633GC / 633F4 OPERATOR’S MANUAL F/N 70944 Oct 09 © 2009 ICS, Blount Inc.
INTRODUCTION / TABLE OF CONTENTS TITLE 633GC / 633F4 OPERATOR’S MANUAL INTRODUCTION This manual outlines the maintenance and operation of ICS® manufactured products. The 633GC / 633F4 chainsaw is designed to cut concrete, stone, and masonry when used with the appropriate genuine ICS Diamond Chain. Ductile iron pipe may be cut ONLY if using PowerGritTM Utility Saw Chain.
SYMBOLS & LABELS TITLE 633GC / 633F4 OPERATOR’S MANUAL THE FOLLOWING SYMBOLS & DEFINITIONS ARE FOUND THROUGHOUT THIS MANUAL AND ARE DESIGNED TO MAKE YOU AWARE OF POTENTIAL HAZARDS OR UNSAFE PRACTICES. WARNING A potentially hazardous situation exists which, if not avoided, could result in death or serious injury. CAUTION A potentially hazardous situation exists which, if not avoided, may result in minor or moderate injury or property damage.
633GC / 633F4 OPERATOR’S MANUAL TITLE SAFETY THE FOLLOWING SYMBOL APPLIES TO ALL THE ITEMS LISTED ON THIS PAGE WARNING A potentially hazardous situation exists which, if not avoided, could result in death or serious injury. Chain breakage can result in high-speed ejection of parts, which can result in death or serious personal injury to operators or bystanders. The items listed below are critical to minimizing the risk of chain breakage and injury.
SAFETY TITLE 633GC / 633F4 OPERATOR’S MANUAL THE FOLLOWING SYMBOL APPLIES TO ALL ITEMS LISTED ON THIS PAGE CAUTION A potentially hazardous situation exists which, if not avoided, may result in minor or moderate injury or property damage. • Always turn a diamond chainsaw OFF when performing maintenance on the saw including chain tensioning. • Never use equipment that is not functioning properly. Have the saw repaired by qualified service personnel. • Turn engine OFF before refueling.
33GC / 633F4 OPERATOR’S MANUAL TITLE SAFETY THE FOLLOWING SYMBOL APPLIES TO ALL ITEMS LISTED ON THIS PAGE IMPORTANT A potential situation exists which, if not avoided, may result in product or property damage. Note: The diamond chainsaw is equipped with a two-stroke engine and must always be run using a mixture of gasoline and ICS® two-stroke engine oil. It is important to accurately measure the amount of oil to be mixed to ensure that correct mixture is obtained.
TECHNICALTITLE SPECIFICATIONS 8 633GC / 633F4 OPERATOR’S MANUAL Engine Type 2-stroke, Air Cooled Displacement 101cc (6.2 cu in) Horsepower 6.5 HP (4.8 kw) @ 8700 RPM Engine Speed 11,500+/-500 RPM, Mechanically governed Diamond Chain Speed 4,950 fpm (25m/s), free running Idling Speed 2800-3200 RPM Weight 27.5 lbs (12.5kg) with guide bar and diamond chain Cut Depth 14 in (36cm) & 16.2 in (41cm) Bar Lengths 14 in (36cm) & 16.
633GC / 633F4 OPERATOR’S MANUAL TITLE SET-UP GUIDE BAR AND DIAMOND CHAIN INSTALLATION STEP 3 Mount the diamond chain on the guide bar starting at the drive sprocket and continue over the guide bar nose. STEP 1 Loosen side cover nuts and remove side cover. Install the diamond chain correctly. If using a single bumper chain, the bumper must always lead the segment into the cut as shown here. STEP 2 Place bar onto studs and chain adjustment pin. STEP 4 Install the side cover.
SET-UP TITLE 633GC / 633F4 OPERATOR’S MANUAL GUIDE BAR AND DIAMOND CHAIN INSTALLATION 3/4" (18 mm)** ** As measured without pulling downward (eg. hanging by gravity) STEP 5 Make sure all the drive links are inside the guide bar groove then lift the bar nose and tension the chain by turning the screw clockwise. STEP 6 If the chain is too loose, it could come off the bar, or it will allow the drive sprocket to spin without turning the chain, which can chew up the chain drive links.
