McCulloch MXC1640DK, MXC1640DH, MXC1840DH, MXC1840D, MXC1640D User Manual

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USER MANUAL

Gasoline Chain Saws

Models : MXC1640D, MXC1640DK, MXC1640DH, MXC1840D, MXC1840DK,

MXC1840DH

SAFETY

OPERATION

MAINTENANCE

This product has been tested at a computed kickback angle (CKA) and conforms to ANSI B175.1-2000, Annex C. CAN/CSA-Z62.1-03

WARNING • PLEASE READ

Beware of kickback. Hold chain saw firmly with both hands when using. For your own safety, please read and follow the

ety precautions in this manual before attempting to operate your chain saw. Improper use can cause serious injury.

saf

inted in China

PN 9096-31P202

INTRODUCTION 1 - GENERAL INFORMATION

PLEASE READ

Dear Customer, Thank you for purchasing a McCulloch product. With prop-

er operation and maintenance, it will provide you with years of service.

In order to make the best use of your investment, be CER-

TAIN to familiarize yourself with the contents of the ENTIRE user manual before attempting to operate and

maintain your unit. Be sure to carefully follow the step-by-step instructions in

this manual to start, operate and maintain your new product.

In the manual there will be the following call-outs: NOTE:, WARNING / CAUTION and WARRANTY.

A NOTE: is used to convey additional information, to high- light a particular explanation, or to expand a step description.

A WARNING or CAUTION identifies a procedure which, if not undertaken or if improperly done, can result in serious personal injury and/or damage to the unit.

The (WARRANTY SYMBOL) serves notice that unless instructions or procedures are followed, any damage caused will void the warranty and repairs will be at owner’s expense.

Pay particular attention to the safety precautions. They are written for your protection and contain important information you must know to safely operate your chain saw.

FOR WARRANTY OR SERVICE CONTACT THE NEAREST AUTHORIZED SERVICE CENTER - LOCATE YOUR NEAR-

EST SERVICE CENTER BY CALLING THE TOLL FREE

NUMBER IN THIS MANUAL.

TABLE OF CONTENTS

1 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . .3

1-1. General Identification 1-2. Safety Features

2 SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

2-1. Kickback Safety Precautions 2-2.

Other Safety Precautions 2-3. General Safety Precautions for chain saw users 2-4. More About Kickback 2-5. Kickback safety Labels 2-6. International Symbols

3 ASSEMBLY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . .7

3-1.

Introduction 3-2. Assembly Requirements 3-3. Guide Bar / Saw Chain / Clutch Cover Installation 3-4. Saw Chain Tension Adjustment 3-5. CHAIN BRAKE

4 FUEL AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . .10

4-1. Fuel 4-2. Mixing Fuel 4-3. Fuel and Lubrication Symbols

Fuel Mixing Table 4-4. Recommended Fuels 4-5. Chain and Bar Lubrication

5 OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . .11

5-1. Engine Pre-Start Checks 5-2. To Start Engine 5-3. Re-Starting a Warm Engine 5-4. To Stop Engine 5-5. CHAIN BRAKE 5-6. Saw Chain / Bar Lubrication 5-7. Automatic Oiler

6 GENERAL CUTTING INSTRUCTIONS . . . . . . . . . . . . . . . .13

6-1. Felling 6-2. Limbing 6-3.

Bucking

6-4. Bucking Using a Sawhorse

7 MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . .15

7-1.

Pre

ventive Maintenance

7-2. Air Filter

Fuel Filter

7-3. 7-4. Spark Arrester Screen

k Plug

Spar

7-5.

uretor Adjustment

Carb

7-6.

ing a Chain Sa

Stor

7-7.

Removing a Unit From Storage

7-8.

AR / CHAIN MAINTENANCE

Guide Bar Maintenance

8-1.

Chain Maintenance

8-2.

Chain Replacement Inf

8-3.

OUBLESHOO

ONE YEAR LIMITED WARRANTY . . . . . . . . . . . . . . . . . . .21

2 3

Mechanical Test

Operational Test

THE ENGINE

TING

. . . . . . . . . . . . . . . . . . . . . .

mation

. . . . . . . . . . . . . . . . . .

1-1.GENERAL IDENTIFICATION

1. SAW CHAIN

2. GUIDE BAR

3. SPARK ARRESTER SCREEN

4. CHAIN BRAKE

5. FRONT HANDLE

6. ST

7. STOP SWITCH

8. SAFETY TRIGGER

9. REAR HANDLE / BOOT LOOP

10.

11. OIL TANK CAP

12. STARTER COVER

13.

14. CHAIN TENSION RING

15. MUFFLER SHIELD

16.

17. AIR CLEANER COVER

18. CHOKE LEVER

19.

20. PRIMER BULB

21. THROTTLE / TRIGGER

22.

23.

24. SCREWDRIVER/WRENCH

25.

LEVER /HAND GUARD

ARTER HANDLE

TANK CAP

FUEL

UCKING SPIKE

ARK PLUG

THROTTLE LATCH

CHAIN COVER CONTROL BUTTON CHAIN CA

TCHER

CARRY CASE (Available on some models)

1-2. SAFETY FEATURES

Numbers preceding the descriptions correspond with the numbers on preceding page to help you locate the safety feature.

1 LOW KICKBACK SAW CHAIN helps significantly reduce

kickback, or the intensity of kickback, due to specially designed depth gauges and guard links.

2 GUIDE BAR reduced kickback guide bar helps significantly

reduce kickback by reducing the guide bar tip radius.

3 SPARK ARRESTER SCREEN retains carbon and other

flammab engine exhaust flow. Compliance with local, state and federal laws and/or regulations governing the use of a spark arrester screen is the user’ Precautions for additional information.

