Service Manual - 633GC
Contents
1. F N 73472 Oct 07 2007 ICS Blount Inc 3 2 SPECIFICATIONS SPECIFICATIONS 633GC SERVICE MANUAL Engine Type Specifications 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 Ibs 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 WGAKS w throttle shaft seals Air Filtration Washable cotton K amp 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 sq2. A Clean with cleaning solution B Replace if worn or broken 841 Install starter rope and tie knot 8 12 Install pulley A Wind rope onto pulley clockwise leaving 4 6 10 15 cm out B Make sure that the pulley spring catch is in the spring hook 8 13 Install center screw A Use blue Loctite B Torque to 26 in Ibs 2 9 Nm 24 2007 ICS Blount Inc F N 73472 Oct 07 633GC SERVICE MANUAL 8 STARTER STARTER 814 Wind the recoil spring A Line rope up with notch on pulley B Rotate the pulley with the rope clockwise 5 times C Untangle rope and release 8 15 Assemble starter cord shield 8 16 Remove starter pawl snap rings pawls spring and plain washer 8 17 Inspect and clean pawl components A Inspect the components Replace if necessary B Clean the components with a brush and solvent F N 73472 Oct 07 2007 ICS Blount Inc 25 STARTER STARTER 633GC SERVICE MANUAL 8 18 Assemble components A Make sure the snap ring spring is in the correct position B Make sure the spring is in the correct position 8 19 Install starter cover A Pull out cord 4 6 10 15 cm Slowly release while placing cover to allow pawls to engage 8 20 Install starter cover screws A Use blue Loctite B Torque to 60 in Ibs 6 8 Nm 26 2007 ICS Blount Inc F N 73472 Oct 07 633GC SERVICE MANUAL 9 This section covers the removal inspection and assembly of the
3. SERVICE MANUAL F N 73472 Oct 07 2007 ICS Blount Inc 633GC SERVICE MANUAL TABLE OF CONTENTS OF CONTENTS SECTION SECTION TITLE PAGE NUMBER 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 amp RIM SPROCKET 18 8 STARTER SYSTEM 22 9 WALLWALKER 27 10 CYLINDER COVER 29 11 MUFFLER 31 12 CARBURETOR 32 13 CYLINDER amp PISTON 34 14 WATER HOSE amp 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 F N 73472 Oct 07 2007 ICS Blount Inc 1 SHOPMANUALUSE MANUAL USE 633GC SERVICE MANUAL 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 pl
4. bearing clutch cup with rim sprocket inside clutch spacer washer and clutch assembly 712 Install clutch A Tighten firmly A Left hand threads 73472 Oct 07 2007 ICS Blount Inc 21 8 STARTER 8 1 8 2 8 3 gt 8 5 This section covers the removal of the starter cover replacement of the starter rope and replacement of the recoil spring Remove starter cover screws Remove starter cover assembly from saw Remove starter cord shield screws Relieve spring tension Pull 4 6 10 15 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 22 2007 ICS Blount Inc 633GC SERVICE MANUAL F N 73472 Oct 07 633GC SERVICE MANUAL 5 8 6 Remove starter pulley 8 7 Inspect coil spring 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 8 8 A Apply light weight oil 8 9 Replace parts carefully mu A zm an T ry L 1 ai F 73472 Oct 07 2007 ICS Blount Inc 23 8 STARTER 633GC SERVICE MANUAL 8 10 Inspect pulley spring catch
5. E YES Loose flywheel Replace key and reinstall flywheel 68 2007 ICS Blount Inc 73472 Oct 07 633GC SERVICE MANUAL 26 FUEL SYSTEM LEAKS 26 This section covers testing the fuel system for leaks Engine starvation can result from a leak or malfunction of any of the main components of the fuel system The five main components are the fuel tank fuel tank breather fuel filter delivery tubes and carburetor 261 Remove and inspect the fuel filter A Replace the fuel filter if there is any foreign material in the felt or the internal screen 26 2 Test the main fuel pick up tube for leaks A Install the pressure gauge and bulb to filter end of fuel line B Pressurize the tube to 7 psi 0 5 bar C If the pressure does not maintain separate the fuel line from the carburetor F N 73472 Oct 07 2007 ICS Blount Inc 69 26 FUEL SYSTEM LEAKS 633GC SERVICE MANUAL D Plug one end of the main fuel pick up tube E Re pressurize the tube to 7 psi 0 5 bar F Replace the tube if pressure is not maintained G If the main fuel pick up tube does maintain pressure than the leak has been isolated to the carburetor Refer to the Walbro Diaphragm Carburetor Service Manual 26 3 The fuel tank breather stabilizes the pressure in the fuel tank preventing both excessive pressure which could flood the engine and negative pressure which could starve the engine of fuel 26 4 Testin