633GC / 633F4 OPERATOR’S MANUAL TITLE SET-UP GUIDE BAR AND DIAMOND CHAIN INSTALLATION STEP 9 Continue to lift up on the nose of the guide bar and firmly tighten the side cover nuts. NOTE: To prevent chain tensioner breakage, be sure the side cover nuts are tightened to approximately 20 ft-lbs (27 Nm). STEP 10 Attach to water source with pressure of not less than 20 psi (1.5 bar).
OPERATION TITLE 633GC / 633F4 OPERATOR’S MANUAL FUEL HANDLING CAUTION FUEL MIXTURE: 25:1 gasoline/oil mixture. GASOLINE OIL GASOLINE OIL US Gallon 1 2 1/2 5 US Fl oz 5.2 12.8 25.6 Liters 1 5 10 20 ml 40 200 400 800 • Use premium unleaded gasoline with a minimum octane rating of 90. If lower octane gasoline is used, engine temperature will increase which can result in a piston seizure and damage to the engine. • Always provide adequate ventilation when handling fuel.
633GC / 633F4 OPERATOR’S MANUAL TITLE OPERATION STARTING AND STOPPING A DIAMOND CHAINSAW WARNING Never start a diamond saw without the bar, chain and side cover properly assembled. Otherwise, the clutch can come loose and cause personal injuries. CAUTION Always move a diamond chainsaw at least 10 feet (3 m) away from the fueling area before starting. IMPORTANT Place the diamond saw on clear ground. Ensure that secure footing is established and chain is not contacting any objects.
OPERATION TITLE 633GC / 633F4 OPERATOR’S MANUAL PRE-CUT CHECKLIST • Proper Chain Installation: The bumper should lead the segment into the cut, double bumper chains may be mounted in either direction. • Proper Chain Tension: The chain should be tight but easily pulled around the guide bar by hand. • Ensure all safety devices are properly mounted and functional and that all controls are in proper working order.
633GC / 633F4 OPERATOR’S MANUAL TITLE OPERATION CUTTING WITH THE 633GC To start a cut, hold trigger on full throttle and slowly plunge the nose of the bar straight into the wall. Lengthen the cut and engage the point of the fixed Wallwalker ®. Use the fixed Wallwalker ® as a pivot point and pull up on the rear handle to rotate the bar into the cut. CUTTING TIPS • Always operate the diamond chainsaw at full throttle. Apply enough feed force so that the free running RPM drops 20 to 30%.
OPERATION TITLE 633GC / 633F4 OPERATOR’S MANUAL CUTTING DUCTILE IRON PIPE WITH THE POWERGRITTM UTILITY SAW CHAIN NEVER cut ductile iron pipe with the saw unless using PowerGrit Utility Saw Chain. The following are safety precautions that should always be followed when using PowerGrit. • Before cutting, make sure the pipe is in a safe condition to be cut. Support the work piece in such a way that the cut remains open during the cutting operation and when the cut is finished.
633GC / 633F4 OPERATOR’S MANUAL TITLE MAINTENANCE Follow these simple maintenance guidelines and the 633GC Concrete Cutting Saw will keep running at its very best. AFTER EACH USE 1. Rinse the saw, guide bar and diamond chain with water. 2. Follow instructions on the Daily Maintenance Label, located on the air filter cover. 3. Inspect and tighten all fasteners as necessary. 4. Inspect drive sprocket for tooth wear and replace if tooth tips are pointed. 5. Inspect the starter cord. Replace if frayed. 6.
MAINTENANCE TITLE 633GC / 633F4 OPERATOR’S MANUAL AIR FILTER IMPORTANT The air filter is made from a nylon micro mesh air filter and an internal spit-back screen. Both must be kept clean for the engine to operate properly. If the saw is not reaching full RPM, most likely one or both of the air filters are dirty. • The air filter (Figure 1) should be free of holes and white in color. • Replace air filter when dirty. • The spit-back screen (Figure 2) should be free of holes and be white in color.