4 CHAIN BRAKE®LEVER / HAND GUARD protects the

operator’s left hand in the event it slips off the front handle while sa

4 CHAIN BRAKE®is a safety feature designed to reduce the

possibility of injury due to kickback by stopping a moving saw chain in milliseconds. It is activated by the CHAIN BRAKE

Stop switch must be pushed to ON position to start or restart engine

8 SAFETY TRIGGER prevents accidental acceleration of the

engine saf

23 CHAIN CATCHER reduces the danger of injury in the event

saw chain breaks or derails during operation. The chain catcher is designed to intercept a whipping chain.

le particles over 0.023 inches (0.6mm) in size from

See Saf

s responsibility

unning.

w is r

lever.

OP SWITCH

. Throttle trigger (21) cannot be squeezed unless the

ety latch is depressed.

immediately stops the engine when tr

ety

ipped.

2 - SAFETY PRECAUTIONS

SAFETY PRECAUTIONS FOR CHAIN SAW USERS

(ANSI B175.1-2000, Annex C. CAN/CSA-Z62.1-03)

2-1. KICKBACK SAFETY PRECAUTIONS

WARNING

Kickback may occur when the nose or tip of the guide bar touches an object, or when the wood closes in and pinches the saw chain in the cut. If bar tip makes contact with something it may cause a lightning-fast reverse reaction, kicking the guide bar up and back towards the operator. Pinching the saw chain along the top of the guide bar may push the guide bar rapidly back towards the operator.Either of these reactions may cause you to lose control of the saw, which could result in serious personal injury. Do not rely exclusively upon the safety devices built into your saw. As a chain saw user, you should take several steps to keep your cutting jobs free from accident or injury.

1. With a basic understanding of kickback, you can reduce or eliminate the element of surprise. Sudden surprise contributes to accidents.

2. Keep a good firm grip on the saw with both hands, the right hand on the rear handle, and the left hand on the front handle, when the engine is running. Use a firm grip with thumbs and fingers encircling the chain saw handles. A firm grip will help you reduce kickback and maintain control of the saw. Don’t let go.

3. Make sure that the area in which you are cutting is free from obstructions. Do not let the nose of the guide bar contact a log, branch, or any other obstruction which could be hit while you are operating the saw.

4. Cut at high engine speeds.

5. Do not overreach or cut above shoulder height.

6. Follow manufacturer’s sharpening and maintenance instructions for the saw chain.

7. Only use replacement bars and chains specified by the manufacturer or the equivalent.

w chain is chain that has met the

k sa

TE:Low-kic

kickback performance requirements of ANSI B175.1-2000

ican National Standard for Power Tools Gasoline-

(Amer

ered Chain Sa

P on the representative sample of chain saws below 3.8 c.i.d. specified in ANSI B175.1-2000.

2-2. OTHER SAFETY PRECAUTIONS

1. DO NOT operate a chain saw with one hand! Serious injury to the operator, helpers, bystanders, or any combination of these persons may result from onehanded operation. A chain saw is intended for twohanded use.

DO NO

3. Use safety footwear, snug-fitting clothing, protective gloves, and eye, hearing and head protection devices.

kbac

T oper

ws Saf

ate a chain sa

ety Requirements) when tested

w when y

ou are f

atigued.

NOTE: These safety precautions are intended primarily for the consumer or occasional user. When using a chain saw for logging purposes, refer to the Code of Federal

4. Use caution when handling fuel. Move the chain saw at least 9.1m (30 feet) from the fueling point before starting the engine.

5. DO NOT allow other persons to be near when starting or cutting with the chain saw. Keep bystanders and animals out of the work area.

6. DO NOT start cutting until you have a clear work area, secure footing, and a planned retreat path from the falling tree.

7. Keep all parts of your body away from the saw chain when the engine is running.

8. Before you start the engine, make sure that the saw chain is not contacting anything.

9. Carry the chain saw with the engine stopped, the guide bar and saw chain to the rear, and the muffler away from your body.

10. DO NOT operate a chain saw that is damaged, improperly adjusted, or not completely and securely assembled. Be sure that the saw chain stops moving when the throttle control trigger is released.

11. Shut off the engine before setting the chain saw down.

12. Use extreme caution when cutting small size brush and saplings because slender material may catch the saw chain and be whipped toward you or pull you off balance.

13. When cutting a limb that is under tension, be alert for springback so that you will not be struck when the tension in the wood fibers is released.

14. Keep the handles dry, clean, and free of oil or fuel mix-

ture

15. Operate the chain saw only in well-ventilated areas.

16. DO NOT operate a chain saw in a tree unless you

ve been specifically trained to do so.

17. All chain saw service, other than the items listed in the user manual safety and maintenance instructions, should be performed by competent chain saw service personnel.

18. When transporting your chain saw, use the appropriate guide bar scabbard.

19. DO NOT operate your chain saw near or around flam-

le liquids or gases whether in or out of doors. An

mab explosion and/or fire may result.

USE THE RIGHT TOOL: Cut wood only. Do not use

20. the chain sa

or e

ed. plastic

21. Do not attempt to add fuel or lubricating oil to saw while engine is r

4 5

w f

xample

, masonry, or non-building materials.

