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ICS 633GC Manual

Cut-off saw
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633GC Cut-Off Saw
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  • Page 1 633GC Cut-Off Saw Shop Manual...

  • Page 3: Table Of Contents

    WATER HOSE & CAP IGNITION COIL FLYWHEEL BOTTOM GUARD FRONT HANDLE FUEL TANK CRANKCASE BAR STUD TENSIONER CARBURETOR TUNING IDLE SPEED ADJUSTMENT TROUBLESHOOTING DIAGRAMS TROUBLESHOOTING: FUEL SYSTEM LEAKS TROUBLESHOOTING: CRANKCASE LEAKS APPENDIX . SPARK PLUG REFERENCE GUIDE Copyright © 2005 ICS, Blount Inc.

  • Page 4: Shop Manual Use

    This manual contains all the technical information necessary for carrying out repairs on the 633GC cut-off 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 cut-off saw.

  • Page 5: Tools

    633GC SHOP MANUAL 1. TOOLS 633GC Service Tool Kit - P/N 7700 DESCRIPTION 752 SCRENCH 754 PRESSURE GAUGE BULB 7542 COIL/FLYWHEEL TIMING SHIM 7543 CYLINDER ASSEMBLY CLAMPS & PISTON STOP 7546 63 SHOCK ABSORBER TOOL 7547 SPARK TESTER 7548 63 FLYWHEEL DISASSEMBLY TOOL...

  • Page 6: Saw Specifications

    Champion RCJ-7Y (for conversion chart see appendix) Clutch Three-weight, single spring, centrifugal Fuel Mix Ratio 25: gasoline to oil with oil brand name gasoline and ICS 2-stroke ® engine oil, or other high quality 2-stroke engine oil for air cooled engines.

  • Page 7: Serial Number Location

    633GC SHOP MANUAL 3. SERIAL # LOCATION 3 This section shows the two locations of the serial number. Copyright © 2005 ICS, Blount Inc.

  • Page 8: Spare Parts Diagram

    633GC SHOP MANUAL 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 633GC Replacement Parts Price List. TORQUE LOCTITE ® DESCRIPTION PART NUMBER in‑lbs.
  • Page 9 WRIST PIN SNAP RING 73259 PISTON WRIST PIN 73208 COMPLETE CYLINDER/PISTON ASSEMBLY 73442 CRANKSHAFT FLYWHEEL WOODRUFF KEY 73264 CRANKSHAFT BEARING (FLYWHEEL END) 73209 CRANKSHAFT ASSEMBLY 73443 CRANKSHAFT BEARING (CLUTCH SIDE) 73200 CRANKCASE OUTSIDE SEAL-CLUTCH SIDE 73202 Copyright © 2005 ICS, Blount Inc.
  • Page 10 4. SPARE PARTS DIAGRAM 633GC SHOP MANUAL Copyright © 2005 ICS, Blount Inc.
  • Page 11 TUBE FITTING-BACKSIDE BAR MOUNT 73386 COVER GUARD MOUNTING WASHER 73396 COVER GUARD MOUNTING BOLT 73397 COVER GUARD 70967 WATER TUBE O-RING 7468 633GC PLASTIC CAP 504389 Not Shown. Gasket Set, includes parts 73434, 73436, 73456 73435 Copyright © 2005 ICS, Blount Inc.
  • Page 12 633GC SHOP MANUAL TORQUE LOCTITE ® DESCRIPTION PART NUMBER in‑lbs. WASHER 73897 SHOULDER SCREW, HAND GUARD 7436 633GC SIDE COVER PLUG KIT 744 633GC HAND GUARD 7435 SCREW 73284 COVER SIDE BAR PLATE 73309 RUBBER BUMPER, COVER 7330 COVER RUBBER FLAP...
  • Page 13 CARBURETOR STANDOFF SUPPORT 73387 BOLT 73278 CARBURETOR SUPPORT SCREW 73340 CARBURETOR MIXTURE SCREW GROMMET 7334 CARBURETOR 73454 INSULATOR TO CYLINDER GASKET 73455 CARBURETOR INSULATOR 73344 INSULATOR FOAM GASKET 73345 CARBURETOR TO INSULATOR GASKET 73456 Copyright © 2005 ICS, Blount Inc.
  • Page 14 FUEL CAP O-RING 73448 FUEL TANK SCREW 73372 FUEL FILTER 73459 FUEL LINE 73375 FUEL BREATHER PIPE 73376 SHOCK ABSORBER 73377 WASHER 73250 SCREW (REAR HANDLE, UPPER) 73379 BUMPER, SHOCK ABSORBER, FUEL TANK TOP 73270 Copyright © 2005 ICS, Blount Inc.
  • Page 15 WATER HOSE COVER 7464 WATER SHUT-OFF VALVE 7458 WATER HOSE O-RING 7468 RING NUT 7457 FITTING 7467 WATER HOSE GASKET 7469 WASHER 7395 GUARD FLAP SPACER 7480 633GC WALLWALKER LEVER ARM 504387 GUARD FLAP SCREW 7479 Copyright © 2005 ICS, Blount Inc.