6. Inc F N 73472 Oct 07 WASHER 633GC SERVICE MANUAL 4 SPARE PARTS DIAGRAM SPARE PARTS DIAGRAM FILTER COVER KNOB WASHER FILTER KNOB O RING AIR FILTER COVER ASSEMBLY SCREW CYLINDER COVER CARBURETOR ATTACHMENT SCREW CARBURETOR ATTACHMENT SCREW WASHER INTAKE MANIFOLD RUBBER INTAKE MANIFOLD BRACKET FILTER CANNISTER COVER O RING AIR FILTER AIR FILTER GASKET AIR FILTER CANNISTER POLY FILTER CANNISTER GASKET PREFILTER PLASTIC SECONDARY FILTER FILTER SUPPORT SCREW FILTER SUPPORT CARBURETOR STANDOFF SUPPORT BOLT CARBURETOR SUPPORT SCREW CARBURETOR MIXTURE SCREW GROMMET CARBURETOR INSULATOR TO CYLINDER GASKET CARBURETOR INSULATOR INSULATOR FOAM GASKET CARBURETOR TO INSULATOR GASKET F N 73472 Oct 07 2007 ICS Blount Inc 1 1 4 SPARE PARTS DIAGRAM 633GC SERVICE MANUAL KEY DESCRIPTION TORQUE LOCTITE PART NUMBER Nm in Ibs 272 73457 73897 N FRONT HANDLE ASSEMBLY WASHER FRONT HANDLE BOLT 5 43 X TRIGGER LOCK PIN TRIGGER LOCK PIN WASHER TRIGGER LOCK SPRING TRIGGER LOCK BUTTON TRIGGER PIVOT PIN THROTTLE LEVER TRIGGER LOCKOUT LEVER TRIGGER LOCKOUT LEVER SPRING FUEL TANK ASSEMBLY SCREW 7 61 X THROTTLE OPERATING WIRE MOUNTING NUT REAR HANDLE REAR BOLT 3 26 X REAR HANDLE ASSEMBLY FUEL CAP ASSEMBLY FUEL CAP O RING FU
7. Torque nut to 390 in lbs 44 Nm 46 2007 ICS Blount Inc F N 73472 Oct 07 633GC SERVICE MANUAL 17 BOTTOM GUARD 17 This section covers the removal inspection and installation of the bottom guard A Remove bottom guard screws and split washers B Inspect bottom guard Replace if damaged O D Assemble in reverse order F N 73472 Oct 07 2007 ICS Blount Inc 47 18 FRONT HANDLE 633GC SERVICE MANUAL 18 This section covers the removal inspection and installation of the front handle 181 Remove front handle screws on right side 18 2 Remove front handle screws on bottom 18 3 Install front handle Roll front handle into place Install front handle screws 4 Use blue Loctite Torque to 43 in Ibs 4 9 Nm m 48 2007 ICS Blount Inc F N 73472 Oct 07 633GC SERVICE MANUAL 19 FUELTANK 19 This section covers the disassembly inspection and assembly of the vibration isolaters fuel tank and rear handle 19 1 Remove vibration isolator screws and wave washers on clutch side of saw 19 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 73472 Oct 07 2007 ICS Blount Inc 49 633GC SERVICE MANUAL 19 3 Separate crankcase and fuel tank NOTE During assembly be careful not to kink the fuel line between the crankcas
8. WallWalker and guard flap 9 1 Inspect WallWalker tip A If the tip is worn as shown replace 9 2 Remove crankcase screws and wave washers 9 3 Remove WallWalker from saw 9 4 Remove guard flap screws and washer 9 5 Remove and inspect guard flap A Replace the flap if it is torn or damaged in any way F N 73472 Oct 07 2007 ICS Blount Inc 9 WALLWALKER 27 9 WALLWALKER WALLWALKER 633GC SERVICE MANUAL 9 6 Assemble in the reverse order A Install crankcase screws and wave washers B Use blue Loctite C Torque to 70 in Ibs 7 9 Nm a m aem 28 2007 ICS Blount Inc F N 73472 Oct 07 633GC SERVICE MANUAL 10 CYLINDER COVER CYLINDER COVER 10 This section covers the disassembly and assembly of the cylinder cover Removal of the air intake components and front handle is required Refer to sections 5 and 18 if necessary 101 Remove the cylinder cover screws 10 2 Remove spark plug lead from cylinder cover 10 3 Partially remove intake manifold from cylinder cover while lifting cylinder cover away from saw 10 4 Inspect cylinder cover for damage A Replace if necessary 10 5 Make sure carburetor screw boot and cylinder cover plug are in place 73472 Oct 07 2007 ICS Blount Inc 29 10 CYLINDERCOVER CYLINDER COVER 633GC SERVICE MANUAL 10 6 Install cylinder cover A Pull spark plug lead into slot in cylinder cover B Push the
