Blount ICS 613GC User's Manual
Contents
1. F N 71537 Oct 07 2007 ICS Blount Inc 3 2 SPECIFICATIONS SPECIFICATIONS 613GC SERVICE MANUAL Engine Type SPECIFICATIONS 2 Stroke Single Cylinder Air Cooled Displacement 4 9 cu in 80 7 cc Horsepower 5 7 hp 4 2 kW 9000 rpm Engine Speed 12 000 500 rpm electronically governed 2800 3200 rpm idle Chain Speed 5300 fpm 27 m s free running 4000 fps 20 m s in the cut Weight 21 lbs 9 5 kg with bar and chain Cutting Depth Up to 12 inches 30 cm Dimensions 18 inches 45 cm length 11 5 inches 29 cm height 10 inches 25 cm width Carburetor Walbro diaphragm WJ 85B Air Filtration Dry nylon Starter Dust and water shielded Ignition Electronic speed governing water sealed Clutch Three weight single spring centrifugal Fuel Mix Ratio 25 1 gasoline to oil with brand name gasoline and ICS 2 stroke engine oil or other high quality 2 stroke engine oil for air cooled engines Fuel Capacity 0 23 gal 0 88 liter 15 18 minute run time Water Supply Minimum 20 psi 1 5 bar Noise Level 100 dB 1 meter Vibration Level 10 5 m s Spark Plug TYPE Champion RCJ 7Y for spark plug reference guide see page 78 Spark Plug Gap 0 02 inches 0 5 mm Sprocket Type 8 tooth rim sprocket 2007 ICS Blount Inc F N 71537 Oct 07 613GC SERVICE MANUAL 3 SERIAL LOCATIO2. 71537 Oct 07 2007 ICS Blount Inc 57 20 CRANKCASE 613GC SERVICE MANUAL 20 3 Heat the flywheel side crankcase with heat gun for 5 minutes approximately 150 F 65 5 C 20 4 Remove the flywheel side crankcase tap crankshaft with plastic mallet A Suspend above work surface B Tap with mallet NOTE A nut should always be placed on a threaded shaft when pounding or pressing on it 20 5 Remove the flywheel side crankcase seal with 1 2 13 mm socket 58 2007 ICS Blount Inc F N 71537 Oct 07 613GC SERVICE MANUAL 20 CRANKCASE 20 6 Heat the clutch side crankcase with heat gun to 150 F 65 5 C 20 7 Remove crankshaft from the clutch side crankcase tap crankshaft with a plastic mallet A Suspend above work surface B Tap with plastic mallet 20 8 Remove the bearing from the 2 flywheel side of crankshaft F N 71537 Oct 07 2007 ICS Blount Inc 59 20 CRANKCASE CRANKCASE 613GC SERVICE MANUAL 209 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 2043 Tap with bearing driver and mallet 60 2007 ICS Blount Inc F N 71537 Oct 07 613GC SERVICE MANUAL BEENDEN CRANKCASE 20 14 Repeat with other half n 20 15 Install crankshaft into clutch side of case 20 16 Place clutch side crank case seal on cranksha
3. CYLINDER TO MUFFLER GASKET CARBURETOR ATTACHMENT SCREW WASHER MUFFLER ASSEMBLY CYLINDER BLOCK BOLT X X X 73869 73868 MUFFLER MOUNTING SCREW CARBURETOR PULSE TUBE MUFFLER SUPPORT BRACKET MUFFLER SUPPORT BRACKET SCREW COMPLETE CARBURETOR WJ 85B INTAKE MANIFOLD FLANGE SCREW 1 WASHER CARBURETOR SUPPORT BRACKET DECOMPRESSION VALVE INTAKE MANIFOLD FLANGE INTAKE MANIFOLD CARBURETOR PULSE TUBE PROTECTOR WASHER CARBURETOR ATTACHMENT SCREW SCREW SCREW GUIDE MUFFLER DEFLECTOR SCREW F N 71537 Oct 07 2007 ICS Blount Inc 7 4 SPARE PARTS DIAGRAM 613GC SERVICE MANUAL DESCRIPTION CRANKSHAFT SEAL FLYWHEEL SIDE CRANKSHAFT BEARING CRANKSHAFT FLYWHEEL WOODRUFF KEY CRANKSHAFT ASSEMBLY WRIST PIN NEEDLE BEARING CLUTCH SIDE MAIN BEARING SEAL INSIDE CRANKSHAFT BUSHING KEY DESCRIPTION OUTER CRANKCASE SEAL CLUTCH SIDE OUTER CRANKCASE SEAL BODY OUTER CRANKCASE SEAL BODY SCREW WASHER CLUTCH SPACER WASHER 8T RIM SPROCKET KIT CLUTCH NEEDLE BEARING 613GC CLUTCH DRUM ASSEMBLY CLUTCH SPACER WASHER INSIDE CLUTCH CLUTCH SPRING CO N O on o 8 2007 ICS Blount Inc F N 71537 Oct 07 613GC SERVICE MANUAL 4 SPARE PARTS DIAGRAM DESCRIPTION GUARD FLAP TORQUE TORQUE E PART NUMBER WAL
4. Refer to Carburetor Tuning section Repair or replace fuel tank breather Is too much fuel Carburetor is tuned reaching the incorrectly carburetor Plugged fuel tank breather NO Is the flywheel key t YES Loose flywheel Replace key and reinstall flywheel F N 71537 Oct 07 2007 ICS Blount Inc 73 26 FUEL SYSTEM LEAKS 613GC SERVICE MANUAL 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 Testthe main fuel pick up tube for leaks A Install the pressure gauge and bulb B Pressurize the tube to 7 psi 0 5 bar C Ifthe pressure does not maintain separate the fuel line from the carburetor 74 2007 ICS Blount Inc F N 71537 Oct 07 613GC SERVICE MANUAL 26 FUEL SYSTEMLEAKS _ D E 26 3 26 4 Plug one end of the main fuel pick up tube Re pressurize the tube to 7 psi 0 5 bar Replace the tube if pressure is not maintained If the main fuel pick up tube does maintain pressure then the leak ha been isolated to the carburetor Refer to the Walbro Diaphragm Carburetor Service Manual The fuel
