ICS 633GC User manual

© Copyright ICS 2003 P/N 70944 Dec 03
633GC
Concrete Cutting Chainsaw
OPERATOR’S MANUAL
ICS, Blount Inc.
4909 SE International Way
Portland, OR 97222
www.icsbestway.com

633GC OPERATOR’S MANUAL
2
TABLE OF CONTENTS
SYMBOLS & LABELS 3
SAFETY 4
TECHNICAL SPECIFICATIONS 7
SET-UP 8
OPERATION 10
MAINTENANCE 15
TROUBLESHOOTING 24
REFERENCE 25

633GC OPERATOR’S MANUAL
3
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
WARNING
CAUTION
IMPORTANT

633GC OPERATOR’S MANUAL
4
SAFETY
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 chain breakage and injury.
•DO NOT operate a diamond chainsaw with a damaged, modified, broken, or missing side
cover, bottom guard, or guard flap. The side cover, bottom guard, and guard flap provides
protection against contact with moving parts, ejected debris, broken chain, thrown water and
concrete slurry.
•DO NOT install or run the chain backwards. The bumper must lead the segment into the cut.
•DO NOT insert a diamond chainsaw into a slot narrower than the 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 chain.
•DO NOT run a diamond chainsaw upside-down. Concrete debris can fly back into the
operator’s face.
•DO NOT cut ductile iron pipe with the diamond chainsaw. Segment loss or chain breakage
may occur.
WARNING
Bumper

633GC OPERATOR’S MANUAL
5
SAFETY
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 diamond chainsaw OFF when performing maintenance on the saw including
chain tensioning.
•Never use equipment that is not functioning properly. Have the saw repaired by qualified
service personnel.
•Turn engine OFF before refueling. Keep away from open flame. Always provide for good
ventilation when handling fuel. Move diamond chainsaw at least 10 feet (3 m) away from
refueling area before starting.
•SealPro™ diamond chains require a minimum water pressure of 20 psi (1.4 bar). Insufficient
water supply may result in excessive wear to the chain, which can lead to loss of strength and
chain breakage.
•Never start a diamond chainsaw unless the bar, chain and side cover
are properly installed.
GENERAL SAFETY PRECAUTIONS
•Always wear protective clothes, 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.
CAUTION

633GC OPERATOR’S MANUAL
6
SAFETY
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 diamond chainsaw is equipped with a two-stroke engine and must always be run using
a mixture of gasoline and two-stroke engine oil. 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 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 can result in a piston seizure and
damage to the engine.
•Use “high quality” two-stroke engine oil, which is specifically developed for chain saws. Fuel
mixture: 4%, 25:1 gasoline/oil mixture. This is twice as much oil as 50:1. Incorrect fuel
mixture is the number one cause of piston seizure failure.
•Never use two-stroke oil intended for water-cooled engines, such as outboard engine oil.
•Never use oil intended for four-stroke engines.
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 fuel at idle, cycling the throttle every 5 to 10
minutes to prevent loading.
•Failure to break-in an engine can result in piston seizure.
IMPORTANT

633GC OPERATOR’S MANUAL
7
TECHNICAL SPECIFICATIONS
Engine 2 Stroke, Air cooled
Displacement 101cc (6.2 cu in)
Horsepower 6.5 HP (4.8kw) @ 8700 RPM
Carburetor Walbro WGAK3, Throttle shaft sealed
Idling Speed 2800-3200 rpm
No Load Maximum Speed 11,500+/-500 rpm, Mechanically governed
Ignition Selettra electronic – Water resistant
Spark Plug Champion CJ7Y or Bosch BWS7F
Fuel ratio 4%, (25:1 gasoline/oil)
Fuel Capacity 1 Liter (34oz)
Clutch Centrifugal, three shoe, single spring
Weight with Bar and Chain 27.5 lbs (12.5kg)
Bar Lengths 14 in (36cm) & 16 in (41cm)
Actual Cutting Lengths 14 in (36cm) & 16.2 in (41cm)
Vibration Level 8 meters/sec² (front handle)
Noise Level 102dB at 3 ft (1m)
Water Pressure Requirements Minimum: 20 psi (1.4 bar)
Water Flow Requirements 2 gpm(8 lpm) minimum
Chain Speed 4,950 fpm (25m/s), free running)
Engine Break-in Period One tank, without feed load, cycling throttle

633GC OPERATOR’S MANUAL
8
SET-UP
BAR AND CHAIN INSTALLATION
STEP 5
Make sure all the drive links are inside the bar
groove then pre-tension the chain.
STEP 1
Disconnect chain brake arm, loosen side cover
nuts and remove side cover.
STEP 3
Move chain adjuster pin back towards drive
sprocket by turning chain-tensioning screw
counter clockwise.
STEP 4
Mount the chain on the bar starting at the
drive sprocket & continue over the bar nose.
Install the chain correctly. The bumper must
always lead the segment into
the cut as shown here.
STEP 2
Place bar onto studs and chain adjustment pin.