9. clutch side of crankcase Tap crankshaft with a plastic mallet A Suspend above work surface B Tap with plastic mallet 20 8 Remove the bearing from the flywheel side of crank shaft 54 2007 ICS Blount Inc F N 73472 Oct 07 633GC SERVICE MANUAL 20 CRANKCASE CRANKCASE 20 9 Remove the bearing seal and bushing from the clutch side of crankshaft 20 10 Clean mating crankcase faces 20 11 Heat crankcase halves to 150 F 20 12 Install bearing into crankcase halves 20 13 Tap with bearing driver and mallet F N 73472 Oct 07 2007 ICS Blount Inc 55 20 CRANKCASE CRANKCASE 633GC SERVICE MANUAL 20 14 Repeat with other half 20 15 Install crankshaft into clutch side of case 20 16 Place clutch side of crank case seal on crankshaft lightly with bearing driver and mallet 2007 ICS Blount Inc F N 73472 Oct 07 56 633GC SERVICE MANUAL 20 CRANKCASE 20 17 Coat crankcase gasket with ICS 2 stroke engine oil 20 18 Align crankcase gasket on flywheel side crankcase pins 20 19 Place crankcase halves together and align crankcase pins 73472 Oct 07 2007 ICS Blount Inc 57 20 CRANKCASE CRANKCASE 633GC SERVICE MANUAL 20 20 Assemble crankcase halves tap with bearing driver and mallet 20 21 Install main crankcase bolts A Use blue Loctite B Torque to 70 in lbs 7 9 Nm NOTE Tighten bolts hand tight
10. in min 160 190 sq cm min Masonry soft aggregates 30 50 sq in min 190 320 sq cm min 2007 ICS Blount Inc F N 73472 Oct 07 633GC SERVICE MANUAL 3 SERIAL LOCATION SERIAL LOCATION 3 This section shows the two locations of the serial number 73472 Oct 07 2007 ICS Blount Inc 5 4 SPARE PARTS DIAGRAM SPARE PARTS DIAGRAM 633GC SERVICE 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 DESCRIPTION ena PART NUMBER STARTER ROPE STARTER ROPE RETAINER STARTER ROPE HANDLE STARTER HOUSING OIL CAP SCREW 43 STARTER COVER STARTER ROPE WASHER STARTER COIL SPRING amp HOUSING STARTER SPRING COVER STARTER BUSHING STARTER ROPE PULLEY STARTER PULLEY WASHER STARTER PULLEY SCREW STARTER PULLEY COVER STARTER PULLEY COVER SCREW STARTER COVER DUST SHIELD STARTER COVER ASSEMBLY COMPLETE IGNITION TOGGLE SWITCH IGNITION TOGGLE PLATE ON OFF IGNITION TOGGLE SWITCH NUT SPARK PLUG CAP SPARK PLUG CAP SPRING IGNITION COIL WITH SPARK PLUG LEAD amp PRIMARY IGNITION COIL MOUNTING SCREW WASHER FLYWHEEL MOUNTING WASHER FLYWHEEL MOUNTING NUT STARTER PAWL KIT FLYWHEEL ASSEMBLY REPLACEMENT KIT 1 2 3 4 5 6 7 8 6 2007 ICS Blount Inc F N 73472 Oct 0
11. screw out counterclockwise 1 16 of a turn at a time A Pulse the throttle to help stabilize the system A Do not hold the saw at maximum rpm for more than 5 seconds 64 2007 ICS Blount Inc F N 73472 Oct 07 633GC SERVICE MANUAL 23 CARBURETOR TUNING 2311 When the carburetor is adjusted correctly set the limiter caps with a 74 straight blade screwdriver A H horizontal B L vertical YY F N 73472 Oct 07 2007 ICS Blount Inc 65 24 IDLE SPEED ADJUSTMENT 633GC SERVICE MANUAL 24 This section covers idle speed adjustment 241 If engine stops while idling p Make sure the chain is properly 1 tensioned B Turn T screw clockwise until chain begins to move C Back T screw out 75 turn DO 24 2 If chain turns at idle A BackT screw out until chain stops moving 66 2007 ICS Blount Inc F N 73472 Oct 07 633GC SERVICE MANUAL 25 DIAGRAMS DIAGRAMS 25 This section provides several flowcharts to aid diagnosing common problems CHECK POSSIBLE CAUSE REPAIR Clean or replace the air filter Inspect air intake sysetm for water Inspect fuel system for water tighten clean or rreplace spark plug Dirty or clogged air filter Water has been ingested Loose or dirty spark plug A A dirty air filter is the 1 reason for engine problems The engine runs rough at all speeds Operator is overworking See Operator s Manual See Carburetor Tu
12. sure that the plug will work SPARK PLUG REFERENCE GUIDE ICS RESISTOR CHAMPION RESISTOR BOSCH RESISTOR RESISTOR 73199 RCJ7Y BPMR A WSR7F F N 73472 Oct 07 2007 ICS Blount Inc 73 633GC SERVICE MANUAL ICS Blount Inc 4909 SE International Way Portland OR 97222 Tel 800 321 1240 Fax 503 653 4393 icsbestway com 2007 ICS Blount Inc 73472 Oct 07