5. SERVICE MANUAL F N 71537 Oct 07 2007 ICS Blount Inc 613GC 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 15 6 SPARK PLUG 17 7 CLUTCH amp RIM SPROCKET 19 8 STARTER SYSTEM 23 9 WALLWALKER 29 10 CYLINDER COVER 31 11 MUFFLER 34 12 CARBURETOR 36 13 CYLINDER amp PISTON 38 14 WATER HOSE 47 15 IGNITION COIL 49 16 FLYWHEEL 51 17 BOTTOM GUARD 53 18 FRONT HANDLE 54 19 FUEL TANK 55 20 CRANKCASE 57 21 BAR STUDS 65 22 TENSIONER 66 23 CARBURETOR TUNING 67 24 IDLE SPEED ADJUSTMENT 71 25 TROUBLESHOOTING DIAGRAMS 72 26 TROUBLESHOOTING FUEL SYSTEM LEAKS 74 27 TROUBLESHOOTING CRANKCASE LEAKS TT APPENDIX 1 SPARK PLUG REFERENCE GUIDE 78 F N 71537 Oct 07 2007 ICS Blount Inc 1 SHOPMANUAL MANUAL USE 613GC SERVICE MANUAL Shop Manual Use This manual contains all the technical information necessary for carrying out repairs on the 613GC 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 plas
6. adjust the T screw clockwise to raise RPM counterclockwise to lower RPM 23 7 With a tachometer check the saw full throttle rom with no bar and chain A Target 11 000 500 rpm 23 8 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 Do not hold the saw at max rpm for more than 5 seconds or cylinder damage could occur F N 71537 Oct 07 2007 ICS Blount Inc 69 23 CARBURETOR TUNING 613GC SERVICE MANUAL 23 9 When the carburetor is adjusted correctly set the limiter caps as shown with a 1 4 straight blade T screwdriver A L vertical B H horizontal 70 2007 ICS Blount Inc F N 71537 Oct 07 613GC SERVICE MANUAL 24 IDLE SPEED ADJUSTMENT 24 This section covers idle speed adjustment T 241 If engine stops while idling A Make sure the chain is properly tensioned B Turn T screw clockwise until chain begins to move Back T screw out turn 24 2 If chain turns at idle A BackT screw out until chain stops moving F N 71537 Oct 07 2007 ICS Blount Inc T1 25 DIAGRAMS DIAGRAMS 613GC SERVICE MANUAL 25 This section provides several flowcharts to aid diagnosing common problems CHECK POSSIBLE CAUSE REPAIR Clean or replace the air filter The tre una Dirty or clogged air filter Inspect air intake sysetm for water 9 9 Water has been inges
7. amp RIM SPROCKET 7 7 Assemble clutch shoes as shown i Gre ti 4 11 7 8 Finish installation of clutch shoe as shown TS 2 lt lt m 4 3 7 ML 7 9 Inspect the rim sprocket for wear A Replace if the rim sprocket teeth are worn to points as shown on right F N 71537 Oct 07 2007 ICS Blount Inc 21 7 CLUTCH amp RIM SPROCKET 613GC SERVICE MANUAL 710 Clean and assemble A Clean all parts in solvent B Grease clutch cup bearing with a water proof grease ICS9 P N 70885 C Assemble clutch spacer washer bearing clutch cup with rim sprocket and inside clutch spacer washer 711 Install clutch A Tighten firmly A Left hand threads 22 2007 ICS Blount Inc F N 71537 Oct 07 613GC SERVICE MANUAL 8 STARTER 8 This section covers the removal of the starter cover replacement of the starter rope and replacement of the recoil spring 8 1 Remove starter cover screws 8 2 Remove starter cover assembly from Saw 8 3 Remove starter cord shield screws 8 4 Relieve spring tension A Pull 4 6 of rope out B Line rope up with notch on pulley C Slowly rotate pulley counterclockwise until spring pressure is released Use thumb as a brake 8 5 Remove starter pulley screw and washer NOTE Hold starter cover firmly F N 71537 Oct 07 2007 ICS Blount Inc 23 8 STARTER 613GC SERVICE MANUAL 8 6 Remove starter pulley 8 7 Ins
8. carburetor tunings and clean or replace if necessary F N 71537 Oct 07 2007 ICS Blount Inc 67 23 CARBURETOR TUNING CARBURETOR TUNING 613GC SERVICE MANUAL 231 Basic Setting RPM Settings for saws H 1 3 4 turns from closed NOTE Saw tuned without bar and chain installed L 1 1 4 turns from closed Idle Speed 3 000 500 rpm Full Throttle 11 000 500 rpm Complete carburetor readjustment 23 2 Remove limiter cap A Look into adjustment screw hole Observe orientation of the release slots on the adjustment screw limiter Cap B Insert the limiter cap puller blades into the release slots C Firmly hold the tool shaft while screwing in the puller screw until the screw head is against the puller shaft D Unscrew the puller screw 68 2007 ICS Blount Inc F N 71537 Oct 07 613GC SERVICE MANUAL 23 CARBURETOR TUNING CARBURETOR TUNING 23 3 Using a 5 64 straight blade screwdriver gently turn the adjustment screws clockwise until completely closed 234 Set the adjustment screws at the Basic Setting H 1 3 4 turns from closed L 1 1 4 turns from closed A 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 5 Start the saw and warm up the engine 23 6 With a tachometer check the saw rpm with no bar and chain A Idle 3 000 300 rpm B If the idle rpm does not fall into this rang