, do not use the chain sa

unning.

poses f

or pur

or which it w

as not intend-

or cutting

w f

Regulations, Section 1910.226(5); 2.5.1., of American National Standard Safety Requirements for Pulpwood Logging, ANSI 03.1-1978; and relevant state safety codes. These models are classified according to CAN/ CSAZ62.1-03 as a Class 1C saw. They are intended for infrequent use by homeowners, cottagers, and campers, and for such general applications as clearing, pruning, cutting firewood, etc. They are not intended for prolonged use. If the intended use involves prolonged periods of operation, this may cause circulatory problems in the user’s hands due to vibration. All models covered in this manual employ an antivibration feature for increased comfort and safety.

2-3. GENERAL SAFETY PRECAUTIONS

FOR CHAIN SAW USERS

1. Fatigue causes carelessness. Be more cautious before rest periods and towards the end of your shift.

2. Personal protective clothing required by your safety organizations, government regulations, or your employer should be used. At all times when using a chain saw, snug-fitting clothing, protective eye wear, safety footwear, and hand, leg, and hearing protection should be worn.

3. Before refueling, servicing, or transporting your chain saw, switch off the engine.To help prevent fire, restart your chain saw at least 9.1m (30ft) from the fuelling area.

4. When a chain saw is being used, a fire extinguisher should be available.

5. When felling, keep at least 2 tree lengths away from your fellow workers.

6. Plan your work, ensuring an obstacle-free work area and, in the case of felling, at least one escape path from the falling tree.

w the instructions in your operator’s manual for

ollo

7. starting the chain saw and control the chain saw with

rip on both handles when it is in operation.

m g

a fir Keep handles dry, clean, and free of oil.

8. When transporting your chain saw, use the appropri-

, which should be available

ers

anspor

ate tr for the guide bar and saw chain.

9. Never operate a chain saw that is damaged or improperly adjusted or that is not completely and securely assemb when the power control system trigger is released.

ver adjust the guide bar or saw chain when the

Ne engine is operating.

10.

Beware of carbon monoxide poisoning. Operate the chain sa

11. Do not attempt a pruning or limbing operation in a standing tree unless specifically trained to do so.

12. Guard against kickback. Kickback is the upward motion of the guide bar that occurs when the sa chain, at the nose of the guide bar, contacts an object.

tation co

Be sure that the saw chain stops moving

led.

w in w

entilated areas only

ell-v

Kickback can lead to dangerous loss of control of the chain saw.

13. A chain saw is intended for two-handed use. Serious injury to the operator, helpers, and/or bystanders can result from one-handed oper

14. See section 2-5, 2-6 for symbol definitions, page 5.

15. When carrying a chain saw with the engine running, engage the chain brake.

16. Allow your chain saw to cool before refueling, and do not smoke.

17. Keep other persons or animals a safe distance away from a running chain saw or the area where a tree is being felled.

18. Use extreme caution when cutting small brush and saplings because slender material can catch the saw chain and be whipped toward you.

19. When cutting a limb that is under tension or compression, be alert for springback.

20. This gas-powered saw is classified according to CAN/ CSA-Z62.1-03 as a Class 1C saw. It is intended for infrequent use by homeowners, cottagers, and campers, and for such general applications as clearing, pruning, cutting firewood, etc. It is not intended for prolonged use. Prolonged periods of operation can cause circulatory problems in the user’s hands due to vibration. For such use, it may be appropriate to use a saw having an anti-vibration feature.

ation.

2-4. MORE ABOUT KICKBACK

WARNING

DANGER! BEWARE OF KICKBACK!

Kickback can lead to dangerous loss of control of the chain saw and result in serious or fatal injury to the saw operator or to anyone standing close by. Always be alert. Rotational kickback and pinch-kickback are major chain saw operational dangers and the leading cause of most accidents.

BEWARE OF: ROTATIONAL KICKBACK (Figure 2-4A)

A = Kickback path B = Kic

kback reaction zone

2-4A

2 - SAFETY PRECAUTIONS 3 - ASSEMBLY INSTRUCTIONS

THE PUSH (PINCH-KICKBACK) AND PULL REACTIONS (Figure 2-4B)

A = Pull B = Solid objects C = Push

2-4B

KICKBACK may occur when the NOSE or TIP of the guide bar touches an object, or when wood closes in and pinches the saw chain in the cut. Tip contact in some cases may cause a lightning-fast reverse reaction, kicking the guide bar up and back toward the operator. PINCHING the saw chain along the BOTTOM of the guide bar may PULL the saw forward away from the operator. PINCHING the saw chain along the TOP of the guide bar may PUSH the guide bar rapidly back toward the operator. Any of these reactions may cause you to lose control of the saw, which could result in serious personal injury.

WARNING

The engine exhaust from this product contains chemi-

cals known to the State of California to cause cancer,

birth defects, or other reproductive harm.

2-6. INTERNATIONAL SYMBOLS

Read User Manual.

Wear head, eye and hearing protection.

Wear gloves to protect your hands.

2-5. KICKBACK SAFETY LABELS

Your McCulloch Chain Saw is provided with a safety label located on the chain brake lever. This label, along with the safety instructions on these pages, should be carefully read before attempting to operate this unit.

HOW TO READ SYMBOLS AND COLORS:

RED

WARNING

Used to warn that an unsafe procedure should not be performed.

GREEN

Recommended cutting procedures.

RECOMMENDED

WARNING (Figure 2-5A)

1. Worst-case computed kickback angle.

2. Beware of kickback.

3. Do not attempt to hold saw with one hand.

4. Avoid bar nose contact.

RECOMMENDED

5. Hold saw properly with both hands.

2-5A

Use of these personal safety items is highly recommended to reduce the risk of accidental injur

3-1. INTRODUCTION

This unit is designed f should not be used for commercial purposes or subjected to heavy continuous use. Your new chain saw can be used for a variety of projects such as cutting firewood, making fence posts, felling small trees, limbing, pruning at ground level, and light carpentry. Cut only wood or wood products with your saw.

or occasional homeowner use and

3-2. ASSEMBLY REQUIREMENTS

Your new chain saw will require adjustment of chain, filling the fuel tank with correct fuel mixture and filling the oil tank with lubricating oil before the unit is ready for operation.