13. then torque bolts in sequence listed at right 20 22 Install flywheel side crankcase seal tap with bearing driver and mallet 58 2007 ICS Blount Inc F N 73472 Oct 07 633GC SERVICE MANUAL 20 20 23 Trim crankcase gasket flush 73472 Oct 07 2007 ICS Blount Inc 59 24 BARSTUDAND PAD BAR STUD AND PAD 633GC SERVICE MANUAL 21 This section covers the removal and installation of the bar studs and bar pad 211 Remove bar studs A Install side cover nuts flange to flange B Tighten side cover nuts against each other C Attempt to remove the inside nut which should pull out the bar stud D Repeat on second bar stud 21 2 Assemble in reverse order using blue Loctite 60 2007 ICS Blount Inc F N 73472 Oct 07 633GC SERVICE MANUAL 22 TENSIONER 22 This section covers the removal and installation of the chain tensioner 221 Remove bar plate to expose the chain tensioner 22 2 Unscrew tensioner to remove A Remove tensioner pin B Remove tensioner screw keeper 22 3 Assemble in reverse order 73472 Oct 07 2007 ICS Blount Inc 61 23 CARBURETOR TUNING CARBURETOR TUNING 633GC SERVICE MANUAL 23 This section covers carburetor tuning Included in this section are basic settings idle speed adjustment and complete adjustment The carburetor has been set at the factory for optimal performance and co
14. 7 633GC SERVICE MANUAL 4 SPARE PARTS DIAGRAM SPARE PARTS DIAGRAM DESCRIPTION LOCTITE PART NUMBER in Ibs 272 SPARK PLUG WASHER CYLINDER BLOCK BOLT CYLINDER TO MUFFLER GASKET EXHAUST PIPE WRIST PIN NEEDLE BEARING EXHAUST PIPE MOUNTING SCREW CRANKSHAFT SEAL FLYWHEEL SIDE MUFFLER BODY MUFFLER SUPPORT BRACKET SCREW MUFFLER SUPPORT BRACKET NUT MUFFLER SUPPORT BRACKET MUFFLER SCREW LOCKING PLATE MUFFLER MOUNTING SCREW CYLINDER BASE GASKET PISTON RING PAIR WRIST PIN SNAP RING PISTON WRIST PIN COMPLETE CYLINDER PISTON ASSEMBLY CRANKSHAFT FLYWHEEL WOODRUFF KEY CRANKSHAFT BEARING FLYWHEEL END CRANKSHAFT ASSEMBLY CRANKSHAFT BEARING CLUTCH SIDE CRANKCASE OUTSIDE SEAL CLUTCH SIDE F N 73472 Oct 07 2007 ICS Blount Inc T 633GC SERVICE MANUAL 4 SPARE PARTS DIAGRAM F N 73472 Oct 07 2007 ICS Blount Inc 633GC SERVICE MANUAL KEY DESCRIPTION 4 SPARE PARTS DIAGRAM a ge PART NUMBER NI BOLT CRANKCASE LEFT HALF CRANKCASE RIGHT HALF WASHER TRIGGER ROD GROMMET TRIGGER ROD BUSHING BUMPER SHOCK ABSORBER FUEL TANK TOP N O CHOKE LEVER GROMMET CHOKE LEVER FUEL LINE GROMMET CRANKCASE MAIN BEARING SEAL HOUSING ASSMBLY CLUTCH SIDE SCREW BAR MOUNTING STUD 69 CRANKCASE GASKET CRANKCASE DOWEL PIN PR
15. C SERVICE MANUAL 15 6 Install Ignition coil A Place ignition coil shim 0 012 on magnet counterweight side of flywheel Set ignition coil in place C Install ignition coil screws wave washers and plain washers with blue Loctite D Holding shim rotate flywheel magnet around to coil E Torque ignition coil screws to 52 in Ibs 5 9 Nm F Remove shim rotate flywheel to check clearance G Route ignition stop switch wire through crankcase into carburetor chamber Install wire grommet in crankcase 15 7 Complete ignition wire routing and assemble saw in reverse order 44 2007 ICS Blount Inc F N 73472 Oct 07 633GC SERVICE MANUAL 16 16 1 16 2 16 3 16 4 This section covers the removal inspection and installation of the flywheel Removal of the starter and spark plugs is required Refer to sections 6 and 8 if necessary Remove sparkplug and insert piston stop Remove flywheel nut counter clockwise wave washer and plain washer Install flywheel puller bolts 3 finger tight Turn main puller bolt clockwise with wrench until flywheel releases from the crankshaft Inspect amp clean flywheel Replace if any of the fins are broken 73472 Oct 07 2007 ICS Blount Inc 45 16 FLYWHEEL 633GC SERVICE MANUAL 16 5 Inspect woodruff key A Replace if broken or damaged 16 6 Install flywheel plain washer wave washer and flywheel nut A
16. EL TANK SCREW FUEL FILTER FUEL LINE FUEL BREATHER PIPE 5 43 X 3 26 X oc SHOCK ABSORBER WASHER SCREW REAR HANDLE UPPER BUMPER SHOCK ABSORBER FUEL TANK TOP 12 2007 ICS Blount Inc F N 73472 Oct 07 633GC SERVICE MANUAL 4 SPARE PARTS DIAGRAM SPARE PARTS DIAGRAM 42 49 A 43 7 iE Le LAS 41 55 s gt 57 f 7 gt a c E g sg rN iy 3 47 35 T B3 3781 E 41 M 62 O r 50 64 47 54 RAT 5 1 TORQUE LOCTITE DESCRIPTION COVER GUARD FRONT MOUNT NUT HOSE HANGER BUTTON N 272 PART NUMBER 73392 FITTING WALLWALKER SIDE ARM SCREW FITTING COPPER WASHER 633GC WATER CAP FUEL CAP O RING WATER HOSE HOSE HANGER HOSE CLAMP WATER HOSE SCREW GUARD FLAP CLAMP GUARD FLAP GUARD FLAP WASHER WATER HOSE COVER WATER SHUT OFF VALVE WATER HOSE O RING RING NUT FITTING WATER HOSE GASKET WASHER 73951 GUARD FLAP SPACER 71480 633GC WALLWALKER LEVER ARM 504387 GUARD FLAP SCREW F N 73472 Oct 07 2007 ICS Blount Inc 71479 13 5 1 5 2 5 3 14 This section covers the disassembly inspection and assembly of the air intake Loosen the air filter cover screw and remove air filter cover R