9. WALLWALKER SIDE ARM WASHER WALLWALKER SIDE ARM SCREW SCREW SIDE COVER PLATE LOWER GUARD SIDE COVER INSERT BOTTOM REAR Sl S oleo s m o IN SIDE COVER INSERT TOP REAR SIDE COVER GROMMET SIDE COVER ASSEMBLY COMPLETE F N 71537 Oct 07 x 2007 ICS Blount Inc 1 1 4 SPARE PARTS DIAGRAM SPARE PARTS DIAGRAM 613GC SERVICE MANUAL 12 2007 ICS Blount Inc F N 71537 Oct 07 613GC SERVICE MANUAL DESCRIPTION CYLINDER COVER ASSEMBLY WITH AIR INTAKE 4 SPARE PARTS DIAGRAM TORQUE Nm in Ibs LOCTITE PART NUMBER RO AIR FILTER CANNISTER POLYESTER AIR FILTER COVER ASSEMBLY 3 SCREW 71754 71752 FILTER COVER SCREW FILTER SUPPORT FILTER COVER GASKET SCREW CYLINDER COVER LONG SOCKET HEAD CO Ni PREFILTER PLASTIC SECONDARY FILTER AIR FILTER FLANGE FILTER SUPPORT SCREW X 26 FILTER CANNISTER GASKET O RING TUBE CLAMP NO TABS COMPENSATOR TUBE BREATHER GROMMET THROTTLE ASSEMBLY O RING AIR FILTER F N 71537 Oct 07 2007 ICS Blount Inc X X 13 4 SPARE PARTS DIAGRAM SPARE PARTS DIAGRAM 613GC SERVICE MANUAL Nm in Ibs 242 L2 REARHANDLE HALE REAR HANDLE HALF 73975 SCREW 0 1 THROTTLE LEVER FUEL CAP ASSEMBLY WITH OUTER SEAL RING FUEL CAP O RING FUEL FILTER TRIGGER LOCKOUT LEVER TRIGGER LOCKOUT LEVER SPRIN
10. carburetor body screws to 43 in Ibs 5 Nm B Torque supporter screw with blue Loctite to 43 in Ibs 5 Nm F N 71537 Oct 07 2007 ICS Blount Inc 37 13 CYLINDER amp PISTON CYLINDER amp PISTON 613GC SERVICE MANUAL 13 This section covers the NOTE When replacing the 613GC cylinder disassembly inspection and and piston it is necessary to tune the assembly of the cylinder piston carburetor prior to returning the saw to and related components service see section 23 Removal of several component groups is required Refer to sections 5 6 10 and 12 if necessary 13 1 Remove carburetor base screws A Remove carburetor base from rear manifold B Remove carburetor base from pulse tube 13 2 Remove pulse tube and protective spring from cylinder base 38 2007 ICS Blount Inc F N 71537 Oct 07 613GC SERVICE MANUAL 13 CYLINDER amp PISTON 13 3 Remove rear manifold clamp 13 4 Remove rear manifold from cylinder A Inspect for holes and tears 13 5 Remove cylinder screws 4 and wave washers 13 6 Remove cylinder A Remove cylinder gasket and clean case F N 71537 Oct 07 2007 ICS Blount Inc 39 13 CYLINDER amp PISTON CYLINDER amp PISTON 613GC SERVICE MANUAL 13 7 Remove wrist pin retaining clips 2 13 8 Press wrist pin out with an 8 mm deep socket 13 9 Remove piston and inspect Replace if damaged 13 10 Remove wrist pin bea
11. tool down 13 21 Install cylinder A Remove ring compression tool B Slide cylinder down piston and into crankcase C Align cylinder bolt holes with crankcase 13 22 Install 4 cylinder screws and washers A Use blue Loctite B Torque bolts to 95 5 in Ibs 11 Nm 44 2007 ICS Blount Inc F N 71537 Oct 07 613GC SERVICE MANUAL 13 CYLINDER amp PISTON CYLINDER amp PISTON 13 23 Install rear manifold A Lubricate rear manifold with ICS 2 stroke oil B Push rear manifold onto cylinder intake C Align rear manifold seam with cylinder and crankcase seam 13 24 Install rear manifold clamp A Torque to 11 in Ibs 1 Nm 13 25 Install protective spring onto pulse tube 13 26 Install the pulse tube onto cylinder barb l F N 71537 Oct 07 2007 ICS Blount Inc 45 13 CYLINDER amp PISTON 613GC SERVICE MANUAL 13 27 Install carburetor base A Slip pulse tube into carburetor base B Slip rear manifold into carburetor base E M C Make sure rear manifold lip is flat j 13 28 Install carburetor base screws A Use blue Loctite on screws without ground wire B Make sure to include stop switch mm wire C Torque to 35 in Ibs 4 Nm 46 2007 ICS Blount Inc F N 71537 Oct 07 613GC SERVICE MANUAL 14 WATERHOSE WATER HOSE 14 This section covers water hose and water tank cap 141 Loosen hose cl
