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
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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
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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

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 CRANKCASE LEFT HALF 73444
2 CRANKCASE RIGHT HALF 73445
3 BOLT 73278
4 WASHER 73897
5 TRIGGER ROD GROMMET 73268
6 TRIGGER ROD BUSHING 73269
7 BUMPER, SHOCK ABSORBER, FUEL TANK TOP 73270
8 CHOKE LEVER GROMMET 73389
9 CHOKE LEVER 73213
10 FUEL LINE GROMMET (CRANKCASE) 73390
11 MAIN BEARING SEAL HOUSING ASSMBLY-CLUTCH SIDE 73446
12 SCREW 8 69 X 73275
13 BAR MOUNTING STUD 19.5 173 X 73280
14 CRANKCASE GASKET 73447
15 CRANKCASE DOWEL PIN 73281
18 PREMIUM TENSIONER KIT (REPLACES 73283), ASSEMBLY 73935
19 BAR MOUNT PAD COVER PLATE 73225
20 SCREW X 73284
21 WASHER 73285
22 CRANKCASE OUTSIDE SEAL-CLUTCH SIDE 73202
23 CRANKCASE PLUG O-RING 73391
24 CRANKCASE PLUG 73286
25 SEAL HOUSING O-RING 73287
26 SEAL HOUSING MOUNTING SCREW (3) 3 26 X 73288
27 CLUTCH SIDE MAIN BEARING SEAL-INSIDE 73289
31 WATER TUBE (IN TANK) 73384
32 WATER TUBE FITTING 73385
33 TUBE FITTING-BACKSIDE BAR MOUNT 73386
38 COVER GUARD MOUNTING WASHER 73396
39 COVER GUARD MOUNTING BOLT 3 26 X 73397
40 COVER GUARD 70967
52 WATER TUBE O-RING 71468
53 633GC PLASTIC CAP 504389
Not Shown. Gasket Set, includes parts 73434, 73436, 73456 73435

633GC SHOP MANUAL
10 Copyright © 2005 ICS, Blount Inc.
4. SPARE PARTS DIAGRAM
KEY DESCRIPTION TORQUE LOCTITE® PART NUMBER
Nm in‑lbs. 272
5 WASHER 73897
10 SHOULDER SCREW, HAND GUARD X 71436
13 633GC SIDE COVER PLUG KIT 71441
14 633GC HAND GUARD 71435
18 SCREW 73284
19 COVER SIDE BAR PLATE 73309
20 RUBBER BUMPER, COVER 73310
21 COVER RUBBER FLAP 73311
22 SIDE COVER W/O BRAKE COMPONENTS 73449
23 COVER CLAMPING NUT 73313
25 CLUTCH SPACER WASHER 73314
26 CLUTCH NEEDLE BEARING 73423
27 CLUTCH CUP WITH SPLINED ADAPTER 70948
30 CLUTCH SPRING 73317
31 CLUTCH ASSEMBLY 5 44 73451
32 8T RIM SPROCKET KIT 70949
43 CLUTCH SHIELD 73452
44 CHAIN COVER RUBBER INSERT-MIDDLE 73315
45 CHAIN COVER RUBBER INSERT-TOP 73316
46 633GC HAND GUARD SCREW 71437
47 633GC CLUTCH SPACER 504568

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 FILTER COVER KNOB 3 26 73320
2 WASHER 73897
3 FILTER KNOB O-RING 73322
4 AIR FILTER COVER ASSEMBLY 71721
5 SCREW 5 43 X 73230
6 CYLINDER COVER 71722
7 CARBURETOR ATTACHMENT SCREW 5 43 X 73326
8 CARBURETOR ATTACHMENT SCREW WASHER 73327
9 INTAKE MANIFOLD RUBBER 73328
10 INTAKE MANIFOLD BRACKET 73329
11 FILTER CANNISTER COVER 73330
12 O-RING, AIR FILTER 73331
13 AIR FILTER GASKET 71719
14 AIR FILTER CANNISTER, POLY 71752
15 FILTER CANNISTER GASKET 73335
16 PREFILTER PLASTIC, SECONDARY FILTER 73336
17 FILTER SUPPORT SCREW 5 43 X 73337
18 FILTER SUPPORT 73338
19 CARBURETOR STANDOFF SUPPORT 73387
20 BOLT 6 52 X 73278
21 CARBURETOR SUPPORT SCREW 3 26 X 73340
22 CARBURETOR MIXTURE SCREW GROMMET 73341
23 CARBURETOR 73454
24 INSULATOR TO CYLINDER GASKET 73455
25 CARBURETOR INSULATOR 73344
26 INSULATOR FOAM GASKET 73345
27 CARBURETOR TO INSULATOR GASKET 73456