633GC OPERATOR’S MANUAL
9
SET-UP
BAR AND CHAIN INSTALLATION
Note 1: Be aware that the bar rails may develop sharp edges over time so always pull the chain by the
diamond segments.
Note 2: Do not “over tension” the chain. Loss of power will result. It is normal for the drivelinks to hang
underneath the bar. The chain should be tight but be able to be pulled around the bar by hand.
Note 3: To prevent chain tensioner breakage, be sure the side cover nuts are tightened to approximately
20 ft-lbs (27Nm).
STEP 7
Manually pull the chain across the top of the
bar away from the Wallwalker®. It is normal
for the chain hanging under the bar to
alternately tighten and loosen as the chain
rotates. See Note 1.
STEP 8
Hold the bar nose up and tension the chain.
The chain should be tight but able to be pulled
around the bar b
y
hand. See Note 2
STEP 9
Continue to lift up on the nose of the bar and
firmly tighten the side cover nuts.
See Note 3.
STEP 6
Install side cover and thread the side cover
nuts on finger tight. Reattach the chain brake
arm.

633GC OPERATOR’S MANUAL
10
OPERATION
FUEL HANDLING
•FUEL MIXTURE: 4% 25:1 gasoline/oil mixture.
GASOLINE OIL
US
Gallon US Fl oz
1 5.2
2 ½ 12.8
5 25.6
GASOLINE OIL
Liters ml
1 40
4 160
10 400
20 800
•Use high quality, 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 for good ventilation when handling fuel.
•Take care when handling gasoline. Avoid direct contact with skin and avoid inhaling fuel vapor.
FUEL MIXING
•Always mix the gasoline and oil in a clean container intended for fuel.
•Keep canister tightly closed in order to avoid any moisture getting into the mixture.
•Always start by filling half the amount of the gasoline to be used. Then add the entire amount of two-
stroke oil. Mix (shake) the fuel mixture. Then add the remaining amount of gasoline.
•Do not mix more than one-month’s supply of fuel. This avoids the risk of oil separation and gasoline
breakdown (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 engine before fueling.
•Before fueling, clean the area around fuel cap to ensure that no dirt falls into the fuel tank.
Contamination in the fuel tank can lead to malfunction.
•Thoroughly shake the mixture in the canister before fueling.
•Slowly open the fuel cap, so that possible pressure build-up in the tank is released.
•After fueling, tighten the fuel cap carefully and secure with a wrench.
CAUTION

633GC OPERATOR’S MANUAL
11
OPERATION
STARTING AND STOPPING A DIAMOND CHAINSAW
Never start a diamond chainsaw without the bar, chain and side
cover properly assembled. Otherwise, the clutch can come loose
and cause personal injuries.
Always move a diamond chainsaw at least 10 feet (3 m) away from
the fueling area before starting.
Place the diamond chainsaw on clear ground, ensure that secure
footing is established and chain is not contacting any objects.
COLD ENGINE
•Disengage the chain brake by pulling the hand guard towards the front handle.
•Toggle ignition switch to the start position and pull the choke lever out.
•Lock throttle in start position by depressing the trigger interlock and trigger at the same time.
Depress and hold throttle lock button while releasing trigger and trigger interlock in succession.
•Open water valve ¼ turn for starting. Once saw has started, fully open water valve.
•Place diamond chainsaw on the ground making sure the chain is free of any obstructions. Place right
foot on the base of the rear handle. Place left hand on front handle. With right hand, slowly pull
starter handle until the starter pawls engage. Then give a short strong pull on the starter handle.
Allow the starter rope to rewind and pull again as necessary.
•As soon as the engine fires, push the choke lever in. Continue to pull starter as necessary. When
engine starts, depress trigger to unlock and allow engine to idle. Cycle the throttle several times to
help warm up the engine.
WARM ENGINE
•Use the same procedure as for starting cold engine, but without choke. If choke is used, the
carburetor will flood with gas. To recover from a flooded engine, push choke lever in, hold the trigger
fully open, and pull starter handle until engine starts.
Note: It may be necessary to use the side of your foot to hold the trigger fully open.
STOPPING THE SAW
•To turn the engine off, toggle ignition switch to the, “STOP” position. Close water valve.
WARNING
CAUTION
IMPORTANT