WARNING

DO NOT start saw engine until unit is properly prepared. Read the entire user manual before attempting to operate

your unit. Pay particular attention to all safety precautions. Your user manual is both a reference guide and handbook

provided to furnish you with general information to assemble, operate and maintain your saw.

3-3. GUIDE BAR / SAW CHAIN / CLUTCH

COVER INSTALLATION

WARNING

Always wear protective gloves when handling chain.

1. Place power unit on flat surface.

2. Make sure the CHAIN BRAKE into the DISENGAGED position. (Fig. 3-3A)

3. Loosen button (C) slightly by turning knob counterclockwise and then turn the chain tension ring (B) counter-clockwise to relief chain tension. (Fig. 3-3B)

4. To remove the sprocket cover (A), turn button (B) counter-clockwise. (Fig. 3-3B)

Remove saw chain from around the guide bar and the

Slide the guide bar, from the unit.

et.

sproc

6. Place the slotted end of the guide bar over the bar bolt

Slide guide bar behind clutch drum (E) until the

(D). guide bar stops. (Fig. 3-3C)

Spread the chain out with the cutting edges (F) of the chain pointing in the DIRECTION OF R 3-3D).

8. Slip the chain around the sprocket (G) behind the

e sure the links fit between the sprock-

clutch (H). et teeth. (Fig. 3-3E)

9. Guide the drive links into the groove (I) and around the end of the bar. (Fig. 3-3E)

Mak

lever is pulled back

OTATION (Fig.

3-3A

3-3B

3-3C

3-3D

Wear safety boots to protect against electric shock.

6 7

3-3E

3 - ASSEMBLY INSTRUCTIONS

NOTE: The saw chain may droop slightly on the lower part

. This is normal.

of bar

10. Turn the knob (J) COUNTERCLOCKWISE until the TANG (K) is to the end of its travel. (Fig. 3-3F)

11. Install the clutch cover making sure the tang is positioned in the lower hole in the guide bar. Make sure the chain does not slip off of the bar.

12. Lock the screw (N) be tight, and follow step 13 to adjust the chain tension.

13. Turn the tension ring clockwise tight (M); pull the control button by arrow direction (L) to turn tightly be clockwise then push the control button back. (Fig. 33G)

NOTE: The guide bar retaining knob is installed only hand tight at this point because saw chain adjustment is required. Follow instructions in Section, Saw Chain Tension Adjustment.

3-3F

3-4. SAW CHAIN TENSION ADJUSTMENT

Proper tension of saw chain is extremely important and must be checked before starting, as well as during any cutting operation. Taking the time to make needed adjustments to the saw chain will result in improved cutting performance and prolonged chain life.

WARNING

Always wear heavy duty gloves when handling saw chain or making saw chain adjustments.

TO ADJUST SAW CHAIN:

1. Hold nose of guide bar up and turn adjustment chain ring (A) CLOCKWISE to increase chain tension. Turning chain ring (A) COUNTERCLOCKWISE will decrease amount of tension on chain. Ensure the chain fits snugly all the way around the guide bar. (Fig. 3-4A)

2. After making adjustment, and while still holding nose of bar in the uppermost position, tighten the bar retaining button (B) securely. Chain has proper tension when it has a snug fit all around and can be pulled around by gloved hand. (Fig. 3-BA)

NOTE: If chain is difficult to rotate on guide bar or if it binds, too much tension has been applied. This requires minor adjustment as follows: A. Loosen the bar retaining knob so it is finger tight.

Decrease tension by turning the bar adjustment chain ring COUNTERCLOCKWISE slowly. Move chain back and forth on bar. Continue to adjust until chain rotates freely, but fits snugly. Increase tension by turning bar adjustment chain ring CLOCKWISE.

B. When saw chain has proper tension, hold nose of bar

in uppermost position and tighten the bar retaining nut securely.

CAUTION

w saw chain stretches, requiring adjustment after as

A ne few as 5 cuts. This is normal with a new chain, and the interval between future adjustments will lengthen quickly.

CAUTION

If saw chain is TOO LOOSE or TOO TIGHT, the sprocket, bar, chain, and crankshaft bearings will wear more rapidly. Study Figure 3-4B for information concerning correct cold tension (A), correct warm tension (B), and as a guide for when saw chain needs adjustment (C).

3-4B

3-5. CHAIN BRAKE®MECHANICAL TEST

Your chain saw is equipped with a CHAIN BRAKE®that reduces possibility of injury due to kickback. The brake is activated if pressure is applied against brake lever when, as in the event of kickback, operator’s hand strikes the lever. When the brake is actuated, chain movement stops abruptly.

WARNING

The purpose of the CHAIN BRAKE®is to reduce the possibility of injury due to kickback; however, it cannot provide the intended measure of protection if the sa carelessly.

ys test the CHAIN BRAKE

Alw

iodically while on the job

per

ore using y

bef

w is oper

our sa

ated

w and

TO TEST CHAIN BRAKE®:

1. The CHAIN BRAKE®is DISENGAGED (chain can ve) when BRAKE LEVER IS PULLED BACK AND

mo LOCKED. Be sure the chain break latch is in the on position. (Figure 3-5A).

2. The CHAIN BRAKE

when brake lever is in forward position and the chain brake latch is in the off position. You should not be able to move chain (Figure 3-5B).