633GC SHOP MANUAL
12 Copyright © 2005 ICS, Blount Inc.
4. SPARE PARTS DIAGRAM
KEY DESCRIPTION TORQUE LOCTITE® PART NUMBER
Nm in‑lbs. 272
1 FRONT HANDLE ASSEMBLY 73457
2 WASHER 73897
3 FRONT HANDLE BOLT 5 43 X 73349
4 TRIGGER LOCK PIN 73353
5 TRIGGER LOCK PIN WASHER 73354
6 TRIGGER LOCK SPRING 73355
7 TRIGGER LOCK BUTTON 73356
8 TRIGGER PIVOT PIN 73357
9 THROTTLE LEVER 73358
10 TRIGGER LOCKOUT LEVER 73359
11 TRIGGER LOCKOUT LEVER SPRING 73360
12 FUEL TANK ASSEMBLY 73458
13 SCREW 7 61 X 73275
14 THROTTLE OPERATING WIRE 73366
15 MOUNTING NUT 73367
16 REAR HANDLE REAR BOLT 3 26 X 73368
17 REAR HANDLE ASSEMBLY 73369
18 FUEL CAP ASSEMBLY 73370
19 FUEL CAP O-RING 73448
20 FUEL TANK SCREW 73372
21 FUEL FILTER 73459
22 FUEL LINE 73375
23 FUEL BREATHER PIPE 73376
24 SHOCK ABSORBER 5 43 X 73377
25 WASHER 73250
26 SCREW (REAR HANDLE, UPPER) 3 26 X 73379
27 BUMPER, SHOCK ABSORBER, FUEL TANK TOP 73270

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
34 COVER GUARD FRONT MOUNT NUT 73392
35 HOSE HANGER BUTTON 71744
36 FITTING 71454
37 WALLWALKER SIDE ARM SCREW 0.5 43 X 71478
41 FITTING 71453
42 COPPER WASHER 71456
43 633GC WATER CAP 504388
44 FUEL CAP O-RING 73448
45 WATER HOSE 71455
46 HOSE HANGER 71461
47 HOSE CLAMP 71465
49 WATER HOSE SCREW 71463
50 GUARD FLAP CLAMP 71531
51 GUARD FLAP 71534
54 GUARD FLAP WASHER 71483
55 WATER HOSE COVER 71464
56 WATER SHUT-OFF VALVE 71458
57 WATER HOSE O-RING 71468
58 RING NUT 71457
59 FITTING 71467
60 WATER HOSE GASKET 71469
61 WASHER 73951
62 GUARD FLAP SPACER 71480
63 633GC WALLWALKER LEVER ARM 504387
64 GUARD FLAP SCREW 0.5 43 71479

14 Copyright © 2005 ICS, Blount Inc.
633GC SHOP MANUAL
5.3 Remove pre filter from air filter
mount.
A Clean filter with cleaning solution and
water.
B Let dry and reinstall.
5.2 Remove filter canister cover and air
filter.
A Inspect air filter.
B Replace filter if necessary (P/N
71752)
5 This section covers the
disassembly, inspection, and
assembly of the air intake.
5.1 Loosen the air filter cover screw and
remove air filter cover.
5. AIR INTAKE

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Copyright © 2005 ICS, Blount Inc.
633GC SHOP MANUAL
5.4 Secure air filter mount screws (3).
A Make sure filter canister gasket and
air filter water seal are secure.
B Replace air filter water seal if it is
damaged, permanently depressed,
hard due to slurry, or missing
(P/N 71719).
5.5 Assemble filter system in the reverse
order.
5. AIR INTAKE

16 Copyright © 2005 ICS, Blount Inc.
633GC SHOP MANUAL
6 This section covers the removal,
inspection, and installation of
the spark plug.
6.1 Remove the spark plug lead.
6.2 Clean area around the spark plug
to prevent debris from entering the
cylinder.
6.3 Remove the spark plug.
6.4 Inspect the spark plug.
A If dirty clean with a wire brush as
shown.
6. SPARK PLUG

17
Copyright © 2005 ICS, Blount Inc.
633GC SHOP MANUAL
B 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.
6.5 Assemble in the reverse order.
A Make sure the plug boot is seated
completely.
6. SPARK PLUG

18 Copyright © 2005 ICS, Blount Inc.
633GC SHOP MANUAL
7 This section covers clutch
removal, rim sprocket removal,
inspection, and assembly. Refer
to sections 5 and 6 if necessary.
7.1 Insert piston stop tool into spark plug
hole.
7.2 Pull starter handle until piston stops
against tool.
7.3 Remove clutch shield with small
screwdriver.
7. CLUTCH & RIM SPROCKET