17. EMIUM TENSIONER KIT REPLACES 73283 ASSEMBLY BAR MOUNT PAD COVER PLATE SCREW WASHER CRANKCASE OUTSIDE SEAL CLUTCH SIDE CRANKCASE PLUG O RING CRANKCASE PLUG SEAL HOUSING O RING 1 173 SEAL HOUSING MOUNTING SCREW 3 CLUTCH SIDE MAIN BEARING SEAL INSIDE WATER TUBE IN TANK WATER TUBE FITTING TUBE FITTING BACKSIDE BAR MOUNT COVER GUARD MOUNTING WASHER COVER GUARD MOUNTING BOLT COVER GUARD WATER TUBE O RING s EE gaa BRE ee PLASTIC CAP 73444 73445 L Bee Not Shown Gasket Set includes s EE gaa BRE TERES 73434 73436 73456 F N 73472 Oct 07 2007 ICS Blount Inc 4 SPARE PARTS DIAGRAM SPARE PARTS DIAGRAM 633GC SERVICE MANUAL DESCRIPTION FORME COC TITE PART NUMBER Nm in Ibs 272 73897 SHOULDER SCREW HAND GUARD X 71436 633GC SIDE COVER PLUG KIT 71441 633GC HAND GUARD 71435 SCREW 73284 COVER SIDE BAR PLATE 73309 RUBBER BUMPER COVER 73310 COVER RUBBER FLAP 73311 SIDE COVER W O BRAKE COMPONENTS 73449 COVER CLAMPING NUT 73313 CLUTCH SPACER WASHER 73314 CLUTCH NEEDLE BEARING 73423 CLUTCH CUP WITH SPLINED ADAPTER 70948 CLUTCH SPRING 73317 CLUTCH ASSEMBLY 5 44 73451 8T RIM SPROCKET KIT 70949 CLUTCH SHIELD 73452 CHAIN COVER RUBBER INSERT MIDDLE 73315 CHAIN COVER RUBBER INSERT TOP 73316 633GC HAND GUARD SCREW 71437 633GC CLUTCH SPACER 504568 1 0 2007 ICS Blount
18. KET 633GC SERVICE MANUAL 7 7 2 7 3 18 This section covers clutch removal rim sprocket removal inspection and assembly 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 2007 ICS Blount Inc F N 73472 Oct 07 633GC SERVICE MANUAL 7 CLUTCH amp RIM SPROCKET CLUTCH amp RIM SPROCKET 74 Remove clutch A Left hand threads rotate clockwise to loosen NOTE If an impact wrench is available steps 7 1 and 7 2 do not have to be performed 7 5 Remove all drive components 7 6 Inspect the clutch shoes for wear A Replace if the shoe has less than 0 04 1 mm of material as shown 73472 Oct 07 2007 ICS Blount Inc 19 7 CLUTCH amp RIM SPROCKET CLUTCH amp RIM SPROCKET 633GC SERVICE MANUAL 7 7 Inspect spring for cracks 7 8 Assemble clutch shoes as shown 7 9 Finish installation of clutch shoe as shown 20 2007 ICS Blount Inc F N 73472 Oct 07 633GC SERVICE MANUAL 7 CLUTCH amp RIM SPROCKET CLUTCH amp RIM SPROCKET E 710 Inspect the rim sprocket for wear A Replace if the rim sprocket teeth are worn to points as shown on right 711 Clean and assemble A Clean all parts in solvent B Grease clutch cup bearing with a waterproof grease ICS P N 70885 C Assemble clutch use spacer washer
19. R amp PISTON 633GC SERVICE MANUAL 13 19 Install 4 cylinder screws and washers A Use blue Loctite B Torque bolts to 104 in Ibs 11 75 Nm 13 20 Install insulator base A Install insulator base screws use blue Loctite and torque to 52 in Ibs 6 Nm 2007 ICS Blount Inc F N 73472 Oct 07 40 633GC SERVICE MANUAL 14 WATER HOSE 14 This section covers water hose and water tank cap 141 Remove water connection from hose end 14 2 Remove starter cover screw with hose hanger from saw 14 3 Remove water hose connector 14 44 Unscrew water tank cap from saw 73472 Oct 07 2007 ICS Blount Inc 41 14 WATERHOSE WATER HOSE 633GC SERVICE MANUAL 14 5 Release water tank cap from water tank tube A Depress orange fitting as shown 14 6 Assemble in the reverse order 2007 ICS Blount Inc F N 73472 Oct 07 42 633GC SERVICE MANUAL 15 IGNITION COIL 15 This section covers the removal inspection and installation of the ignition coil Removal of the starter is required Refer to section 8 if necessary 151 Remove starter 15 2 Remove starter flywheel shroud by unhooking wires 15 3 Remove ignition coil screws wave washers and plain washers 15 4 Remove ignition coil 15 5 Inspect A Look for cracked missing insulation B Clean flywheel magnets and coil if rusty F N 73472 Oct 07 2007 ICS Blount Inc 43 45 IGNITIONCOIL 633G
20. astic 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 Forbest 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 2 2007 ICS Blount Inc F N 73472 Oct 07 633GC SERVICE MANUAL 633GC Service Tool Kit P N 71700 DESCRIPTION SCRENCH PRESSURE GAUGE BULB COIL FLY WHEEL TIMING SHIM CYLINDER ASSEMBLY CLAMPS amp PISTON STOP 613 SHOCK ABSORBER TOOL SPARK TESTER 613 FLYWHEEL DISASSEMBLY TOOL LIMITER CAP REMOVAL TOOL ELECTRONIC TACHOMETER 613GC INDUCTION SEAL FLANGE W SCREWS 613GC EXHAUST SEAL FLANGE W SCREWS TUNING SCREWDRIVER 633GC FLYWHEEL PULLER 633GC FUEL PRESSURE CAP 613GC amp 633GC MAIN BEARING DRIVER TOOL 633 MAIN BEARING SPACING TOOL 633GC SHOCK ABSORBER TOOL 633GC INTAKE PORT COVER TOOL 633GC EXHAUST PORT COVER TOOL