633GC / 633F4 OPERATOR’S MANUAL TITLE MAINTENANCE STARTER ROPE REPLACEMENT • Remove the four screws attaching the starter assembly to the crankcase, and remove the starter cover assembly. • Remove the three starter pulley cover screws. • Remove the starter pulley cover. • Pull the rope out until the notch in the pulley has made at least two full revolutions and is at the rope inlet, then hold the pulley in place (Figure 1).
MAINTENANCE TITLE 633GC / 633F4 OPERATOR’S MANUAL STARTER HOUSING ASSEMBLY • To reattach the starter housing, first pull the starter cord out, then hold the starter housing against the crankcase (Figure 1). Slowly release the starter cord to enable the pulley to fit between the pawls. • Insert and tighten the screws. Use blue Loctite® #242. Figure 1 CHAIN TENSIONER IMPORTANT The chain tensioner (Figure 2) can become clogged with concrete slurry during cutting.
633GC / 633F4 OPERATOR’S MANUAL TITLE MAINTENANCE DRIVE SPROCKET IMPORTANT The drive sprocket (rim sprocket) is a wear item and should be replaced every 2-3 diamond chains. IMPORTANT The needle bearing inside the splined adapter should be greased regularly and should be replaced with each new clutch cup. A rim sprocket system (Figure 1) consists of a clutch cup w/ splined adapter and a rim sprocket. When the rim sprocket wears out, it is the only part that needs to be replaced.
MAINTENANCE TITLE 633GC / 633F4 OPERATOR’S MANUAL DRIVE SPROCKET INSTALLATION • Slide the rim sprocket onto the splined adapter, either side out. • Apply a liberal amount of grease to the needle bearing. • Place the thin metal washer onto drive shaft. Slide the needle bearing and clutch cup w/rim sprocket onto shaft (Figure 1). • Install the clutch by turning it counter clockwise on the drive shaft and firmly tighten. Replace the clutch slurry shield.
633GC / 633F4 OPERATOR’S MANUAL TITLE MAINTENANCE CARBURETOR • The function of the carburetor is to mix fuel with air. Adjustments other than idle speed should be made by a servicing dealer. • Before adjusting the engine idle speed, make sure the air filter is clean and the engine is warmed up. T – Idle Screw is adjusted so that the engine idles smoothly but the clutch does not engage.
MAINTENANCE TITLE 633GC / 633F4 OPERATOR’S MANUAL After Every Use …. After 10 hours …. 1. Rinse saw, bar & chain with water. 3. Inspect, flush and grease the chain tensioner. 1. Remove the starter cover and lubricate the starter recoil spring. Clean the fins and the starter pawls on the flywheel with a wire brush, then grease starter pawls. 4. Inspect drive sprocket for wear. Replace sprocket if groove cuts through the top of the tooth. 2. Remove & clean the spark plug. Check the electrode gap.
633GC / 633F4 OPERATOR’S MANUAL TROUBLESHOOTING TROUBLESHOOTING • SAW WON’T REACH FULL RPM – Air filter or pre filter may be dirty. • SLOW CHAIN SPEED – Chain tension too tight. Chain should always be able to be pulled around the bar by hand. It is normal for the chain drive links to hang below the bar. • POOR CUTTING SPEED – Diamonds may be “glazed over”. Make a few cuts in an abrasive material such as a cinder block to expose the diamonds. • PREMATURE CHAIN STRETCH – Not enough water pressure.
REFERENCE 633GC / 633F4 OPERATOR’S MANUAL APPROXIMATE CUTTING RATES Material Cutting Rate Hard aggregate & 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) INCH-FOOT DEFINITION An in-ft is a measure of how much material is to be cut. An in-ft is defined as: depth in inches times length in feet. Note: 129 in-ft = 1m2 Example: How many in-ft are in this doorway? 1.
633GC / 633F4 OPERATOR'S MANUAL ICS, Blount Inc. 4909 SE International Way Portland, OR 97222 Tel 800-321-1240 Fax 503-653-4393 icsbestway.com © 2009 ICS, Blount Inc.