633GC OPERATOR’S MANUAL
12
OPERATION
PRE-CUT CHECKLIST
•Proper Chain Installation: The bumper should lead the segment into the cut.
•Proper Chain Tension: The chain should be tight but easily pulled around the bar 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 clothes, including hard hat, eye protection, hearing protection, non-slip safety
boots, gloves and avoid loose fitting clothes
•Adequate Water Supply and Pressure:
Minimum Flow: 2 gpm (8 lpm)
Minimum Water Pressure: 20 psi (1.4 bar)
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.
Note: Diamond chains with SealPro™ require a minimum water
pressure of 20 psi (1.4 bar).
PLANNING THE CUT
•Select the proper chain type for the material being cut.
•Outline the cut with a permanent marker for a visual cutting guide.
•Avoid pinching the bar and 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 bar. 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”x12”x12” = 150 lbs. (30cm x 30cm x 30cm = 68kg).
•Check for live electrical wiring near the cutting area or in the concrete to avoid electrocution.
IMPORTANT

633GC OPERATOR’S MANUAL
13
OPERATION
CUTTING WITH THE 633GC
To start a cut, hold trigger on full throttle and slowly plunge the nose of the bar straight into the wall.
Lengthen the cut and engage the point of the fixed Wallwalker®. Use the fixed Wallwalker® as a pivot
point and pull up on the rear handle to rotate the bar into the cut.
CUTTING TIPS
•Always operate a diamond chainsaw 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 chain will not have
enough speed to cut effectively. If too little feed force is applied, the diamonds will skid and glaze
over.
•Plunge cut instead of starting at the top of the wall. This will reduce chatter, extend diamond life,
create a straighter cut and more quickly enable the use of the fixed Wallwalker®.
•For straight cuts use the “step cut” method. First score the entire cut line with the nose of the bar
approximately ½ inch (12mm) to 1 inch (25mm) deep. Next, deepen the cut by about 2 inches
(50 mm). This groove will help guide the bar for a straight cut. Then plunge all the way through and
complete the cut using the fixed Wallwalker®.
•Use the fixed Wallwalker® to cut efficiently and reduce user fatigue. The fixed 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 fixed 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 chain life when cutting heavy
rebar.
•Expect more chain stretch when making nose buried cuts for extended periods of time, as the chain
does not have a chance to “throw” the slurry away from the nose of the bar.
•If the saw begins to cut consistently crooked, turn the bar over and use the other side. Dress worn
rails with belt grinder. Note: The normal life of a guide bar is 2 to 3 chains. Heavy rebar can shorten
bar life.
•When using a new chain, you can increase the cutting speed by “opening up the diamonds”. Make a
few cuts in an abrasive material such as a cinder block.
Wallwalker® point

633GC OPERATOR’S MANUAL
14
OPERATION
SYSTEM CLEAN-UP
•After cutting, run saw for at least 15 seconds with the water on to flush slurry and debris from chain,
bar and drive sprocket.
•Wash concrete slurry from saw assembly.
•Avoid getting any water in the carburetor or exhaust system. If water enters exhaust port, point bar
tip down and pull starter handle several times to expel water out of muffler.
•Remove bar and chain. Flush out chain tensioner with high water pressure and lube with grease.
•After cleaning saw, spray entire saw body, chain, bar, drive sprocket, with a lightweight oil. This will
minimize rust and reduce slurry build up on saw assembly.

633GC OPERATOR’S MANUAL
15
MAINTENANCE
Diamond chainsaws operate in very harsh and abusive conditions.
Daily preventative maintenance to the following basic items will
significantly reduce unplanned downtime.
•Fasteners
•Air Filters
•Starter Housing Assembly and Rope
•Sprocket, Clutch and Bearing
•Chain Tensioner
The following sticker is on the saw as a reminder to perform daily maintenance on these basic
items.
FASTENERS
Inspect and tighten all fasteners before and after each use. Use
blue Loctite #242.
•Muffler bolts, torque two upper bolts @ 9 ft-lbs (12Nm), lower bolt @ 3 ft-lbs (4Nm).
•Guard Flap and Bottom Guard bolts.
•Starter Housing Assembly bolts.
•Wallwalker® mounting bolts.
•Cylinder Cover bolts.
CAUTION
IMPORTANT

633GC OPERATOR’S MANUAL
16
MAINTENANCE
AIR FILTERS
The air filtration system consists of a pleated cloth air filter and an
internal spit-back screen. Both must be kept clean for 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 (Figure 1) is a life time filter. To clean use mild soap and
water and let air dry. Do not use hi pressure air to clean or dry air filter.
Compressed air will damage cotton pleats. After filter has been cleaned
and dried, re-oil with K&N filter oil. Apply a bead of oil along the full
length of each pleat. Allow 15-20 minutes for the oil to wick. Avoid over
oiling. One filter requires only a ¼ oz (10ml) of filter oil. The filter
should be reddish-pink color when properly oiled.
•The spit-back screen (Figure 2) should be free of holes and be white in
color. To clean, use 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”
of a turn with wrench.
Figure 1
Figure 2
IMPORTANT
Spit-back
Screen