  • Page 16: Air Intake 4

    Remove filter canister cover and air filter. Inspect air filter. Replace filter if necessary (P/N 7752) Remove pre filter from air filter mount. Clean filter with cleaning solution and water. Let dry and reinstall. Copyright © 2005 ICS, Blount Inc.
  • Page 17 Make sure filter canister gasket and air filter water seal are secure. Replace air filter water seal if it is damaged, permanently depressed, hard due to slurry, or missing (P/N 779). Assemble filter system in the reverse order. Copyright © 2005 ICS, Blount Inc.

  • Page 18: Spark Plug 6

    Remove the spark plug lead. Clean area around the spark plug to prevent debris from entering the cylinder. Remove the spark plug. Inspect the spark plug. If dirty clean with a wire brush as shown. Copyright © 2005 ICS, Blount Inc.
  • Page 19 Gap if necessary to 0.20” (0.5 mm). NOTE: If the sparkplug must be replaced refer to the Spark Plug Reference Guide on page 70. Assemble in the reverse order. Make sure the plug boot is seated completely. Copyright © 2005 ICS, Blount Inc.

  • Page 20: Clutch & Rim Sprocket 8

    Refer to sections 5 and 6 if necessary. Insert piston stop tool into spark plug hole. Pull starter handle until piston stops against tool. Remove clutch shield with small screwdriver. Copyright © 2005 ICS, Blount Inc.
  • Page 21 7. and 7.2 do not have to be performed. Remove all drive components. Inspect the clutch shoes for wear. Replace if the shoe has less than 0.04” ( mm) of material, as shown. Copyright © 2005 ICS, Blount Inc.
  • Page 22 7. CLUTCH & RIM SPROCKET 633GC SHOP MANUAL Inspect spring for cracks. Assemble clutch shoes as shown. Finish installation of clutch shoe as shown. Copyright © 2005 ICS, Blount Inc.
  • Page 23 Grease clutch cup bearing with a waterproof grease (ICS P/N 70885). ® Assemble clutch: use spacer washer, bearing, clutch cup with rim sprocket, inside clutch spacer washer, and clutch assembly. 7.2 Install clutch. Tighten firmly. Left hand threads. Copyright © 2005 ICS, Blount Inc.
  • Page 24 Pull 4-6” (0-5 cm) of rope out. Line rope up with notch on pulley. Slowly rotate pulley counterclockwise until spring pressure is released. Use thumb as a brake. Remove starter pulley screw and washer. NOTE: Hold starter cover firmly. Copyright © 2005 ICS, Blount Inc.
  • Page 25 Replace if spring hook is damaged. Attempting to re-bend the spring hook may cause the hook to break off. Carefully remove coil spring and housing to prevent spring from unwinding. Apply light weight oil. Replace parts carefully. Copyright © 2005 ICS, Blount Inc.
  • Page 26 Wind rope onto pulley clockwise leaving 4-6” (0-5 cm) out. Make sure that the pulley spring catch is in the spring hook. 8.3 Install center screw. Use blue Loctite ® Torque to 26 in-lbs. (2.9 Nm). Copyright © 2005 ICS, Blount Inc.
  • Page 27 Assemble starter cord shield. 8.6 Remove starter pawl snap rings, pawls, spring, and plain washer. 8.7 Inspect and clean pawl components. Inspect the components. Replace if necessary. Clean the components with a brush and solvent. Copyright © 2005 ICS, Blount Inc.
  • Page 28 8.9 Install starter cover. Pull out cord 4-6” (0-5 cm). Slowly release while placing cover to allow pawls to engage. 8.20 Install starter cover screws. Use blue Loctite”. Torque to 60 in-lbs. (6.8 Nm). Copyright © 2005 ICS, Blount Inc.

  • Page 29: Wallwalker

    Remove crankcase screws and wave washers. Remove WallWalker from saw. ® Remove guard flap screws and washer. Remove and inspect guard flap. Replace the flap if it is torn or damaged in any way. Copyright © 2005 ICS, Blount Inc.
  • Page 30 9. WALLWALKER 633GC SHOP MANUAL Assemble in the reverse order. Install crankcase screws and wave washers. Use blue Loctite ® Torque to 70 in-lbs. (7.9 Nm). Copyright © 2005 ICS, Blount Inc.

