ICS MERIT - User Manual

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Rev 12.17.19

TROUBLESHOOTING

The following contains general troubleshooting problems and solutions for Merit at saws, please

refer to the Owner’s Manual that is specic to your saw. If you do not have a manual or do not know the

model of your saw, please check the ID Plate located in the lower rear control panel near the battery.

For additional questions, or to request a copy of the Owner’s Manual,

please email: Service@icsdiamondtools.com.

Problem Possibilities Solution (see “How to”) How to

Saw will not

raise, or

rises slowly out

of the cut

Pump pressure set too low

Low hydraulic oil/leaking oil

Bad lift pump

Increase pump pressure

Replace lift pump

Call service for support

Pump pressure can be increased or decreased

by adjusting the pressure relief setting located

on the pump manifold. Make small adjustments

and recheck - Add blade guard(s) to the front of

the saw for extra load weight.

Loss of 12v power supply

Check connections to the solenoid

Check ground connection to the pump

Check connections at the battery posts

Check solenoid

Check battery charge

Make sure there are no cracks or breaks in the

copper solenoid bracket, and battery posts/

conections are tight and free of debris.

Test solenoid using a multimeter or

other device, check the battery for

proper voltage.

Hydraulic oil leak or low oil level

Check ttings and hoses for leaks, and

check oil level in reservoir

Inspect the ttings, connections and along the

hose routing for oil leaks and seepage.

Note: always support the weight of the saw

when working with a raised hydraulic system

(under pressure). Reservior contains 1 qt of ATF.

Standard (Mechanical lever)

models- valve is partially

open when lever is in the

closed position

Make sure red lever (under control

panel) is in the closed position

Review Raise/Lower instruction sheet,

call service for assistance

Remove the rear panel to access the red

lever. Loosen the 5/16 bolt and nut holding

the red lever to the main body assembly. Push

red lever forward until the valve has reseated.

Tighten bolt and nut on red lever to secure to

main body.

Button Style models

(electric version) - dump valve

bypass is stuck open

Replace valve

Lower the saw completely to relieve all pressure

in the valve and system. Locate the valve from

the manifold and replace. See technical sheets.

Faulty check-valve in the pump

manifold

Remove check-valve and inspect for

debris that may cause stuck valve or

faulty spring

Lower the saw completely to relieve all pressure

in the valve and system. Remove the raise

control valve and tting to expose the

check-valve inside of the pump manifold. Using

a 3/8 allen wrench, turn clockwise and remove

set screw. Visually inspect for debris.

Compressed air may be used to clear.

See technical sheets.

Need help?

Do you have a question about the ICS MERIT and is the answer not in the manual?

Summary

Troubleshooting Saw Raising Issues

Low Pump Pressure or Hydraulic Oil Problems

Addresses low pump pressure, low hydraulic oil, leaks, and bad lift pumps.

Electrical and Valve Issues for Saw Raising

Covers loss of 12v power, faulty solenoids, and stuck dump valves.

Mechanical Valve and Check-Valve Faults

Details issues with partially open standard valves and faulty check-valves.

Troubleshooting Engine Overheating and Fan Issues

Cooling Fan Not Operating

Diagnoses blown fuses, faulty temperature sensors, and bad relays affecting the fan.

Engine Overheating Causes

Covers loss of 12v power, loose or broken belts, and damaged fan blades.

Troubleshooting Saw Movement and Traction

Mechanical Fan and Drive Shaft Problems

Addresses slow or non-turning fans and issues with the right angle drive shaft.

Positraction and Wheel Lock Issues

Details problems with the differential, positraction engagement, and slurry buildup.

Troubleshooting Saw Starting Problems

Basic Starting Checks

Covers emergency stop, damaged contact blocks, dead battery, and loose cables.

Engine Component Failures

Addresses bad starter, ignition switch, ECU connections, and fuel system issues.

Summary

Troubleshooting Saw Raising Issues

Low Pump Pressure or Hydraulic Oil Problems

Addresses low pump pressure, low hydraulic oil, leaks, and bad lift pumps.

Electrical and Valve Issues for Saw Raising

Covers loss of 12v power, faulty solenoids, and stuck dump valves.

Mechanical Valve and Check-Valve Faults

Details issues with partially open standard valves and faulty check-valves.

Troubleshooting Engine Overheating and Fan Issues

Cooling Fan Not Operating

Diagnoses blown fuses, faulty temperature sensors, and bad relays affecting the fan.

Engine Overheating Causes

Covers loss of 12v power, loose or broken belts, and damaged fan blades.

Troubleshooting Saw Movement and Traction

Mechanical Fan and Drive Shaft Problems

Addresses slow or non-turning fans and issues with the right angle drive shaft.