633GC OPERATOR’S MANUAL
17
MAINTENANCE
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.
•After each usage, thoroughly flush the starter housing assembly
with water.
•Oil the recoil spring by spraying lightweight oil into the port
(Figure 3).
•Oil the starter pawls by spraying lightweight oil into the starter
housing through the vents.
•Check the starter rope for fraying, replace as necessary.
Starter Rope Replacement
•Remove the 4 screws that attach the starter assembly to the
crankcase. Then remove the pulley dust cover.
•Pull the cord out approximately 8” and lift the cord up into the notch
in the pulley (Figure 4). 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 approximately 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.
Tensioning the Recoil Spring
•Lift the starter cord up into the notch on the starter pulley (Figure 5) and
wind the pulley clockwise 7 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 ½ turn. If the pulley turns another ½ turn it is correctly
assembled.
Figure 4
IMPORTANT
Figure 5
Figure 3 Oil Port Open

633GC OPERATOR’S MANUAL
18
MAINTENANCE
Starter Housing Assembly
•To reattach the starter housing, first pull the starter cord out, then
hold the starter housing against the crankcase (Figure 6). Slowly
release the starter cord to enable the pulley to fit between the pawls.
•Insert and tighten the screws. Use blue Loctite # 242.
CHAIN TENSIONER
The chain tensioner (Figure 7) can become clogged with concrete
slurry during cutting. After each usage, thoroughly flush the chain
tensioner with water. Then apply a liberal amount of grease.
Most Common Causes of Tensioner Damage
•Side cover nuts are not tight enough. They should be torqued to
20 ft-lbs (27Nm).
•Chain tensioning is attempted without loosening the side cover
nuts.
•Concrete debris in tensioner pocket.
Figure 6
IMPORTANT
Chain
Tensioner
Figure 7

633GC OPERATOR’S MANUAL
19
MAINTENANCE
DRIVE SPROCKET
The drive sprocket (rim sprocket) is a wear item and should be
replaced with every new chain.
The needle bearing inside the splined adapter should be greased
after every use and should be replaced with every new rim
sprocket.
•A rim sprocket system (Figure 8) consists of a Clutch Cup with a
Splined Adapter and a Rim Sprocket. When the rim sprocket wears out,
only the rim sprocket needs to be replaced. The clutch cup and adapter
are also wear items and will eventually need to be replaced, but will
usually last 3 to 5 rims.
•Inspect drive sprocket for wear. Replace rim sprocket if grooves cut
into the top of the rim
•Check drive sprocket bearing by spinning clutch cup. Replace if worn
out.
•The needle bearing on the drive shaft has to be greased regularly
(daily). Use high quality water-resistant bearing grease.
•Bearing Tip: It is not necessary to remove the clutch cup to grease
the bearing. There is a channel that goes directly from the drive shaft
to the bearing (Figure 9). Simply inject grease directly into the end of
the drive shaft.
Drive Sprocket Removal
•Remove bar, chain, and clutch dust shield.
•Remove spark plug and insert piston stop (supplied with each saw) into
spark plug hole. Pull starter rope gently until the piston stops against
the tool. Using a 19mm wrench, rotate the clutch in the clockwise
direction to remove. If an impact wrench is used the spark plug does
not have to be removed.
•Carefully slide the clutch cup/drive sprocket assembly off the shaft.
The needle bearing may stay with the cup or remain on the shaft.
Remove the needle bearing and inspect for heavy wear or damage.
IMPORTANT
IMPORTANT
Figure 8
Figure 9
Splined
Adapter
Clutch
Cu
p
Rim
Sprocket
Grease
Hole

633GC OPERATOR’S MANUAL
20
MAINTENANCE
Drive Sprocket Installation
•Assemble the rim sprocket onto the splined adapter, either direction.
•Slide thin metal washer onto drive shaft, slide new needle bearing onto
shaft and slide new clutch cup assembly onto bearing (Figure 10).
•Apply a liberal amount of waterproof grease to the needle bearing by
simply injecting it directly into the end of the drive shaft. Rotate the
clutch cup while grease is being injected to ensure that the entire
bearing is coated.
•Install the clutch by rotating it counter clockwise onto the drive shaft and
firmly tighten. Torquing the clutch is not necessary, as starting the saw
will automatically tighten the clutch. Replace clutch slurry shield.
Installation of drive sprocket assembly is now complete.
SPARK PLUG
•A worn or fouled spark plug can result in loss of power, difficult to start
or rough idle (Figure 11).
•If the spark plug is dirty, clean with a wire brush and check the electrode
gap. Readjust if necessary. The correct gap is 0.50mm (.020”).
•The spark plug should be replaced after 40 hours of operation or earlier
if the electrodes are badly eroded.
•Always use the recommended spark plug type. An incorrect spark plug
can severely damage the piston and cylinder.
Figure 11
Figure 10