ICS 633GC User manual

F/N 70944 Oct 09 © 2009 ICS, Blount Inc.
633GC / 633F4
OPERATOR’S MANUAL

F/N 70944 Oct 09 © 2009 ICS, Blount Inc.
TITLE633GC / 633F4 OPERATOR’S MANUAL
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INTRODUCTION / TABLE OF CONTENTS
SYMBOLS & LABELS 4
SAFETY 5
TECHNICAL SPECIFICATIONS 8
SET-UP 9
OPERATION 12
MAINTENANCE 17
TROUBLESHOOTING 25
REFERENCE 26
INTRODUCTION
This manual outlines the maintenance and operation of ICS®manufactured products.
The 633GC / 633F4 chainsaw is designed to cut concrete, stone, and masonry when used with the
appropriate genuine ICS Diamond Chain. Ductile iron pipe may be cut ONLY if using
PowerGritTM Utility Saw Chain.
To get the maximum benefit from your saw, and ensure maximum safety, be sure to read this manual
thoroughly, and periodically review safety instructions.
TABLE OF CONTENTS

© 2009 ICS, Blount Inc. F/N 70944 Oct 09
TITLE 633GC / 633F4 OPERATOR’S MANUAL
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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
IMPORTANT
WARNING
CAUTION

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SAFETY
WARNING
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 diamond chain,
thrown water and concrete slurry.
• DO NOT operate a saw with loose, missing, damaged or improperly repaired parts.
• 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.
• NEVER cut ductile iron pipe with the saw (except when using PowerGritTM Utility Saw
Chain). Segment loss or diamond chain breakage may occur.
• See page 16 for information about cutting ductile iron pipe with PowerGrit chain.

© 2009 ICS, Blount Inc. F/N 70944 Oct 09
TITLE 633GC / 633F4 OPERATOR’S MANUAL
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SAFETY
CAUTION
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 adequate
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 (1.5 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clothing,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.

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SAFETY
IMPORTANT
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 ICS®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.
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 may result in piston seizure.
• This engine is designed to be operated on premium 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 will result in a piston seizure
and damage to the engine.
• Fuel mixture: 25:1 gasoline/oil mixture. Incorrect fuel mixture is the number one cause of
piston seizure.
• Use ICS®brand two-stroke engine oil, or other high quality 2-stroke oil that has been
formulated for air cooled power equipment.
• Never use two-stroke oil formulated for water-cooled two-cycle engines, such as
outboard motor oil.
• Never use motor oil intended for four-stroke engines.

© 2009 ICS, Blount Inc. F/N 70944 Oct 09
TITLE 633GC / 633F4 OPERATOR’S MANUAL
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TECHNICAL SPECIFICATIONS
Engine Type 2-stroke,AirCooled
Displacement 101cc(6.2cuin)
Horsepower 6.5HP(4.8kw)@8700RPM
Engine Speed 11,500+/-500RPM,Mechanically
governed
Diamond Chain Speed 4,950fpm(25m/s),freerunning
Idling Speed 2800-3200RPM
Weight 27.5lbs(12.5kg)withguidebarand
diamond chain
Cut Depth 14in(36cm)&16.2in(41cm)
Bar Lengths 14in(36cm)&16.2in(41cm)
Carburetor WalbroWGAK3,Throttleshaftsealed,
Ignition Selettra electronic – Water resistant
Clutch Centrifugal, three shoe, single spring
Fuel ratio 25:1gasoline-to-oil
Fuel Capacity 0.26gallon(1liter)
12-15minutesruntimepertank
Water Supply Minimum20psi(1.5bar)
Water Flow Minimum:2gpm(8lpm)
Noise Level 102dBat3ft(1m)
Vibration Level 8 meters/sec2(fronthandle)
EngineBreak-inPeriod Onetank,withoutcutting,cycling
throttle
SparkPlug Champion CJ7Y or Bosch BWS7F

F/N 70944 Oct 09 © 2009 ICS, Blount Inc.
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SET-UP
STEP 1
Loosen side cover nuts and remove side
cover.
GUIDE BAR AND DIAMOND CHAIN INSTALLATION
STEP 3
Mount the diamond chain on the guide bar
startingatthedrivesprocketandcontinue
over the guide bar nose.
Install the diamond chain correctly.
If using a single bumper chain, the
bumper must always lead the segment
into the cut as shown here.
STEP 4
Install the side cover.
STEP 2
Place bar onto studs and chain adjustment
pin.

© 2009 ICS, Blount Inc. F/N 70944 Oct 09
TITLE 633GC / 633F4 OPERATOR’S MANUAL
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SET-UP
GUIDE BAR AND DIAMOND CHAIN INSTALLATION
STEP 7
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1/2”
(12mm)to3/4”(18mm)**belowthebar,
it’s time to tension the chain. See Note 2.
STEP 6
If the chain is too loose, it could come off
thebar,oritwillallowthedrivesprocketto
spin without turning the chain, which can
chewupthechaindrivelinks.Ifthechain
is too tight, a lot of the saw’s power goes
into turning the chain rather than into the
cut.Inextremeover-tightenedcases,the
saw may not be able to turn the chain at
all. In addition, damage can occur to the
bar nose and premature stretch may occur.
See Note 1.
STEP 8
Beforecutting,checkforpropertensionby
pulling the chain around the bar by hand. If
you cannot easily pull by hand, the chain is
too tight and needs to be loosened a little.
See Note 3.
** As measured without pulling
downward (eg. hanging by gravity)
3/4" (18 mm)**
STEP 5
Makesureallthedrivelinksareinside
the guide bar groove then lift the bar nose
and tension the chain by turning the screw
clockwise.

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SET-UP
Note 1: Be aware that the guide bar rails may develop sharp edges over time so always pull the
diamond chain by the diamond segments.
Note2:Donot“overtension”thediamondchain.Lossofpowerwillresult.Itisnormalforthe
drivelinkstohangunderneaththeguidebar.Thediamondchainshouldbetightbutbeabletobe
pulled around the guide bar by hand.
Note3:Topreventchaintensionerbreakage,besurethesidecovernutsaretightenedto
approximately20ft-lbs(27Nm).
GUIDE BAR AND DIAMOND CHAIN INSTALLATION
STEP 9
Continue to lift up on the nose of the guide
bar and firmly tighten the side cover nuts.
NOTE: To prevent chain tensioner
breakage,besurethesidecovernuts
aretightenedtoapproximately20ft-lbs
(27Nm).
STEP 10
Attachtowatersourcewithpressureofnot
lessthan20psi(1.5bar).