSORBER 4.0 35 505387
8 SHOCKABSORBERWITHSCREW 4.0 35 505658
9 REARHANDLESHOCKABSORBER 505425
10 BUMPER,SHOCKABSORBER,FUELTANKTOP 73270
11 FUELTANK 548391
12 FRONTHANDLEBOLT 7.8 69 X 73983
13 FRONTHANDLE 548483
14 WASHER 73897
15 SCREW 8.8 78 X 73982
16 RUBBERWATERDEFLECTOR 505445
17 FUELBREATHERCOMPLETE 71748
18 FUELBREATHER,REMOTE 71761
19 FUELFILTERCLIP 71588
20 TUBECLAMP 71760
21 BREATHERTUBEELBOW 71759
22 BREATHERTUBEBODY 71751
23 FUELLINE 73375
24 FUELFILTER 73459
25 FUELCAPO-RING 73448
26 FUELCAPASSEMBLY,WITHOUTERSEALRIING 71739
FUELTANK&HANDLEASSEMBLY
1
8
9
8
7
6
5
3
2
8
7
10
11
19
24
25
26
16
15
14
22
21
20
19
18
17
13
12
23
4
©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011
660GC SERVICE MANUAL
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4. SPARE PARTS DIAGRAM
KEY DESCRIPTION
TORQUE LOCTITE
®
PART NUMBER
Nm in‑lbs. 242
1 FLYWHEELSHROUD 548514
2 FLY WH EEL 548515
3 NUT 24.5 217 73891
4 WASHER 73911
5 WASHER 73912
6 STARTERPAWLASSEMBLY 6.8 60 508852
FLYWHEELASSEMBLY
1
6
5
4
3
2
©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011
660GC SERVICE MANUAL
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4. SPARE PARTS DIAGRAM
KEY DESCRIPTION
TORQUE LOCTITE
®
PART NUMBER
Nm in‑lbs. 242
1 IGNITIONTOGGLESWITCHNUT 73239
2 IGNITIONTOGGLEPLATEON/OFF 73238
3 IGNITIONTOGGLESWITCH 73237
4 TOGGLESWITCHCONNECTINGPLATE 71449
5 IGNITIONTOGGLECABLE 73919
6 SCREW 2.9 26 X 73914
7 WASHER 73285
8 WASHER 73890
9 SPARKPLUGBOOTW/SPRING 73241
10 SPARKPLUGSPRING 73917
11 IGNITIONCOILWITHSPARKPLUGLEAD&PRIMARY 505426
IGNITIONASSEMBLY
1
5
4
3
2
6
9
11
8
7
10
©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011
660GC SERVICE MANUAL
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KEY DESCRIPTION
TORQUE LOCTITE
®
PART NUMBER
Nm in‑lbs. 242
1 SCREW 6.8 60 73230
2 STARTERROPEHANDLE 505514
3 STARTERROPE 508854
4 STARTERASSEMBLY 537666
5 STARTERCASEPLATE 71451
6 RECOILHOUSINGSCREW 505380
7 STARTERPULLEYWASHER 73905
8 STARTERASSEMBLYCAP 508853
9 STARTERPULLEYSCREW 2.9 26 X 73907
10 STARTERROPEPULLEY 508857
11 STARTERCOILSPRING&HOUSING 73909
STARTERASSEMBLY
4. SPARE PARTS DIAGRAM
5
8
1
9
7
10
11
6
4
3
2
©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011
660GC SERVICE MANUAL
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KEY DESCRIPTION
TORQUE LOCTITE
®
PART NUMBER
Nm in‑lbs. 242
1 AIRFILTERO-RING 73331
2 FILTERCOVERSCREW 4.0 35 73992
3 AIRFILTERCOVERASSEMBLY(WITH3SCREWS) 537661
4 AIRFILTERFLANGE 71758
5 AIRFILTERCANISTER,POLYESTER 71752
6 PREFILTERPLASTIC,SECONDARYFILTER 73336
7 WASHER 73897
8 CYLINDERCOVERSCREW 4.0 35 X 505429
9 FILTERSUPPORTSCREW 4.9 43 X 505437
10 FILTERSUPPORT 73338
11 CYLINDERCOVER 537660
12 O-RING 71472
13 COMPENSATORTUBE 505382
14 TUBECLAMP 71760
15 FILTERCOVERGASKET 71756
16 BREATHERGROMMET 71763
17 FILTERCANISTERGASKET 73335
AIRFILTERASSEMBLY
4. SPARE PARTS DIAGRAM
16
15
17
©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011
660GC SERVICE MANUAL
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KEY DESCRIPTION
TORQUE LOCTITE
®
PART NUMBER
Nm in‑lbs. 242
1 WATERHOSEGASKET 71469
2 FITTING 71467
3 RINGNUT 71457
4 WATERHOSEO-RING 71468
5 WATERSHUT-OFFVALVE 71458
6 FITTING 71466
7 FITTING 71454
8 HOSECLAMP 71465
9 WATERHOSE 509488
10 HOSEHANGER 71461
11 WATERHOSECOVER 71464
4. SPARE PARTS DIAGRAM
WATERDELIVERYSYSTEM
4
9
8
7
6
5
10
8
11
7
1
3
2
©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011
660GC SERVICE MANUAL
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KEY DESCRIPTION
TORQUE LOCTITE
®
PART NUMBER
Nm in‑lbs. 242
1 GUARDFLAPSCREW 71479
2 GUARDFLAPMOUNTINGBRACKET,FRONT 505491
3 GUARDFLAP 505492
NUT
5 GUARDFLAPMOUNTINGBRACKET,BACK 505490
6 GUARDFLAPNUT 505468
7 BOLT 73983
8 RUBBERBUMPER,COVER 73310
9 SIDECOVERGASKET 505417
10 MOUNTINGNUT 509852
11 RUBBERWALLWALKER 505493
12 SCREW 4.9 43 73982
13 SIDECOVERNUT 27.5 243 73958
14 SIDECOVER 537662
15 FITTING X 71454
16 SIDECOVERPLATE 505419
17 SCREW 71487
4. SPARE PARTS DIAGRAM
SIDECOVERASSEMBLY
1
9
8
7
6
5
3
2
10
16
15
14
13
12
11
4
17
©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011
660GC SERVICE MANUAL
18
4. SPARE PARTS DIAGRAM
KEY DESCRIPTION
TORQUE LOCTITE
®
PART NUMBER
Nm in‑lbs. 242
1 CARBURETORREPAIRKIT 548394
2 CARBURETORWALBRO
HDA-225 548393
CARBURETORREPAIRKIT
2
2
1
©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011
660GC SERVICE MANUAL
19
5. AIR INTAKE
5 Thissectioncoversthe
disassembly,inspection,and
assemblyoftheairinduction
system.
5.1 Loosentheairfiltercoverscrews
andremoveairfiltercover.
5.2 Removeairfilterfromcover.
A Inspectairfilter.
B Replaceifnecessary(P/N71752).
5.3 Removesecondaryfilterfrom
airfiltermount.
A Cleansecondaryfilterwithcleaning
solutionandanylonbrush.
B Letdryandreinstall.
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ICS 660GC User manual

ICS
Brand
ICS
Model
660GC
Category
Power chainsaws
Type
User manual
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