12. CAUSE REPAIR Clean rebuild or replace the recoil Dirty or broken recoil starter Does the engine Cranky NO ster Inspect for internal damage such Internal damage as seized piston YES The ignition switch is Move switch to ON and re test OFF Tighten connections or replace Is there spark NO Faulty ignition ground ground 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 Clean and the plug to properly gapped Improper y 0 020 inch 0 05 mm e Plug is internally faulty or ihe wrone tube Replace with the correct plug 9 see Spark Plug Reference Guide Loose spark plug Insure cylinder If below 125 psi excess Tighten plug and re test c c is above wear on the piston Replace piston and cylinder 5 psi cylinder rings Is the fuel fresh NO Fuelis old varnished or Empty tank and re fill with fresh Is the fuel mixed 50 1 contaminated fuel of the correct mixture 25 1 Clogged fuel filter Replace fuel filter breather breather Damaged fuel line Replace fuel line Is the fuel reaching the carburetor NO Damaged pulse tube Replace pulse tube Plugged fuel tank e Repair or replace fuel tank
13. G WASHER SCREW SHOCK ABSORBER TUBE CLAMP WITH TABS FUEL LINE SHOCK ABSORBER REAR HANDLE BUMPER SHOCK ABSORBER FUEL TANK TOP FRONT HANDLE BOLT FRONT HANDLE FUEL BREATHER COMPLETE WATER DEFLECTOR BOTTOM BREATHER TUBE BODY BREATHER TUBE ELBOW FUEL BREATHER REMOTE BREATHER TUBE EXTENSION TUBE CLAMP NO TABS NO oo o O1 O 14 2007 ICS Blount Inc F N 71537 Oct 07 613GC SERVICE MANUAL 5 This section covers the disassembly inspection and assembly air induction system 5 1 Loosen the air filter cover screws and remove air filter cover 5 2 Remove air filter from cover A Inspect air filter B Replace if necessary 5 3 Clean filter with cleaning solution and a nylon brush A Clean filter with cleaning solution and water B Let dry and reinstall F N 71537 Oct 07 2007 ICS Blount Inc 15 613GC SERVICE MANUAL 5 6 16 Inspect air filter cover gasket Replace if permanently depressed or hard due to slurry Inspect filter cannister gasket Clean Replace if necessary Secure air filter mount screws 2007 ICS Blount Inc F N 71537 Oct 07 613GC SERVICE MANUAL 6 SPARKPLUG SPARK PLUG 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 th
14. LWALKER LEVER ARM GUARD FLAP CLAMP WASHER WALLWALKER LEVER ARM SCREW GUARD FLAP SCREW 0 5 43 0 5 43 GUARD FLAP WASHER GUARD FLAP SPACER WATER HOSE GASKET FITTING RING NUT WATER HOSE O RING WATER SHUT OFF VALVE FITTING WATER HOSE HOSE CLAMP HOSE HANGER WATER HOSE COVER WATER HOSE SCREW FITTING COPPER WASHER WATER TANK CAP FUEL CAP O RING TUBE FITTING FITTING O RING HOSE HANGER BUTTON F N 71537 Oct 07 2007 ICS Blount Inc 4 SPARE PARTS DIAGRAM 613GC SERVICE MANUAL 73390 71736 73281 KEY DESCRIPTION TORQUE EE HUE PART NUMBER Nm 5 242 X X X CRANKSHAFT BEARING CRANKCASE ASSEMBLY RIGHT HALF CHOKE LEVER SPLIT PIN CRANKCASE GASKET CRANKCASE BOLT 69 WASHER BOTTOM COVER BAR MOUNT PAD SPACER COVER GUARD MOUNTING BOLT 69 SCREW CRANKCASE 43 BAR MOUNTING STUD 104 SCREW 69 BAR MOUNT PAD COVER PLATE PREMIUM TENSIONER KIT REPLACES 73283 ASSEMBLY TENSIONER SCREW RETAINER CHOKE LEVER CRANKCASE GROMMET RIGHT SIDE CHOKE LEVER BUSHING 1 0 2007 ICS Blount Inc F N 71537 Oct 07 613GC SERVICE MANUAL KEY DESCRIPTION N SIDE COVER INSERT TOP 4 SPARE PARTS DIAGRAM et PART NUMBER SIDE COVER NUT 73958 CHAIN COVER CAP MOUNTING NUT 71462
15. N 3 613GC Cut Off serial number series F N 71537 Oct 07 2007 ICS Blount Inc 5 4 SPARE PARTS DIAGRAM 613GC 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 613GC Replacement Parts Price List KEY DESCRIPTION TORQUE LOCTITE PART NUMBER Nm in Ibs 242 X N SCREW STARTER ROPE HANDLE STARTER ROPE 35 73866 505514 STARTER COIL SPRING amp HOUSING STARTER CASE PLATE STARTER COIL SPRING amp HOUSING SCREW STARTER ROPE PULLEY 3 4 5 6 7 8 STARTER PULLEY WASHER STARTER PULLEY SCREW STARTER COVER ASSEMBLY STARTER COVER AIR DEFLECTOR NUT WASHER 73911 WAVE WASHER 73912 FLYWHEEL ASSEMBLY 509163 STARTER PAWL ASSEMBLY 509207 SCREW 73914 SWITCH IGNITION TOGGLE 73237 IGNITION TOGGLE CABLE 73919 SCREW 73914 WAVE WASHER 73285 PLAIN WASHER SPARK PLUG CAP SPARK PLUG SPRING IGNITION COIL WITH SPARK PLUG LEAD amp PRIMARY SWITCH GROUND CONNECTION PLATE 2007 ICS Blount Inc F N 71537 Oct 07 613GC SERVICE MANUAL 4 SPARE PARTS DIAGRAM SPARE PARTS DIAGRAM KEY DESCRIPTION PORQUE PART NUMBER Nm in Ibs 2 42 pes COMPLETE PISTON CYLINDER ASSEMBLY CYLINDER BASE GASKET ASSEMBLY SPARK PLUG
