ICS 633GC User manual

633GC Cut-Off Saw
Shop Manual

633GC SHOP MANUAL
1
Copyright © 2005 ICS, Blount Inc.
TABLE OF CONTENTS
SHOP MANUAL USE 2
1 TOOLS 3
2 SAW SPECIFICATIONS 4
3 SERIAL NUMBER LOCATION 5
4 SPARE PARTS DIAGRAM (TORQUE AND LOCTITE®)6
5 AIR INTAKE 14
6 SPARK PLUG 16
7 CLUTCH & RIM SPROCKET 18
8 STARTER SYSTEM 22
9 WALLWALKER 27
10 CYLINDER COVER 29
11 MUFFLER 31
12 CARBURETOR 32
13 CYLINDER & PISTON 34
14 WATER HOSE & CAP 41
15 IGNITION COIL 43
16 FLYWHEEL 45
17 BOTTOM GUARD 47
18 FRONT HANDLE 48
19 FUEL TANK 49
20 CRANKCASE 52
21 BAR STUD 60
22 TENSIONER 61
23 CARBURETOR TUNING 62
24 IDLE SPEED ADJUSTMENT 66
25 TROUBLESHOOTING DIAGRAMS 67
26 TROUBLESHOOTING: FUEL SYSTEM LEAKS 69
27 TROUBLESHOOTING: CRANKCASE LEAKS 72
APPENDIX
1. SPARK PLUG REFERENCE GUIDE 73
SECTION SECTION TITLE PAGE NUMBER

633GC SHOP MANUAL
2Copyright © 2005 ICS, Blount Inc.
SHOP MANUAL USE
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.
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 the
633GC 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.

633GC SHOP MANUAL
3
Copyright © 2005 ICS, Blount Inc.
1. TOOLS
633GC Service Tool Kit - P/N 71700
P/N DESCRIPTION
1 71521 SCRENCH
2 71541 PRESSURE GAUGE BULB
3 71542 COIL/FLYWHEEL TIMING SHIM
4 71543 CYLINDER ASSEMBLY CLAMPS & PISTON STOP
5 71546 613 SHOCK ABSORBER TOOL
6 71547 SPARK TESTER
7 71548 613 FLYWHEEL DISASSEMBLY TOOL
8 71550 LIMITER CAP REMOVAL TOOL
9 71565 ELECTRONIC TACHOMETER
10 71569 613GC INDUCTION SEAL FLANGE W/ SCREWS
11 71570 613GC EXHAUST SEAL FLANGE W/SCREWS
12 71573 TUNING SCREWDRIVER
13 73410 633GC FLYWHEEL PULLER
14 73425 633GC FUEL PRESSURE CAP
15 73428 613GC & 633GC MAIN BEARING DRIVER TOOL
16 73429 633 MAIN BEARING SPACING TOOL
17 73430 633GC SHOCK ABSORBER TOOL
18 73431 633GC INTAKE PORT COVER TOOL
19 73432 633GC EXHAUST PORT COVER TOOL
12345
6 7 8 9 10
11 12 13 14 15
16 17 18 19

633GC SHOP MANUAL
4Copyright © 2005 ICS, Blount Inc.
2. SPECIFICATIONS
Specifications
Engine Type 2-Stroke Single Cylinder Air Cooled
Displacement 6.2 cu.inch (101 cc)
Horsepower 6.1 hp (4.6 kw) @ 8700 rpm
Engine Speed 11,500 ± 500 rpm, mechanically governed
2500-2800 rpm @ idle
Piston ring gap (Maximum) .040 in. (1 mm)
Chain Speed 4950 fpm (25 m/s), free running
4000 fps (20 m/s), in the cut
Weight 27.5 lbs. (12.5 kg)
Cutting Depth Up to 16 inches (40.6 cm)
Dimensions 23 inches (58 cm) length
14 inches (35 cm) height
12 inches (30 cm) width
Carburetor Walbro diaphragm WGAK3 w/ throttle shaft seals
Air Filtration Washable cotton (K&N) or washable dry nylon
Starter Dust and water shielded
Ignition Electronic, water sealed
Spark plug type Champion RCJ-7Y (for conversion chart see appendix)
Clutch Three-weight, single spring, centrifugal
Fuel Mix Ratio 25:1 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.
Fuel Capacity .26 gal (1 liter)
15-18 minute run time
Water Supply Minimum 20 psi (1.5 bar)
Noise Level 102 dB @ 1 meter
Vibration Level 8 m/s @ front handle
Cutting Rate Hard aggregates w/ steel: 15-25 sq-in/min (90-160 sq-cm/min)
Medium aggregates: 20-30 sq-in/min (160-190 sq-cm/min)
Masonry, soft aggregates: 30-50 sq-in/min (190-320 sq-cm/min)

633GC SHOP MANUAL
5
Copyright © 2005 ICS, Blount Inc.
3. SERIAL # LOCATION
3 This section shows the two locations of the serial number.