21. cylinder cover down on the crankcase guide intake manifold into cylinder cover 10 7 Push down cylinder cover until it sits flat on crankcase A Install the cylinder cover screws using blue Loctite B Torque to 35 in Ibs 4 0 Nm 30 2007 ICS Blount Inc F N 73472 Oct 07 633GC SERVICE MANUAL 44 MUFFLER 11 This section covers the disassembly inspection and assembly of the muffler Removal of the WallWalker and cylinder cover is required Refer to sections 9 and 10 if necessary 111 Bend the corner of the muffler screw locking plate away from the muffler screw 11 2 Remove muffler screws muffler support bracket nut and muffler assembly 11 3 Clean and inspect parts of muffler assembly A Replace any damaged components 11 4 Install muffler A Assemble muffler screws muffler support bracket muffler screw locking plate B Thread muffler screws into cylinder torque to 104 in Ibs 11 75 Nm C Bend muffler screw locking plate over flat edge of muffler screw D Install muffler support bracket nut use blue Loctite torque to 26 in Ibs 2 9 Nm F N 73472 Oct 07 2007 ICS Blount Inc 31 12 CARBURETOR CARBURETOR 633GC SERVICE MANUAL 12 This section covers the removal and installation of the carburetor Removal of several groups of components is needed Refer to sections 5 and 10 If necessary carburetor tuning is covered in section 23 12 1 Remove fuel lin
22. e and fuel tank 19 4 Remove vibration isolators from fuel tank 6 if necessary 19 5 Separate the fuel tank halves A Remove the rear handle B Remove the screws 9 around the tank 50 2007 ICS Blount Inc F N 73472 Oct 07 633GC SERVICE MANUAL 19 FUELTANK 19 6 Separate the fuel tank halves using a large screwdriver A Clean the joining surface of the tank halves B Assemble in the reverse order NOTE Use a fuel proof liquid gasket material to reseal the tank Scotch Grip 847 when assembling fuel tank F N 73472 Oct 07 2007 ICS Blount Inc 51 20 CRANKCASE CRANKCASE 633GC SERVICE MANUAL 20 This section covers the disassembly inspection and assembly of the crankcase seals and crankshaft bearings 20 1 Remove outer crankshaft seal housing screws and wave washers 20 2 Remove crankcase bolts 52 2007 ICS Blount Inc F N 73472 Oct 07 633GC SERVICE MANUAL 20 CRANKCASE CRANKCASE 20 3 Heat the flywheel side of crankcase with heat gun to 150 F 65 5 O 20 4 To remove the flywheel side of crankcase tap crankshaft with plastic mallet A Suspend above work surface B Tap with mallet 20 5 Remove the flywheel side of crankcase seal 73472 Oct 07 2007 ICS Blount Inc 53 20 CRANKCASE CRANKCASE 633GC SERVICE MANUAL 20 6 Heat the clutch side of crankcase with heat gun to 150 F 65 5 C 20 7 To remove crankshaft from the
23. e from carburetor and plug 12 2 Remove choke lever from carburetor 12 3 Remove carburetor attachment screws 32 2007 ICS Blount Inc F N 73472 Oct 07 633GC SERVICE MANUAL 12 CARBURETOR CARBURETOR 12 4 Remove intake manifold 12 5 Remove carburetor A Lift and twist carburetor away from throttle linkage to remove 12 6 Assemble in the reverse order A Torque carburetor body screws to 43 in lbs 4 9 Nm 73472 Oct 07 2007 ICS Blount Inc 33 13 CYLINDER amp PISTON CYLINDER amp PISTON 633GC SERVICE MANUAL 13 This section covers the disassembly inspection and assembly of the cylinder piston and related components Removal of several component groups is required Refer to sections 5 6 10 and 12 if necessary 13 1 Remove insulator base screws A Remove carburetor insulator from cylinder 13 2 Remove cylinder screws 4 and wave washers 34 2007 ICS Blount Inc F N 73472 Oct 07 633GC SERVICE MANUAL 13 CYLINDER amp PISTON CYLINDER amp PISTON 13 3 Remove cylinder A Remove cylinder gasket and clean case 13 4 Remove wrist pin retaining clips 13 5 Press wrist pin out with an 8 mm deep socket 13 6 Remove piston and inspect Replace if damaged F N 73472 Oct 07 2007 ICS Blount Inc 35 13 CYLINDER amp PISTON CYLINDER amp PISTON 633GC SERVICE MANUAL 13 7 Remove wrist pin bearing 13 8 Cylinder gasket A Oil gasket