NOTE: The brake lever should snap into both positions. If strong resistance is felt, or lever does not move into either position, do not use your saw. Take it immediately to an Authorized Service Center for repair.

is ENGAGED (chain is stopped)

3-5A

OFF

3-5B

3-3G

3-4A

8 9

4 - FUEL AND LUBRICATION

5 - OPERATING INSTRUCTIONS

4-1. FUEL

Use regular g McCulloch 40:1 2-cycle engine oil for best results. Use mixing ratios in Section 4-3.

Never use straight gasoline in your unit.This will cause

permanent engine damage and void the manufacturer’s warranty for that product. Never use a fuel mixture that has been stored for over 90 days.

If 2-cycle lubricant other than Genuine McCulloch

Lubricant is to be used, it must be a premium grade oil for 2-cycle air cooled engines mixed at a 40:1 ratio. Do not use any 2-cycle oil product with a recommended mixing ratio of 100:1. If insufficient lubrication is the cause of engine damage, it voids the manufacturer’s engine warranty for that occurrence.

rade unleaded gasoline mixed with Genuine

4-2. MIXING FUEL

Mix fuel with Genuine McCulloch brand 2 cycle oil in an approved container. Use mixing table for correct ratio of fuel to oil. Shake container to ensure thorough mix.

Lack of lubrication voids engine warranty.

4-3.FUEL AND LUBRICATION SYMBOLS

Gasoline and Oil Mix 40:1

Oil Only

FUEL MIXING TABLE

GASOLINE

McCulloch 40:1 Ratio

Lubricant

1 U.S. Gal. 3.2 oz. 95ml (cc) 5 Liters 4.3 oz. 125ml (cc) 1 lmp. Gal. 4.3 oz. 125ml (cc)

Mixing

Procedure

40 Parts Gasoline to

1 Part Lubricant

1ml=1cc

4-4.RECOMMENDED FUELS

Some conventional gasolines are being blended with oxygenates such as alcohol or an ether compound to meet clean air standards. Your McCulloch engine is designed to operate on any gasoline intended for automotive use including oxygenated gasolines.

4-5.CHAIN AND BAR LUBRICATION

Always refill the chain oil tank each time the fuel tank is refilled. We recommend using Genuine McCulloch Chain, Bar and Sprocket Oil, which contains additives to reduce friction and wear and to assist in the prevention of pitch formation on the bar and chain.

5-1. ENGINE PRE-START CHECKS

WARNING

Never start or operate the saw unless the bar and chain are properly installed.

1. Fill the fuel tank (A) with correct fuel mixture (Figure 5-1A).

2. Fill the oil tank (B) with correct chain and bar oil (Figure 5-1A).

3. Be certain the CHAIN BRAKE before starting unit (Figure 5-1A).

NOTE: See page 9 Fig. 3-5A & 3-5B.

5-1A

5-2. TO START ENGINE

1. Press red STOP switch to the “I” ON position (Fig. 52A).

2. Pull out the choke (A) to the point where it latches in place. (Fig. 5-2B)

3. Push the primer bulb (B) 10 times. (Fig. 5-2C)

4. Latch throttle advance: depress latch and hold (C) squeeze throttle trigger (D) release trigger and then the latch. (Fig. 5-2D)

5. Place the saw on a firm and level surface. Hold the saw securely with your foot as illustrated. Pull sharply on the starter 4 times. Watch the chain in case it runs. (Fig. 5-2E)

NOTE: Easy Start power assist starting significantly reduces the pulling effort. Pull the starter cord slowly to about 3 1/2 feet, the power assist will turn over the engine with little resistence from the engine

Push in the chok

7. Hold the saw securely and tug sharply on the starter 4 times. The engine should start.

8. Let the engine run for 10 seconds to warm up. Press the trigger (F) and put it into idle. (Fig. 5-2G) If the engine does not star

steps

e (E) as f

is disengaged (C)

ar it will go

, repeat the abo

t up

. (Fig. 5-2F)

After warm up - See the User's Manual section 5-2, step 7

- If unit does not Idle after restarting 2 times, follow these

5-2F

5-2A

5-2C

5-2G

steps to adjust idle

1. Idle adjustment access (G). (Figure 5-2H)

2. Using a Phillips or slotted screwdriver - turn screw 1/4 to 1/2 turn clockwise (to the right). Unit should then idle properly. (Figure 5-2H)

NOTE: If chain turns while idling - turn screw back to the left until chain stops and unit continues to idle.

5-2B

5-2D 5-2E

IMPORTANT IDLING INFORMATION

In some cases due to operating conditions (altitude, temperature etc.) your chain saw may need a slight adjustment to the idle speed.

10 11

5-2F 5-2G

5 - OPERATING INSTRUCTIONS

6 - GENERAL CUTTING INSTRUCTIONS

5-3. RE-STARTING A WARM ENGINE

1. Make sure the on/off switch is in the “I” position.

2. Depress the primer bulb 10 times.

3. Set the throttle latch. Latch throttle advance: depress latch and hold squeeze throttle trigger release trigger and then the latch.

4. Pull the starter rope rapidly 4 times. The engine should start.

5. Release the throttle latch. The throttle latch will be released while you press the trigger.

6. If the engine still can not start, follow the step as “To start engine” section in this user manual.

5-4. TO STOP ENGINE

1. Release trigger and allow engine to return to idle speed.

2. Press STOP switch down to stop engine Figure 5-4A.

NOTE: For emergency stopping, simply activate CHAIN BRAKE

INER

NOTE: THIS SAW IS EQUIPPED WITH AN INERTIA CHAIN BRAKE.IF THE SAW KICKS BACK WHILE IN USE, THE INER THE BRAKE. A BRAKE BAND AROUND THE CLUTCH DRUM ACTIVATES AND STOPS THE MOVING CHAIN.

and move STOP switch down.

