ICS 603GC Install guide
603GC Gas Utility Saw
Shop Manual
TITLE603GC SHOP MANUAL
1
Copyright © May 24, 2006 ICS, Blount Inc.
TABLE 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 19
6 SPARK PLUG 21
7 CLUTCH & RIM SPROCKET 23
8 STARTER SYSTEM 27
9 WALLWALKER 33
10 CYLINDER COVER 35
11 MUFFLER 39
12 CARBURETOR 41
13 CYLINDER & PISTON 43
14 WATER HOSE 52
15 IGNITION COIL 53
16 FLYWHEEL 55
17 FRONT HANDLE 57
18 FUEL TANK 58
19 CRANKCASE 60
20 BAR STUDS 68
21 TENSIONER 69
22 CARBURETOR TUNING 70
23 IDLE SPEED ADJUSTMENT 74
24 TROUBLESHOOTING DIAGRAMS 75
25 TROUBLESHOOTING: FUEL SYSTEM LEAKS 77
26 TROUBLESHOOTING: CRANKCASE LEAKS 80
APPENDIX
1. SPARK PLUG REFERENCE GUIDE 81
TITLE 603GC SHOP MANUAL
2Copyright © May 24, 2006 ICS, Blount Inc.
SHOP MANUAL USE
Shop Manual Use
This manual contains all the technical information necessary for carrying out repairs on the
603GC 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 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.
603GC SHOP MANUAL
3
Copyright © May 24, 2006 ICS, Blount Inc.
1. TOOLS
KEY P/N DESCRIPTION
SERVICE 71572 TOOL KIT
1 71521 SCRENCH, 13-19mm
2 71541 PRESSURE GAUGE BULB
3 71542 COIL/FLYWHEEL TIMING SHIM
4 71543 CYLINDER ASSEMBLY CLAMPS & PISTON STOP
5 73462 MAIN BEARING DRIVER TOOL
6 71546 SHOCK ABSORBER TOOL
7 71547 SPARK TESTER
8 71548 FLYWHEEL PULLER TOOL
9 71550 LIMITER CAP REMOVAL TOOL
10 71565 ELECTRONIC TACHOMETER
11 71569 INDUCTION SEAL FLANGE W/ SCREWS
12 71570 EXHAUST SEAL FLANGE W/ SCREWS
13 71573 TUNING SCREWDRIVER
Gas Saw Service Tool Kit - P/N 71572
1 2 3 4
6 7 8 9 10
11 12 13
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603GC SHOP MANUAL
4Copyright © May 24, 2006 ICS, Blount Inc.
2. SPECIFICATIONS
SPECIFICATIONS
Engine Type 2-Stroke Single Cylinder Air Cooled
Displacement 3.9 cu. in. (64 cc)
Horsepower 4.2 hp (3.1 kW) @ 9500 rpm
Engine Speed 12,500 ± 500 rpm, electronically governed
2800-3200 rpm @ idle
Weight 18.5 lbs. (8.4 kg) with bar and chain
Cutting Depth Up to 9 inches (23 cm)
Dimensions 18 inches (45 cm) length
11.5 inches (29 cm) height
10 inches (25 cm) width
Carburetor Walbro diaphragm HDA-225
Air Filtration Canister, polyester
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 (0.18 gal / 0.68 lit)
15-18 minute run time
Water Supply Minimum 20 psi (1.5 bar)
Noise Level 100 db @ 1 meter
Vibration Level 11.0 m/s
Spark Plug TYPE Champion RCJ-7Y (for spark plug reference guide see page 81)
Spark Plug Gap 0.02 inches (0.5 mm)
Sprocket Type 8-tooth rim sprocket
5
Copyright © May 24, 2006 ICS, Blount Inc.
3. SERIAL # LOCATION
3 603GC Cut-Off serial number series.
603GC SHOP MANUAL
603GC SHOP MANUAL
6Copyright © May 24, 2006 ICS, Blount Inc.
4. SPARE PARTS DIAGRAM
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
603GC Replacement Parts Price List.
KEY DESCRIPTION TORQUE LOCTITE®
PART NUMBER
Nm in‑lbs. 242
6 WRIST PIN NEEDLE BEARING 505403
11 CYLINDER BLOCK BOLT & WASHER 1.1 95 X 73874
16 CYLINDER BASE GASKET 505439
17 SPARK PLUG 2.8 243 73199
25 COMPLETE CYLINDER & PISTON ASSEMBLY 505428
33 WASHER 73963
50 SCREW PLUG 73965
60 DECOMPRESSION VALVE 1.3 113 71642
CYLINDER & PISTON ASSEMBLY
603GC SHOP MANUAL
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Copyright © May 24, 2006 ICS, Blount Inc.
4. SPARE PARTS DIAGRAM
KEY DESCRIPTION TORQUE LOCTITE®
PART NUMBER
Nm in‑lbs. 242
1 CRANKCASE PLUG 505407
2 CRANKCASE 505410
3 CRANKCASE DOWEL PIN 73281
4 CHOKE LEVER 505409
5 BAR MOUNTING STUD 509555
6 CRANKCASE GROMMET 505408
7 WASHER 73897
9 BAR MOUNT PAD COVER PLATE 505467
12 CRANKCASE GASKET 505440
13 CHOKE LEVER BUSHING 73955
15 CRANKCASE BOLT 0.8 69 X 73930
18 SCREW, 5 X 50mm 0.5 43 X 509709
22 CRANKCASE 505427
25 TENSIONER 505393
27 CRANKSHAFT BEARING 505375
28 FUEL LINE GROMMET 505627
CRANKCASE ASSEMBLY
603GC SHOP MANUAL
8Copyright © May 24, 2006 ICS, Blount Inc.
4. SPARE PARTS DIAGRAM
KEY DESCRIPTION TORQUE LOCTITE®
PART NUMBER
Nm in‑lbs. 242
1 CRANKSHAFT SEAL FLYWHEEL SIDE 73877
2 CRANKSHAFT BEARING 505375
4 CRANKSHAFT SEAL 505381
5 CRANKSHAFT BUSHING X 509487
6 WRIST PIN NEEDLE BEARING 505403
7 CRANKSHAFT ASSEMBLY 505397
KEY DESCRIPTION TORQUE LOCTITE®
PART NUMBER
Nm in‑lbs. 242
8 CLUTCH SPRING 505434
10 CRANKCASE SEAL RETAINER 505423
11 CRANKSHAFT SEAL 505381
14 CLUTCH SPACER 505421
16 CLUTCH 3.4 295 505442
17 CLUTCH SPACER INSIDE 505436
20 CLUTCH BEARING 505378
21 8T RIM SPROCKET KIT 70949
23 OUTER CRANKCASE SEAL BODY SCREW 0.3 26 X 73940
24 WAVE WASHER, 4.5mm 73285
26 CLUTCH CUP WITH SPLINED ADAPTOR 505422
CLUTCH & CRANKCASE ASSEMBLY
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