16. UAL 10 CYLINDER COVER 10 This section covers the disassembly and assembly of the cylinder cover Removal of the air intake components and front handle is necessary Refer to sections 1 and 14 if needed 10 4 Remove the air filter mount screws 10 2 Remove the cylinder cover screws 3 10 3 Remove spark plug lead from cylinder cover 10 4 Remove fuel tank breather cap and clamp 10 5 Partially remove intake manifold from cylinder cover 10 6 Remove cylinder cover A Pull up on front B Push intake manifold through hole C Make sure throttle linkage is disengaged from cylinder cover D Guide fuel breather tube and compensator tube through cylinder cover F N 71537 Oct 07 2007 ICS Blount Inc 31 10 CYLINDER COVER 613GC SERVICE MANUAL 10 7 Remove stop switch leads EN 10 8 Inspect cylinder cover for damage Replace if necessary 10 9 Check cylinder cover water seal and filter cover gasket are in place and in good condition A Replace if necessary 10 10 Reassemble stop switch leads 10 11 Make sure carburetor screw boot is in place 10 12 Lubricate compensating tube and fuel tank breather tube with soapy water guide through cylinder cover Install compensating tube first NOTE Be careful as to not pull tubes away from their point of connection Approximately 3 4 of tube should protrude from cylinder cover 32 2007 ICS Blount Inc F N 71537 Oct 07 613GC SER
17. VICE MANUAL 10 CYLINDER COVER 10 13 Install cylinder cover A Pull spark plug lead into slot in cylinder cover B Align throttle linkage with cylinder cover and crankcase C Push the cylinder cover down on the crankcase guide intake manifold into cylinder cover D Install the cylinder cover screws Use blue Loctite Torque to 35 in lbs 4 0 Nm E Install fuel tank breather and clamp 10 14 Install air filter mount A Guide carburetor compensating tube through air filter mount Make sure manifold sits flat over lip on cylinder cover B Install air filter mount screws 3 using blue Loctite C Torque to 43 in Ibs 4 9 NM 10 15 Install air filters and cover A Install pre filter Install clean air filter Install air filter flange and tighten m Install air filter cover and tighten F N 71537 Oct 07 2007 ICS Blount Inc 33 613GC SERVICE MANUAL 11 This section covers the disassembly inspection and assembly of the muffler Removal of the WallWalker and cylinder cover is necessary Refer to sections 7 and 10 if necessary 11 1 Remove muffler support screws 11 2 Remove muffler screws and serrated washers located inside the muffler 11 3 Remove muffler and heat shield gasket A Replace any damaged components 34 2007 ICS Blount Inc F N 71537 Oct 07 613GC SERVICE MANUAL 11 4 Install muffler A Insert muffler screws and serrated washer 2 into muffl
18. amp screw 14 2 Remove water connection from hose 14 3 Remove hose from hose hanger 14 4 Remove water hose connector 14 5 Unscrew water tank cap from saw F N 71537 Oct 07 2007 ICS Blount Inc 47 14 WATER HOSE 613GC SERVICE MANUAL 14 6 Release water tank cap from water tank tube A Depress orange fitting as shown 14 7 Assemble in the reverse order 2007 ICS Blount Inc F N 71537 Oct 07 48 613GC SERVICE MANUAL 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 flywheel shroud by unhooking wires 15 2 Remove ignition coil screws wave washers and plain washers 15 3 Remove ignition coil 15 4 Inspect A Look for cracks missing insulation B Clean flywheel magnets and coil if rusty amp F N 71537 Oct 07 2007 ICS Blount Inc 49 15 IGNITIONCOIL 613GC SERVICE MANUAL 15 5 Install Ignition coil A Place ignition coil shim 0 012 on magnet counterweight side of flywheel B Set ignition coil in place C Install ignition coil screws wave washers and plain washers with blue Loctite Holding shim rotate flywheel magnet around to coil E Torque ignition coil screws to 26 in Ibs 3 Nm F Remove shim rotate flywheel to check clearance 15 6 Install flywheel shroud 15 7 Route yellow ignition stop switch wire through crankc