5-4A

TIA CHAIN BRAKE

TIA OF

THE MOVING SAW WILL ACTIVATE

CTION :

5-5.CHAIN BRAKE®OPERATIONAL TEST

Test the CHAIN BRAKE®periodically to ensure proper function. Perform a CHAIN BRAKE®test prior to initial cutting, following extensive cutting, and definitely following any CHAIN BRAKE®service.

TEST CHAIN BRAKE®AS FOLLOWS:

Place sa

2. Start engine.

3. Grasp the rear handle (A) with your right hand (Figure 5-5A).

4. With your left hand, hold the front handle (B) [not CHAIN BRAKE

w on a clear

, firm, flat surface.

lever (C)] firmly (Figure 5-5A).

5. Squeeze the throttle trigger to 1/3 throttle, then immediately activate the CHAIN BRAKE®lever (C) (Figure 55A).

WARNING

Activate the CHAIN BRAKE®slowly and deliberately. Keep the chain from touching anything; don’t let the saw tip forward.

6. Chain should stop abruptly. When it does, immediately release the throttle trigger.

WARNING

If chain does not stop, turn engine off and take your unit to the nearest Authorized Service Center for service.

7. If CHAIN BRAKE®functions properly, turn the engine off and return the CHAIN BRAKE GAGED position.

to the DISEN-

6-1.FELLING

elling is the term for cutting down a tree. Small trees up to

F 6-7 inches (15-18cm) in diameter are usually cut in a single cut. Larger trees require notch cuts. Notch cuts determine the direction the tree will fall.

FELLING A TREE:

WARNING

A retreat path (A) should be planned and cleared as necessary before cuts are started. The retreat path should extend back and diagonally to the rear of the expected line of fall, as illustrated in Figure 6-1A.

CAUTION

If felling a tree on sloping ground, the chain saw operator should keep on the uphill side of the terrain, as the tree is likely to roll or slide downhill after it is felled.

NOTE: Direction of fall (B) is controlled by the notching cut. Before any cuts are made, consider the location of larger branches and natural lean of the tree to determine the way the tree will fall.

WARNING

Do not cut down a tree during high or changing winds or if there is a danger to property. Consult a tree professional. Do not cut down a tree if there is a danger of striking utility wires; notify the utility company before making any cuts.

5-5A

GENERAL GUIDELINES FOR FELLING TREES:

5-6.SAW CHAIN / BAR LUBRICATION

Adequate lubrication of the saw chain is essential at all times to minimize friction with the guide bar.

er starve the bar and chain of oil. Running the saw with

Nev too little oil will decrease cutting efficiency, shorten saw chain life, cause rapid dulling of chain, and cause excessive wear of bar from overheating. Too little oil is evidenced by smoke, bar discoloration or pitch build-up.

TE:Saw chain stretches during use, particularly when it

is new, and it will occasionally be necessary to adjust and tighten it. New chain will require adjustment after about 5 min

utes of operation.

5-7.AUTOMATIC OILER

our chain sa

Y oiler system. The oiler automatically delivers the proper amount of oil to the bar and chain. As the engine speed increases flow adjustment. The oil reservoir will run out at approximately the same time as the fuel supply runs out.

w is equipped with an automatic clutch dr

, so does the oil flo

w to the bar pad.

There is no

iven

Normally felling consists of 2 main cutting operations, notching (C) and making the felling cut (D). Start making the upper notch cut (C) on the side of the tree facing the felling direction (E). Be sure you don t make the lower cut too deep into the trunk. The notch (C) should be deep enough to create a hinge (F) of sufficient width and strength. enough to direct the fall of the tree for as long as possible.

The notch should be wide

WARNING

Never walk in front of a tree that has been notched. Make the felling cut (D) from the other side of the tree and

1.5 - 2.0 inches (3-5 cm) above the edge of the notch (C) (Figure 6-1B). Never saw completely through the trunk. Always leave a hinge

. The hinge guides the tree. If the trunk is completely cut through, control over the felling direction is lost. Insert a wedge or felling lever in the cut well before the tree becomes unstable and starts to move. This will prevent the

ve mis-

guide bar from binding in the f judged the f entered the range of the falling tree before you push it over.

alling direction.

elling cut if y e sure no b

Mak

ou ha

ystanders ha

WARNING

Before making the final cut, always recheck the area for bystanders, animals or obstacles.

12 13

FELLING CUT:

Use wooden or plastic wedges (G) to prevent binding

1. the bar or chain (H) in the cut. Wedges also control felling (Figure 6-1C).

2. When diameter of wood being cut is greater than the bar length, make 2 cuts as shown (Figure 6-1D).

WARNING

As the felling cut gets close to the hinge, the tree should begin to fall.When tree begins to fall, remove saw from cut, stop engine, put chain saw down, and leave area along retreat path (Figure 6-1A).

6-1A

6-1B

6-1C

6-1D

6 - GENERAL CUTTING INSTRUCTIONS

7 - MAINTENANCE INSTRUCTIONS

6-2. LIMBING

Limbing a tree is the process of remo from a fallen tree. Do not remove supporting limbs (A) until after the log is bucked (cut) into lengths (Figure 6-2A). Branches under tension should be cut from the bottom up to avoid binding the chain saw.

ving the branches

WARNING

Never cut tree limbs while standing on tree trunk.