  • Page 31: Cylinder Cover

    Partially remove intake manifold from cylinder cover while lifting cylinder cover away from saw. 0.4 Inspect cylinder cover for damage. Replace if necessary. 0.5 Make sure carburetor screw boot and cylinder cover plug are in place. Copyright © 2005 ICS, Blount Inc.
  • Page 32 Push the cylinder cover down on the crankcase, guide intake manifold into cylinder cover. 0.7 Push down cylinder cover until it sits flat on crankcase. Install the cylinder cover screws using blue Loctite ® Torque to 35 in-lbs. (4.0 Nm). Copyright © 2005 ICS, Blount Inc.

  • Page 33: Muffler

    04 in-lbs. (.75 Nm). Bend muffler screw locking plate over flat edge of muffler screw. Install muffler support bracket nut (use blue Loctite ); torque to 26 in- ® lbs. (2.9 Nm). Copyright © 2005 ICS, Blount Inc.

  • Page 34: Carburetor

    Refer to sections 5 and 0. If necessary, carburetor tuning is covered in section 23. 2. Remove fuel line from carburetor and plug. 2.2 Remove choke lever from carburetor. 2.3 Remove carburetor attachment screws. Copyright © 2005 ICS, Blount Inc.
  • Page 35 12. CARBURETOR 2.4 Remove intake manifold. 2.5 Remove carburetor. Lift and twist carburetor away from throttle linkage to remove. 2.6 Assemble in the reverse order. Torque carburetor body screws to 43 in-lbs. (4.9 Nm). Copyright © 2005 ICS, Blount Inc.

  • Page 36: Cylinder & Piston

    Removal of several component groups is required. Refer to sections 5, 6, 0, and 2 if necessary. 3. Remove insulator base screws. Remove carburetor insulator from cylinder. 3.2 Remove cylinder screws (4) and wave washers. Copyright © 2005 ICS, Blount Inc.
  • Page 37 3.3 Remove cylinder. Remove cylinder gasket and clean case. 3.4 Remove wrist pin retaining clips 3.5 Press wrist pin out with an 8 mm deep socket. 3.6 Remove piston and inspect. Replace if damaged. Copyright © 2005 ICS, Blount Inc.
  • Page 38 Remove wrist pin bearing. 3.8 Cylinder gasket Oil gasket with ICS 2-stroke ® engine oil. Install gasket and align holes and notch. 3.9 Install wrist pin bearing in rod. Oil bearing with ICS 2-stroke ® engine oil. Copyright © 2005 ICS, Blount Inc.
  • Page 39 633GC SHOP MANUAL 13. CYLINDER & PISTON 3.0 Install rings. 3. Ring orientation. 3.2 Install one wrist pin retaining clip. Copyright © 2005 ICS, Blount Inc.
  • Page 40 13. CYLINDER & PISTON 633GC SHOP MANUAL 3.3 Make sure wrist pin retaining clip is in the proper orientation. 3.4 Lubricate wrist pin and partially install in piston. 3.5 Align piston in correct orientation. EXHAUST INTAKE Copyright © 2005 ICS, Blount Inc.
  • Page 41 Compress rings with ring compression tool. Slide cylinder onto piston, pushing ring compression tool down. 3.8 Install cylinder. Remove ring compressor. Slide cylinder onto piston and into crankcase. Align cylinder bolt holes with crankcase. Copyright © 2005 ICS, Blount Inc.
  • Page 42 3.9 Install 4 cylinder screws and washers. Use blue Loctite ® Torque bolts to 04 in-lbs. (.75 Nm). 3.20 Install insulator base. Install insulator base screws, use blue Loctite and torque to 52 in-lbs. ® (6 Nm). Copyright © 2005 ICS, Blount Inc.

  • Page 43: Water Hose & Cap

    This section covers water hose and water tank cap. 4. Remove water connection from hose end. 4.2 Remove starter cover screw with hose hanger from saw. 4.3 Remove water hose connector. 4.4 Unscrew water tank cap from saw. Copyright © 2005 ICS, Blount Inc.
  • Page 44 14. WATER HOSE 633GC SHOP MANUAL 4.5 Release water tank cap from water tank tube. Depress orange fitting as shown. 4.6 Assemble in the reverse order. Copyright © 2005 ICS, Blount Inc.