19. ase into carburetor chamber 15 8 Complete ignition wire routing 50 2007 ICS Blount Inc F N 71537 Oct 07 613GC SERVICE MANUAL 16 FLYWHEEL 16 This section covers the removal inspection and installation of the flywheel Removal of the starter and spark plug is required Refer to sections 6 and 8 if necessary 16 1 Insert piston stop 16 2 Remove flywheel nut wave washer and plain washer 16 3 Screw on flywheel removal tool finger tight Unscrew tool 1 turns leaving approximately 1 8 inch 5 mm space between tool and flywheel F N 71537 Oct 07 2007 ICS Blount Inc 51 16 UE 613GC SERVICE MANUAL 16 4 Using pliers hold saw up by magnet Zz counterweight 16 5 Strike flywheel removal tool with a ball peen hammer The flywheel should release from crankshaft 16 6 Inspect and clean flywheel Replace if any of the fins are broken 16 7 Inspect woodruff key 16 8 Install flywheel plain washer wave washer and flywheel nut A Torque nut to 217 in lbs 25 Nm 52 2007 ICS Blount Inc F N 71537 Oct 07 613GC 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 O Replace if damaged D Assemble in reverse order F N 71537 Oct 07 2007 ICS Blount Inc 53 18 FRONT HANDLE 613GC SERVICE MANUAL 18 This sectio
20. e cylinder 6 3 Remove the spark plug 6 4 Inspect the spark plug A If dirty clean with a wire brush as shown F N 71537 Oct 07 613GC 2007 ICS Blount Inc 17 6 SPARK PLUG 613GC SERVICE MANUAL B if necessary to 0 02 0 5 mm NOTE If the spark plug must be replaced refer to the Spark Plug Reference Guide on page 78 to select the correct replacement plug 6 5 Assemble in the reverse order A Make sure the plug boot is seated completely F N 71537 Oct 07 2007 ICS Blount Inc 18 613GC SERVICE MANUAL 7 CLUTCH amp RIM SPROCKET CLUTCH amp RIM SPROCKET 7 This section covers clutch removal rim sprocket removal inspection and assembly Refer to sections 5 and 6 if needed 71 Insert piston stop tool into spark plug hole 7 2 Pull starter handle until piston stops against tool 7 3 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 F N 71537 Oct 07 2007 ICS Blount Inc 19 7 CLUTCH amp RIM SPROCKET 613GC SERVICE MANUAL 7 4 Remove all drive components 7 5 Inspect the clutch shoes for wear A Replace if the shoe has less than 0 04 1 mm of material as shown 7 6 Inspect spring for cracks w 20 2007 ICS Blount Inc F N 71537 Oct 07 613GC SERVICE MANUAL 7 CLUTCH 8 RIM SPROCKET CLUTCH
21. er B Hold muffler screws in place with heat shield gasket C Thread muffler screws into cylinder torque to 78 in Ibs 9 Nm 11 5 Install muffler support A Install top 3 muffler support screws and serrated washer finger tight B Install bottom 2 muffler support screws with blue Loctite C Torque top screws to 78 in lbs 9 Nm D Torque bottom screws to 52 in lbs 6 Nm F N 71537 Oct 07 2007 ICS Blount Inc 35 12 CARBURETOR 613GC SERVICE MANUAL 12 This section covers the NOTE All saws are equipped with removal and installation of the carburetor model WJ 85A carburetor Removal of the air intake components and cylinder cover is required Please refer to sections 5 and 10 or 11 if necessary Carburetor tuning is covered in section 23 121 Remove throttle linkage A Push trigger end out of rear handle B Pivot linkage around C Remove carburetor end of linkage from throttle rod tab on carburetor 12 2 Remove choke lever split pin 12 3 Remove choke lever 12 4 Remove adjustment screw boot 36 2007 ICS Blount Inc F N 71537 Oct 07 613GC SERVICE MANUAL 12 CARBURETOR 12 5 Remove carburetor support screw 1 with 4 Torx or straight blade screwdriver 12 6 Remove carburetor body screws 2 12 7 Remove fuel line 12 8 Remove pulse tube 12 9 Remove carburetor compensator tube on top of carburetor 12 410 Assemble in the reverse order A Torque
22. ft A lightly with bearing driver and mallet F N 71537 Oct 07 2007 ICS Blount Inc 61 20 CRANKCASE CRANKCASE 613GC SERVICE MANUAL 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 62 2007 ICS Blount Inc F N 71537 Oct 07 613GC SERVICE MANUAL BEENDEN CRANKCASE 20 20 Assemble crankcase halves tap F with bearing driver and mallet o b CR 20 21 Install main crankcase bolts A Use blue Loctite B Torque to 69 in Ibs 8 Nm NOTE The 3 remaining crankcase bolts will be installed during the completion of the saw assembly 20 22 Install flywheel side crankcase seal tap with bearing driver and mallet F N 71537 Oct 07 2007 ICS Blount Inc 63 20 CRANKCASE CRANKCASE 613GC SERVICE MANUAL 20 23 Trim crankcase gasket flush 64 2007 ICS Blount Inc F N 71537 Oct 07 613GC SERVICE MANUAL 21 5 amp BAR STUDS amp BAR PAD 21 This section covers the removal and installation of the bar studs and bar pad NOTE On saws with Serial s beginning 0482421700 and O71XXXXXXX it is necessary to remove the bar mount pad cover plate first 211 Remove bar studs A Remove side cover B Install side cover nuts flange to flange and tighten together C Attempt to remove the inside nut w