6-2A

6-3. BUCKING

Bucking is cutting a fallen log into lengths. Make sure you have a good footing and stand uphill of the log when cutting on sloping ground. If possible, the log should be supported so that the end to be cut off is not resting on the ground. If the log is supported at both ends and you must cut in the middle, make a downward cut halfway through the log and then make the undercut. This will prevent the log from pinching the bar and chain. Be careful that the chain does not cut into the ground when bucking as this causes rapid dulling of the chain. When bucking on a slope, always stand on the uphill side.

1. Log supported along entire length: Cut from top (overk), being careful to a

b (Figure 6-3A).

2. Log supported on 1 end: First, cut from bottom (under-

buck) 1/3 diameter of log to avoid splintering. Second, cut from above (overbuck) to meet first cut and avoid pinching (Figure 6-3B).

3. Log supported on both ends: First, overbuck 1/3 diam-

eter of log to avoid splintering. Second, underbuck to meet first cut and avoid pinching (Figure 6-3C).

NOTE: The best way to hold a log while bucking is to use a sawhorse. When this is not possible, the log should be raised and supported by the limb stumps or by using supporting logs. Be sure the log being cut is securely supported.

void cutting into the ground

6-3B

6-3C

6-4.BUCKING USING A SAWHORSE

For personal safety and ease of cutting, the correct position for vertical bucking is essential (Figure 6-4A).

VERTICAL CUTTING:

A. Hold the saw firmly with both hands and keep the saw

to the right of your body while cutting. B. Keep the left arm as straight as possible. C. Keep weight on both feet.

CAUTION

While the saw is cutting, be sure the chain and bar are being properly lubricated.

All chain saw service, other than items listed here in your user manual maintenance

instructions, should be performed by your nearest Authorized Service Center.

7-1.PREVENTIVE MAINTENANCE

A good preventive maintenance program of regular inspection and care will increase life and improve performance of your McCulloch chain saw. This maintenance checklist is a guide for such a program. Cleaning, adjustment, and parts replacement may be required, under certain conditions, at more frequent intervals than those indicated.

MAINTENANCE CHECKLIST

EACH USE

ITEM

SCREWS / NUTS / BOLTS INSPECT / TIGHTEN

AIR FILTER CLEAN OR REPLACE

FUEL FILTER / OIL FILTER REPLACE

SPARK PLUG CLEAN / ADJUST / REPLACE

INSPECT

SPARK ARRESTER SCREEN

REPLACE AS REQUIRED

INSPECT

FUEL HOSES

*REPLACE AS REQUIRED

INSPECT

CHAIN BRAKE®COMPONENTS

*REPLACE AS REQUIRED

*Recommended for Maintenance by a Authorized Service Center Technician.

ACTION 10 20

✔

HOURS OF

OPERATION

✔

6-3A

6-4A

14 15

7 - MAINTENANCE INSTRUCTIONS

7-2. AIR FILTER

CAUTION

ver operate saw without the air filter. Dust and dirt will be

Ne drawn into engine and damage it. Keep the air filter clean!

TO CLEAN AIR FILTER:

1. Remove knob (A) holding air filter cover in place, remove the top cover (B) by loosening the cover retaining screws. Cover will lift off.(Figure 7-2A)

2. Completely remove the air filter box (B) from the unit. (Figure 7-2B)

3. Clean air filter box by using air cleaner or brush.

NOTE: Never clean air filter with liquid material or it may cause air filter damaged.

4. Install air filter. Install engine / air filter cover. Make sure latch (E) latch (F) and cover fit properly. Tighten the cover retaining knob securely. (Figure 7-2C & Figure 7-2D)

WARNING

Never perform maintenance when the engine is hot, to avoid any chance of burning hands or fingers.

7-2A

7-2C 7-2D

7-2B

7-3.FUEL FILTER

CAUTION

The fuel filter

er oper

Ne should be replaced after each 20 hours of use. Drain fuel tank completely bef

1. Completely remove the fuel cap from the gas tank.

3. Reach into fuel tank opening and hook fuel line.

NOTE: Do not pull hose completely out of tank.

4. Lift filter (A) out of tank (Figure 7-3A).

ate y

ore changing filter

m a hook at the end.

Bend a piece of soft wire to f

Carefully pull the fuel line toward the opening until you can reach it with y

our fingers.

w without a fuel filter

our sa

5. Pull filter off with a twisting motion. Discard filter.

6. Install new filter. Insert end of filter into tank opening. Make sure filter sits in bottom corner of tank. Use a long handle screwdriver to aid in filter placement if necessary.

7. Fill tank with fresh fuel / oil mixture. See Section 4, Fuel and Lubrication. Install fuel cap.

7-3A

7-5. SPARK PLUG

NOTE: For efficient operation of saw engine, spark plug must be kept clean and properly gapped.

1. Push STOP switch down.

2. Remove air cleaner cover.

3. Disconnect the wire connector (G) from the spark plug (H) by pulling and twisting at the same time (Figure 75A).

4. Remove spark plug with spark plug socket wrench. DO NOT USE ANY OTHER TOOL.

5. Check electrode gaps with wire feeler gauge and set gaps to .025” (.635mm) if necessary.

6. Reinstall a new spark plug.

NOTE: A resistor spark plug must be used for replacement (Part no. 9295-310801).

NOTE: This spark ignition system meets all requirements of the Canadian Interference-Causing Equipment Regulations.

7-4. SPARK ARRESTER SCREEN (Figure 7-

4A)

NOTE: A clogged spark arrester screen will dramatically reduce engine performance.