  • Page 45: Ignition Coil

    Remove starter flywheel shroud by unhooking wires. 5.3 Remove ignition coil screws, wave washers and plain washers. 5.4 Remove ignition coil. 5.5 Inspect. Look for cracked/missing insulation. Clean flywheel magnets and coil if rusty. Copyright © 2005 ICS, Blount Inc.
  • Page 46 52 in-lbs. (5.9 Nm). Remove shim, rotate flywheel to check clearance. Route ignition stop switch wire through crankcase into carburetor chamber. Install wire grommet in crankcase. 5.7 Complete ignition wire routing and assemble saw in reverse order. Copyright © 2005 ICS, Blount Inc.

  • Page 47: Flywheel

    6.3 Install flywheel puller bolts (3) finger tight. Turn main puller bolt clockwise with wrench until flywheel releases from the crankshaft. 6.4 Inspect & clean flywheel. Replace if any of the fins are broken. Copyright © 2005 ICS, Blount Inc.
  • Page 48 16. FLYWHEEL 633GC SHOP MANUAL 6.5 Inspect woodruff key. Replace if broken or damaged. 6.6 Install flywheel, plain washer, wave washer, and flywheel nut. Torque nut to 390 in-lbs. (44 Nm). Copyright © 2005 ICS, Blount Inc.

  • Page 49: Bottom Guard

    633GC SHOP MANUAL 17. BOTTOM GUARD This section covers the removal inspection, and installation of the bottom guard. Remove bottom guard screws and split washers. Inspect bottom guard. Replace if damaged. Assemble in reverse order Copyright © 2005 ICS, Blount Inc.

  • Page 50: Front Handle

    Remove front handle screws on right side. 8.2 Remove front handle screws on bottom. 8.3 Install front handle. Roll front handle into place. Install front handle screws (4). Use blue Loctite ® Torque to 43 in-lbs. (4.9 Nm). Copyright © 2005 ICS, Blount Inc.

  • Page 51: Fuel Tank

    9.2 Remove vibration isolator screws and wave washers on flywheel side of saw. NOTE: Flywheel and cylinder cover do not need to be removed to perform fuel tank maintenance. Copyright © 2005 ICS, Blount Inc.
  • Page 52 9.4 Remove vibration isolators from fuel tank (6) if necessary. 9.5 Separate the fuel tank halves. Remove the rear handle. Remove the screws (9) around the tank. Copyright © 2005 ICS, Blount Inc.
  • Page 53 Clean the joining surface of the tank halves. Assemble in the reverse order. NOTE: Use a fuel proof liquid gasket material to reseal the tank (Scotch Grip #847) when ® assembling fuel tank. Copyright © 2005 ICS, Blount Inc.

  • Page 54: Crankcase

    20. CRANKCASE 633GC SHOP MANUAL This section covers the disassembly, inspection, and assembly of the crankcase seals and crankshaft bearings. 20. Remove outer crankshaft seal housing screws and wave washers. 20.2 Remove crankcase bolts. Copyright © 2005 ICS, Blount Inc.
  • Page 55 50° F (65.5° C). 20.4 To remove the flywheel side of crankcase; tap crankshaft with plastic mallet. Suspend above work surface. Tap with mallet. 20.5 Remove the flywheel side of crankcase seal. Copyright © 2005 ICS, Blount Inc.
  • Page 56 To remove crankshaft from the clutch side of crankcase. Tap crankshaft with a plastic mallet. Suspend above work surface. Tap with plastic mallet. 20.8 Remove the bearing from the flywheel side of crank shaft. Copyright © 2005 ICS, Blount Inc.
  • Page 57 Remove the bearing, seal, and bushing from the clutch side of crankshaft. 20.0 Clean mating crankcase faces. 20. Heat crankcase halves to 50° F. 20.2 Install bearing into crankcase halves. 20.3 Tap with bearing driver and mallet. Copyright © 2005 ICS, Blount Inc.
  • Page 58 20. CRANKCASE 633GC SHOP MANUAL 20.4 Repeat with other half. 20.5 Install crankshaft into clutch side of case. 20.6 Place clutch side of crank case seal on crankshaft. Tap lightly with bearing driver and mallet. Copyright © 2005 ICS, Blount Inc.
  • Page 59 633GC SHOP MANUAL 20. CRANKCASE 20.7 Coat crankcase gasket with ICS ® 2-stroke engine oil. 20.8 Align crankcase gasket on flywheel side crankcase pins. 20.9 Place crankcase halves together and align crankcase pins. Copyright © 2005 ICS, Blount Inc.
  • Page 60 Use blue Loctite ® Torque to 70 in-lbs. (7.9 Nm). NOTE: Tighten bolts hand tight, then torque bolts in sequence listed at right. 20.22 Install flywheel side crankcase seal – tap with bearing driver and mallet. Copyright © 2005 ICS, Blount Inc.
  • Page 61 633GC SHOP MANUAL 20. CRANKCASE 20.23 Trim crankcase gasket flush. Copyright © 2005 ICS, Blount Inc.