633GC SHOP MANUAL
6Copyright © 2005 ICS, Blount Inc.
4. SPARE PARTS DIAGRAM
KEY DESCRIPTION TORQUE LOCTITE® PART NUMBER
Nm in‑lbs. 272
1 STARTER ROPE 73188
2 STARTER ROPE RETAINER 73228
3 STARTER ROPE HANDLE 73189
4 STARTER HOUSING OIL CAP 73229
5 SCREW 5 43 X 73230
6 STARTER COVER 73190
7 STARTER ROPE WASHER 73231
8 STARTER COIL SPRING & HOUSING 73191
9 STARTER SPRING COVER 73232
10 STARTER BUSHING 73192
11 STARTER ROPE PULLEY 73193
12 STARTER PULLEY WASHER 73233
13 STARTER PULLEY SCREW 3 26 X 73234
14 STARTER PULLEY COVER 73235
15 STARTER PULLEY COVER SCREW 2 17 X 73236
16 STARTER COVER DUST SHIELD 73194
17 STARTER COVER ASSEMBLY (COMPLETE) 73195
18 IGNITION TOGGLE SWITCH 73237
19 IGNITION TOGGLE PLATE ON/OFF 4 35 73238
20 IGNITION TOGGLE SWITCH NUT 73239
22 SPARK PLUG CAP 73241
23 SPARK PLUG CAP SPRING 73242
24 IGNITION COIL WITH SPARK PLUG LEAD & PRIMARY 6 52 X 73196
25 IGNITION COIL MOUNTING SCREW 73243
26 WASHER 73897
27 FLYWHEEL MOUNTING WASHER 73245
28 FLYWHEEL MOUNTING NUT 73246
31 STARTER PAWL KIT 504386
32 FLYWHEEL ASSEMBLY REPLACEMENT KIT 73433
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.

633GC SHOP MANUAL
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Copyright © 2005 ICS, Blount Inc.
4. SPARE PARTS DIAGRAM
KEY DESCRIPTION TORQUE LOCTITE® PART NUMBER
Nm in‑lbs. 272
1 SPARK PLUG 27 243 73199
2 WASHER 73250
3 CYLINDER BLOCK BOLT 12 104 X 73251
4 CYLINDER TO MUFFLER GASKET 73434
5 EXHAUST PIPE 73253
6 WRIST PIN NEEDLE BEARING 73211
7 EXHAUST PIPE MOUNTING SCREW 4 35 73254
10 CRANKSHAFT SEAL FLYWHEEL SIDE 73201
11 MUFFLER BODY 73203
12 MUFFLER SUPPORT BRACKET SCREW 4 43 X 73255
13 MUFFLER SUPPORT BRACKET NUT 2.25 26 X 73256
14 MUFFLER SUPPORT BRACKET 73204
15 MUFFLER SCREW LOCKING PLATE 73257
16 MUFFLER MOUNTING SCREW 73258
17 CYLINDER BASE GASKET 73436
18 PISTON RING PAIR 73437
19 WRIST PIN SNAP RING 73259
20 PISTON WRIST PIN 73208
22 COMPLETE CYLINDER/PISTON ASSEMBLY 73442
23 CRANKSHAFT FLYWHEEL WOODRUFF KEY 73264
24 CRANKSHAFT BEARING (FLYWHEEL END) 73209
25 CRANKSHAFT ASSEMBLY 73443
26 CRANKSHAFT BEARING (CLUTCH SIDE) 73200
27 CRANKCASE OUTSIDE SEAL-CLUTCH SIDE 73202

633GC SHOP MANUAL
8Copyright © 2005 ICS, Blount Inc.
4. SPARE PARTS DIAGRAM