24. emove filter canister cover and air filter Inspect air filter Replace filter if necessary P N 71752 Remove pre filter from air filter mount Clean filter with cleaning solution and water Let dry and reinstall 2007 ICS Blount Inc 633GC SERVICE MANUAL F N 73472 Oct 07 633GC SERVICE MANUAL 5 AIRINTAKE 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 F N 73472 Oct 07 2007 ICS Blount Inc 15 6 SPARKPLUG SPARK PLUG 633GC SERVICE 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 Ifdirty clean with wire brush as shown 1 6 2007 ICS Blount Inc F N 73472 Oct 07 633GC SERVICE MANUAL 6 SPARKPLUG SPARK PLUG 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 73472 Oct 07 2007 ICS Blount Inc 17 7 CLUTCH amp RIM SPROC
25. g the fuel tank breather A Attach the pressure gauge and bulb to the fuel tank plug Plug the fuel line at the carburetor end Pressurize the tube to 4 5 psi 0 3 bar B The pressure should reduce to nearly 0 psi 0 bar over about 3 seconds 70 2007 ICS Blount Inc F N 73472 Oct 07 633GC SERVICE MANUAL 26 FUEL SYSTEM LEAKS 26 5 Ifthe pressure does not reduce to 0 psi disassemble or replace the breather A Clean the parts with fuel for the cut off saw B Assemble in reverse order C Make sure that the spring taper is pn oriented in the correct direction F N 73472 Oct 07 2007 ICS Blount Inc T1 27 CRANKCASE 633GC SERVICE MANUAL 27 This section covers testing the crankcase for leaks A leak in the crankcase can cause the engine not to run or to run too lean 271 Install the exhaust seal flange A Be sure the spark plug is installed and tightened firmly 27 2 Install the intake seal flange 27 3 Install the pressure gauge and bulb 27 44 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 T2 2007 ICS Blount Inc F N 73472 Oct 07 633GC SERVICE MANUAL 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
26. ine crank NO starter Internal damage The ignition switch is Move switch to ON and re test OFF Tighten connections or replace Is there spark NO Faulty ignition ground round wire Faulty spark plug lead Repair or replace spark plug lead Faulty ignition coil Replace ignition coil Plug is soaked with fuel Dry plug expel excess fuel from cylinder and crankcase Is the spark plug firing Ng 2 Clean and the plug to properly gapped Improper y 0 020 inch 0 05 mm Plug is internally faulty or the wronq tvpe Replace with the correct plug g yp See Spark Plug Reference Guide Loose spark plug Check cylinder NO If below 125 psi excess Tighten plug and re test compression wear on the piston Replace piston and cylinder cylinder rings Is the fuel fresh NO Fuel is old varnished or Empty tank and re fill with fresh Is the fuel mixed 25 1 contaminated fuel of the correct mixture 50 1 Clogged fuel filter Replace fuel filter Damaged fuel line Replace fuel line Is the fuel reaching the carburetor NO Damaged pulse tube Replace pulse tube Plugged fuel tank Repair or replace fuel tank breather breather Refer to Carburetor Tuning section Repair or replace fuel tank breather Is too much fuel e Carburetor is tuned reaching the incorrectly carburetor Plugged fuel tank breather NO Is the flywheel key
27. mpliance to EPA Phase emissions standards However minor adjustments may be required in certain conditions such as when operating at high elevation or after the saw has been rebuilt NOTES This cut off saws speed is mechanically governed by the carburetor This will prevent the saw from going above 11 500 rpm Attempting to set the carburetor mixture to increase the speed or power beyond this limit may seriously damage the engine Always check the air filter fuel filter and spark plug before making carburetor adjustments and clean or replace if necessary When adjusting the carburetor turn the screws very little no more than 1 4 of turn at a time Minor adjustments will have large effects on the engine Ifthe carburetor has to be readjusted completely the limiter caps must be released before the basic setting can be made Basic Setting if the carburetor needs to be completely readjusted see following procedure A Pull limiter caps using ICS9 P N 71625 B Gently turn both adjusting screws N H and L clockwise as far as possible C Turn screws counter clockwise H 1 turn from closed L 1 1 2 turns from closed Verification of rom with bar and no chain TS Idle 3 000 200 rpm XQ Full throttle 11 000 500 rpm 62 2007 ICS Blount Inc 73472 Oct 07 633GC SERVICE MANUAL 23 CARBURETOR TUNING 231 Complete carburetor readjustment 23 2 Look into adjustment screw h