Positraction and Wheel Lock Issues

Details problems with the differential, positraction engagement, and slurry buildup.

Troubleshooting Saw Starting Problems

Basic Starting Checks

Covers emergency stop, damaged contact blocks, dead battery, and loose cables.

Engine Component Failures

Addresses bad starter, ignition switch, ECU connections, and fuel system issues.

Overview

Function Description
Important Technical Specifications (Derived from Troubleshooting Context)
Usage Features
Maintenance Features

This document provides troubleshooting information for Merit flat saws, designed to assist users in diagnosing and resolving common operational issues. It covers a range of problems related to the saw's hydraulic system, engine, cooling, and starting mechanisms.

Function Description:

The Merit flat saw is a robust piece of equipment used for cutting concrete and other hard surfaces. Its primary function is to provide precise and efficient cutting for various construction and demolition tasks. The saw incorporates a hydraulic system for raising and lowering the blade, an engine for power, and a cooling system to maintain optimal operating temperatures. The troubleshooting guide is intended to help users maintain the saw's functionality and address common malfunctions that may arise during operation.

Important Technical Specifications (Derived from Troubleshooting Context):

Hydraulic System: The saw utilizes a hydraulic system for blade lift and control. Key components include a lift pump, pressure relief setting, solenoid, and a reservoir that holds 1 quart of ATF (Automatic Transmission Fluid). The system operates under pressure, and proper oil levels and leak-free connections are critical for its function.
Electrical System: A 12V power supply is essential for various electrical components, including the lift pump solenoid, engine starter, and cooling fan. The system includes a 40A fuse in the wire harness for the cooling fan, battery posts, and connections that need to be tight and free of corrosion.
Engine and Cooling System: The saw is equipped with an engine that requires a cooling system to prevent overheating. This system includes a cooling fan, a temperature sensor (triggering at 180 degrees F), and a relay. The engine also has an ignition switch, an ECU (Engine Control Unit), a fuel pump, and a fuel filter.
Mechanical Components: The saw features mechanical elements such as a differential, a positraction system, and a right-angle drive shaft. Belts are used in the mechanical fan system, and their tension is adjustable via a blue tensioner.

Usage Features:

Blade Control: The saw's blade can be raised and lowered using a hydraulic system. Users can adjust the pump pressure via a pressure relief setting on the pump manifold for fine-tuning blade control.
Safety Features: An emergency stop mechanism is integrated into the saw, which can be disengaged by pulling and twisting. When working with a raised hydraulic system, it is crucial to support the weight of the saw to ensure safety.
Positraction System: The positraction system can be engaged or disengaged using a cable. The differential cable should be pulled into neutral and twisted to lock the lever in position. To disengage, the "Pull" cable needs to be pushed down.
Engine Start: The saw starts via an ignition switch, and the fuel pump has an audible sound when the key is turned to the "on" position.
Troubleshooting Guidance: The manual provides clear "How to" steps for each troubleshooting solution, guiding users through adjustments, inspections, and part replacements. For instance, it details how to adjust pump pressure, check electrical connections, and inspect mechanical components.

Maintenance Features:

Hydraulic System Maintenance: Regular checks of hydraulic oil level in the reservoir and inspection for leaks in fittings and hoses are essential. The reservoir holds 1 quart of ATF.
Electrical System Maintenance: Users should regularly inspect battery posts and connections for tightness and corrosion. The 40A fuse in the cooling fan's wire harness should be visually inspected.
Engine and Fuel System Maintenance: The fuel tank should be visually inspected for fuel levels (not relying solely on a gauge). The fuel filter needs to be inspected and replaced if clogged or dirty. The engine's ECU connections and ignition switch should be checked for continuity and corrosion.
Cooling System Maintenance: The cooling fan and fan blades should be kept clear. The tension of the fan belt can be adjusted using a blue tensioner.
Mechanical System Maintenance: Belts should be checked for looseness or breakage. The positraction system's shift fork spring may require lubrication with oil or WD-40 to ensure proper release.
Part Replacement: The guide frequently refers to replacing specific parts such as the lift pump, solenoid, relay, belts, right-angle drive box, fan, and various valves. Users are directed to "See parts manual for required parts" or "See technical sheets" for detailed instructions on these replacements.
Professional Support: For complex issues, such as a faulty lift pump, ECU problems, or electrical starter issues, the guide recommends calling service for support or having the component electrically inspected.
Documentation Reference: The document emphasizes referring to the specific Owner's Manual for the saw and checking the ID Plate for model identification. It also suggests reviewing "Raise/Lower instruction sheet" and "technical sheets" for detailed procedures.

ICS MERIT Specifications

General

Brand	ICS
Model	MERIT
Category	Saw
Language	English

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