23. hich should pull out the bar stud D Repeat on second bar stud 21 2 Remove bar pad A Remove sealing o ring 21 3 Assemble in reverse order F N 71537 Oct 07 2007 ICS Blount Inc 65 22 CHAIN TENSIONER CHAIN TENSIONER 613GC SERVICE MANUAL 22 This section covers the removal and installation of the chain tensioner 221 Remove bar plate to expose the chain tensioner NOTE Saws with serial Z s lower than 0482421700 are not equipped with a bar mount pad cover plate 22 2 Unscrew tensioner to remove A Remove tensioner pin B Remove tensioner screw keeper 22 3 Assemble in reverse order 66 2007 ICS Blount Inc F N 71537 Oct 07 613GC SERVICE MANUAL 23 CARBURETOR TUNING CARBURETOR TUNING 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 compliance to EPA Phase emissions standards However minor adjustments may be required in certain conditions such as high elevation NOTES These cut off saws are equipped with an electronic speed limiter as part of the ignition system This will prevent the saw from going above 12 500 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 pre filter fuel filter and spark plug before making
24. n covers the removal inspection and installation of the front handle 18 1 Remove front handle screws on right side 18 2 Remove front handle screws on bottom 18 3 Install front handle A Roll front handle into place Install front handle screws 4 Use blue Loctite Torque to 69 in lbs 8 Nm m 54 2007 ICS Blount Inc F N 71537 Oct 07 613GC SERVICE MANUAL 19 FUELTANK 19 This section covers the disassembly inspection and assembly of the vibration isolaters fuel tank and rear handle 191 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 F N 71537 Oct 07 2007 ICS Blount Inc 613GC SERVICE MANUAL 19 3 Separate crankcase and fuel tank NOTE Saws have a rubber water deflector connected to the 2 bottom vibration isolators on the clutch side circled 19 4 Remove vibration isolators from fuel tank 6 if necessary 19 5 Assemble in reverse order NOTE During assembly be careful to avoid kinking the fuel line 56 2007 ICS Blount Inc F N 71537 Oct 07 613GC SERVICE MANUAL 20 CRANKCASE CRANKCASE 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 gt
25. pect coil spring A Replace if spring hook is damaged Attempting to re bend the spring hook may cause the hook to break off B Carefully remove coil spring and housing to prevent spring from unwinding 8 8 Lubricate with light weight oil 8 9 Replace parts carefully 24 2007 ICS Blount Inc F N 71537 Oct 07 613GC SERVICE MANUAL 8 STARTER 8 10 Inspect pulley spring catch A Clean with cleaning solution B Replace if worn or broken 8 11 Install starter rope and tie knot 8 12 Install pulley A Wind rope onto pulley clockwise leaving 4 6 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 p TT F N 71537 Oct 07 2007 ICS Blount Inc 25 8 STARTER 613GC SERVICE MANUAL 8 14 Wind the recoil spring A Line 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 I lii Wiz ll 8 16 Remove starter pawl screws 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 26 2007 ICS Blount Inc F N 71537 Oct 07 613GC SERVICE MANUAL amp STARTER STARTER 8 18 Assemble components A Make s
26. ring 40 2007 ICS Blount Inc F N 71537 Oct 07 613GC SERVICE MANUAL 13 CYLINDER amp PISTON CYLINDER amp PISTON 13 11 Cylinder gasket A Oil gasket with ICS 2 stroke engine oil B Install and align holes and notch 13 12 Install wrist pin bearing in rod A Oil bearing with ICS 2 stroke engine oil 13 13 Install rings F N 71537 Oct 07 2007 ICS Blount Inc 41 13 CYLINDER amp PISTON 613GC SERVICE MANUAL 13 14 Ring orientation 13 15 Install one wrist pin retaining clip 13 16 Make sure wrist pin retaining clip is in the proper orientation A Improper installation may result in serious engine damage 42 2007 ICS Blount Inc F N 71537 Oct 07 613GC SERVICE MANUAL 13 CYLINDER amp PISTON CYLINDER amp PISTON 13 17 Partially install wrist pin 13 18 Align piston in correct orientation e 1319 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 Make sure wrist pin retaining clip is in the proper orientation see 13 16 F N 71537 Oct 07 2007 ICS Blount Inc 43 13 CYLINDER amp PISTON CYLINDER amp PISTON 613GC SERVICE MANUAL 13 20 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