28. ning section See Saw Specifications section Clean flywheel fins with wire brush See Starter Cover section Clean cylinder fins the saw e Carburetor mixture is too lean Incorrect fuel oil ratio Flywheel fins are clogged Air deflector is missing Cylinder fins are clogged The engine is overheating Clean or replace the air filter Replace fuel filter YES See Carburetor Tuning section Poor acceleration e Incorrect carburetor tune Repair or replace fuel tank Dirty or clogged air filter Plugged fuel tank breather breath r Blocked pulse tube Replace pulse tube Air leak at intake boot cylinder gasket Inspect air intake boot Uneven idle or engine imas runaway crankcase gasket Pressure test crankcase y m Faulty carburetor Replace carburetor diaphragm Diamond chain moves YES Idle speed too high Adjust idle speed at idle Broken clutch spring Replace clutch spring Damaged shock absorber Replace shock absorbers Damaged or broken Excessive vibration Replace flywheel flywheel fins Bent crankshaft Replace crankshaft F N 73472 Oct 07 2007 ICS Blount Inc 67 25 DIAGRAMS 633GC SERVICE MANUAL Saw Will Not Start CHECK POSSIBLE CAUSE REPAIR Clean rebuild or replace the recoil starter Inspect for internal damage such as seized piston Dirty or broken recoil Does the eng
29. ole A Observe orientation of the release slots on the adjustment screw limiter Cap 23 3 Insert the limiter cap puller blades into the release slots A Firmly hold the tool shaft while screwing in the puller screw until the screw head is against the puller shaft B Unscrew the puller screw 23 4 Using a 5 64 straight blade screwdriver gently turn the adjustment screws clockwise until completely closed 23 5 Setthe adjustment screws at the Basic Setting H 1 turn counterclockwise from closed L 1 1 2 turns counterclockwise from closed F N 73472 Oct 07 2007 ICS Blount Inc 63 23 CARBURETOR TUNING CARBURETOR TUNING 633GC SERVICE MANUAL 23 6 Start the saw and warm up the engine NOTE The side cover must be held tightly in place with the side cover nuts using a bar and no chain Failure to do so may result in personal injury 23 7 With a tachometer check the saw rpm with no bar and chain A Idle 3 000 300 rpm If the idle rpm does not fall into this range adjust the T screw slowly 23 8 With a tachometer check the saw full throttle rpm with no bar and chain A Target 11 500 300 rpm 23 9 If the full throttle rpm falls below this range turn the H screw in clockwise 1 16 of a turn at a time A Pulse the throttle to help stabilize the system A Do not hold the saw at maximum rpm for more than 5 seconds 23 10 If the full throttle rom falls above this range turn the H
30. with ICS 2 stroke engine oil B Install gasket and align holes and notch 13 9 Install wrist pin bearing in rod A Oil bearing with ICS 2 stroke engine oil 36 2007 ICS Blount Inc F N 73472 Oct 07 633GC SERVICE MANUAL 13 CYLINDER amp PISTON CYLINDER amp PISTON 13 10 Install rings j 13 41 Ring orientation 13 42 Install one wrist pin retaining clip F N 73472 Oct 07 2007 ICS Blount Inc 37 13 CYLINDER amp PISTON 633GC SERVICE MANUAL 13 13 Make sure wrist pin retaining clip is in the proper orientation 13 14 Lubricate wrist pin and partially install in piston 13 15 Align piston in correct orientation EXHAUST H n _ i 38 2007 ICS Blount Inc F N 73472 Oct 07 633GC SERVICE MANUAL 13 CYLINDER amp PISTON 13 16 Install piston A Oil piston with ICS 2 stroke oil B Align wrist pin with wrist pin bearing C Complete wrist pin installation D Install second wrist pin retaining clip 13 17 Install cylinder A Lubricate cylinder bore with ICS 2 stroke oil B Compress rings with ring compression tool C Slide cylinder onto piston pushing ring compression tool down 13 18 Install cylinder A Remove ring compressor B Slide cylinder onto piston and into crankcase C Align cylinder bolt holes with crankcase F N 73472 Oct 07 2007 ICS Blount Inc 39 13 CYLINDER amp PISTON CYLINDE
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