  • Page 62: Bar Stud

    Tighten side cover nuts against each other. Attempt to remove the inside nut which should pull out the bar stud. Repeat on second bar stud. 2.2 Assemble in reverse order using blue Loctite ® Copyright © 2005 ICS, Blount Inc.

  • Page 63: Tensioner

    This section covers the removal and installation of the chain tensioner. 22. Remove bar plate to expose the chain tensioner. 22.2 Unscrew tensioner to remove. Remove tensioner pin. Remove tensioner screw keeper. 22.3 Assemble in reverse order. Copyright © 2005 ICS, Blount Inc.

  • Page 64: Carburetor Tuning

    Basic Setting – if the carburetor needs to be completely readjusted, see following procedure: A Pull limiter caps using ICS P/N 7625. ® B Gently turn both adjusting screws (H and L) clockwise as far as possible.
  • Page 65 23.5 Set the adjustment screws at the Basic Setting: H =  turn counterclockwise from closed L =  /2 turns counterclockwise from closed Copyright © 2005 ICS, Blount Inc.
  • Page 66 H screw out (counterclockwise) /6 of a turn at a time. Pulse the throttle to help stabilize the system. Do not hold the saw at maximum rpm for more than 5 seconds. Copyright © 2005 ICS, Blount Inc.
  • Page 67 633GC SHOP MANUAL 23. CARBURETOR TUNING 23. When the carburetor is adjusted correctly set the limiter caps with a ¼” straight blade screwdriver. H = horizontal L = vertical Copyright © 2005 ICS, Blount Inc.

  • Page 68: Idle Speed Adjustment

    Make sure the chain is properly tensioned. Turn T screw clockwise until chain begins to move. Back T screw out ½ turn. 24.2 If chain turns at idle: Back T screw out until chain stops moving. Copyright © 2005 ICS, Blount Inc.

  • Page 69: Troubleshooting Diagrams

    • Broken clutch spring. • Replace clutch spring. • Damaged shock absorber. • Replace shock absorbers. • Damaged or broken Excessive vibration. • Replace flywheel. flywheel fins. • Replace crankshaft. • Bent crankshaft. Copyright © 2005 ICS, Blount Inc.
  • Page 70 • Carburetor is tuned section reaching the incorrectly • Repair or replace fuel tank carburetor? • Plugged fuel tank breather breather Is the flywheel key • Loose flywheel • Replace key and reinstall flywheel sheared? Copyright © 2005 ICS, Blount Inc.

  • Page 71: Troubleshooting: Fuel System Leaks

    Install the pressure gauge and bulb to filter end of fuel line. Pressurize the tube to 7 psi (0.5 bar). If the pressure does not maintain, separate the fuel line from the carburetor. Copyright © 2005 ICS, Blount Inc.
  • Page 72 Plug the fuel line at the carburetor end. Pressurize the tube to 4.5 psi (0.3 bar). The pressure should reduce to nearly 0 psi (0 bar) over about 3 seconds. Copyright © 2005 ICS, Blount Inc.
  • Page 73 If the pressure does not reduce to 0 psi, disassemble or replace the breather. Clean the parts with fuel for the cut-off saw. Assemble in reverse order. Make sure that the spring taper is oriented in the correct direction. Copyright © 2005 ICS, Blount Inc.

  • Page 74: Troubleshooting: Crankcase Leaks

    Pressurize the crankcase to 7 psi (0.5 bar). 27.5 If the pressure does not remain the same, use soapy water to find the leak. NOTE: It is recommended that this test be performed after an engine rebuild. Copyright © 2005 ICS, Blount Inc.

  • Page 75: Appendix

    1 The Spark Plug Reference Guide is to be used as a guide only. When trying a plug from a different manufacturer, perform a plug check to be sure that the plug will work. SPARK PLUG REFERENCE GUIDE ICS RESISTOR CHAMPION NGK RESISTOR BOSCH RESISTOR RESISTOR 7399 RCJ7Y BPMR7A WSR7F Copyright © 2005 ICS, Blount Inc.
  • Page 76 ICS, Blount Inc. 4909 SE International Way Portland, Oregon 97222 TEL 800-32-240 FAX 503-653-4393 www.icsbestway.com p/n 7537...

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