27. 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 Fuel tank breather is located inside the air filter compartment F N 71537 Oct 07 2007 ICS Blount Inc Ir ll 75 613GC SERVICE MANUAL 26 5 Testing the fuel tank breather A Attach the pressure gauge and bulb to the main fuel pick up tube at the carburetor 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 26 6 Ifthe pressure does not reduce to 0 psi disassemble or replace the breather A Clean the parts with solvent or fuel UJ Assemble in reverse order C Make sure that the spring taper is oriented in the correct direction 76 2007 ICS Blount Inc F N 71537 Oct 07 613GC SERVICE MANUAL 27 CRANKCASE LEAKS CRANKCASE LEAKS 27 This section covers testing the W waww A crankcase for leaks A leak in the crankcase can cause the 9 engine not to run 4 271 Install the intake seal flange A Plug oylinder pulse tube 27 2 Install the exhaust seal flange 27 3 Block one of the flange tubes with a rubber plug 274 Install the pressure gauge and bulb 27 5 Pressurize the crankcase to 7 psi 0 5 bar 27 6 If the pressure does not remain the same use soapy water to find the leak NOTE It is recommended that
28. ted Inspect fuel system for water all speeds Loose or dirty spark plug Tighten clean or replace spark plug A A dirty air filter is the 1 reason for engine problems Operator is overworking x the saw Carburetor mixture is too 525 See Saw Specifications section The engine is overheating incorrect fuel oil ratio Clean flywheel fins with wire brush Flywheel fins are clogged See Starter Cover section Air deflector is missing Cylinder fins are clogged s HIS cylinder fins See Operator s Manual See Carburetor Tuning section Clean or replace the air filter Replace fuel filter qp emassa 4 Senda acte Repair or replace fuel tank Dirty or clogged air filter Plugged tank breather breather Blocked pulse tube Replace pulse tube Air leak at intake boot Dnevanddiaorcndlhe cylinder gasket or Inspect air intake boot crankcase gasket Pressure test crankcase y y 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 e Replace crankshaft 72 2007 ICS Blount Inc F N 71537 Oct 07 613GC SERVICE MANUAL 25 DIAGRAMS DIAGRAMS Saw Will Not Start CHECK POSSIBLE
29. this test be performed after an engine rebuild F N 71537 Oct 07 2007 ICS Blount Inc 71 APPENDIX 613GC SERVICE MANUAL 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 sure that the plug will work SPARK PLUG REFERENCE GUIDE ICS RESISTOR CHAMPION RESISTOR BOSCH RESISTOR RESISTOR 73199 RCJ7Y BPMR7A WSR7F 78 2007 ICS Blount Inc F N 71537 Oct 07 613GC 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 F N 71537 Oct 07
30. tic 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 orings 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 ICS cut off saws 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 71537 Oct 07 613GC SERVICE MANUAL Gas Saw 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
31. ure the spring is in the correct position B Use blue Loctite on the pawl screws C Torque to 60 in Ibs 6 8 Nm 8 19 Wind the pawl spring A Use needle nose pliers to move the tail of the spring into position 8 20 Install starter cover A Pull out cord 4 6 B Slowly release while placing cover to allow pawls to engage F N 71537 Oct 07 2007 ICS Blount Inc 27 amp STARTER STARTER 613GC SERVICE MANUAL 8 21 Install starter cover screws A Use blue Loctite B Torque to 60 in Ibs 7 Nm 28 2007 ICS Blount Inc F N 71537 Oct 07 613GC SERVICE MANUAL 9 WALLWALKER WALLWALKER 9 This section covers the removal inspection and assembly of the WallWalker and guard flap 9 1 Inspect Wall Walker tip A If the tip is worn as shown replace 9 2 Remove crankcase screws and wave washers 9 3 Remove WallWalker from saw NOTE On late model saws it is necessary to remove the bar plate prior to removing the crankcase screws 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 71537 Oct 07 2007 ICS Blount Inc 29 9 WALLWALKER WALLWALKER 613GC SERVICE MANUAL 9 6 Reassemble in the reverse order A Install crankcase screws and wave washers B Use blue Loctite C Torque to 70 in Ibs 7 9 Nm 2007 ICS Blount Inc F N 71537 Oct 07 30 613GC SERVICE MAN
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