1. Remove the 2 nuts (A) and pull muffler out. (Figure74A).

2. Remove the 1 screw (B) that holds the spark arrester cover (C) . (Figure 7-4B)

3. Discard the used spark arrester screen (D) and replace it with a new one.

4. Reassemble the muffler components and install the muffler to the cylinder.Tighten securely.

7-5A

7-6.CARBURETOR ADJUSTMENT

The carburetor was pre-set at the factory for optimum per-

ormance. If further adjustments are necessary, please take

f your unit to the nearest Authorized Service Center listed in the Yellow Pages.

7-7.STORING A CHAIN SAW

CAUTION

7-3A

16 17

7-4B

Never store a chain saw for longer than 30 days without performing the following procedures. Storing a chain saw for longer than 30 days requires storage maintenance. Unless the storage instructions are followed, fuel remaining in the carburetor will evaporate, leaving gum-like deposits. This could lead to difficult starting and result in costly repairs.

e the fuel tank cap slo

Remo

1. sure in tank. Carefully drain the fuel tank.

2. Start the engine and let it run until the unit stops to

ve fuel from carburetor.

remo

3. Allow the engine to cool (approx. 5 minutes).

wly to release an

y pres

4. Using a spark plug wrench, remove the spark plug.

5. Pour 1 teaspoon of clean 2-cycle oil into the combustion chamber. Pull starter rope slowly several times to coat internal components. Replace spark plug (Figure 7-7A).

NOTE: Store the unit in a dry place and away from possible sources of ignition such as a furnace, gas hot water heater, gas dryer, etc.

7-7A

7-8.REMOVING A UNIT FROM STORAGE

1. Remove spark plug.

2. Pull starter rope briskly to clear excess oil from combustion chamber.

3. Clean and gap spark plug or install a new spark plug with proper gap.

4. Prepare unit for operation.

5. Fill fuel tank with proper fuel / oil mixture. See Fuel and Lubrication Section.

8 - BAR / CHAIN MAINTENANCE

8-1. GUIDE BAR MAINTENANCE

Frequent lubrication of the guide bar (railed bar which supports and carries the saw chain) sprocket tip is required. Proper maintenance of the guide bar, as explained in this section, is essential to keep your saw in good working condition.

SPROCKET TIP LUBRICATION:

CAUTION

The sprocket tip on your new saw has been pre-lubricated at the factory. Failure to lubricate the guide bar sprocket tip as explained below will result in poor performance and seizure, voiding the manufacturer’s warranty. Lubrication of the sprocket tip is recommended after 10 hours of use or once a week, which ever occurs first. Always thoroughly clean guide bar sprocket tip before lubrication.

TOOLS FOR LUBRICATION:

The Lube Gun (optional) is recommended for applying grease to the guide bar sprocket tip. The Lube Gun is equipped with a needle nose tip which is necessary for the efficient application of grease to the sprocket tip.

TO LUBRICATE SPROCKET TIP:

WARNING

Wear heavy duty work gloves when handling the bar and chain.

1. Move the STOP switch down. NOTE: It is not necessary to remove the saw chain to lubri-

cate the guide bar sprocket tip. Lubrication can be done on the job.

2. Clean the guide bar sprocket tip.

3. Using the Lube Gun (optional), insert tip of lube gun into the lubr appears at outside edge of sprocket tip (Figure 8-1A).

4. Rotate saw chain by hand. Repeat lubrication procedure until the entire sprocket tip has been greased.

ication hole and inject g

8-1A

GUIDE BAR MAINTENANCE:

Most guide bar problems can be prevented merely by keeping the chain saw well maintained. Insufficient guide bar lubrication and operating the saw with chain that is TOO TIGHT will contribute to rapid bar wear.

rease until it

To help minimize bar wear, the following guide bar maintenance procedures are recommended. BAR WEAR - Turn guide bar frequently at regular intervals

or example, after 5 hours of use), to ensure even wear on

(f top and bottom of bar. BAR GROOVES - Bar grooves (or rails which support and carry the chain) should be cleaned if saw has been used heavily or if saw chain appears dirty. Rails should always be cleaned every time saw chain is removed. OIL PASSAGES - Oil passages on the bar should be cleaned to ensure proper lubrication of the bar and chain during operation. NOTE: The condition of the oil passages can be easily checked. If the passages are clear, the chain will automatically give off a spray of oil within seconds of starting the

w.Your saw is equipped with an automatic oiler system.

8-3.CHAIN REPLACEMENT INFORMATION

Bar

Length

Drive

Links

Chain Type

(Oregon)

16” Bar 56 DL 91PJ056X N1C-BL-M-56E SK 160SDEA041 16-10-N156-MHC 0.05” 3/8” 5/32” 18” Bar 62 DL 91PJ062X N1C-BL-M-62E SK 180SDEA041 18-10-N1-MHC

There may be other quality equivalent replacement components for achieving kickback protection.

Chain Type

(Carlton)

8-2. CHAIN MAINTENANCE

CHAIN TENSION:

Check the chain tension frequently and adjust as often as necessary to keep the chain snug on the bar, but loose enough to be pulled around by hand.

BREAKING IN A NEW SAW CHAIN:

A new chain and bar will need chain readjustment after as few as 5 cuts.This is normal during the break-in period, and the interval between future adjustments will begin to lengthen quickly.

WARNING

Never have more than 3 links removed from a loop of chain. This could cause damage to the sprocket.

CHAIN LUBRICATION:

Always make sure the automatic oiler system is working properly. Keep the oil tank filled with Genuine McCulloch Chain, Bar and Sprocket Oil. Adequate lubrication of the bar and chain during cutting operations is essential to minimize friction with the guide bar. Never starve the bar and chain of lubricating oil. Running the saw dry or with too little oil will decrease cutting efficiency, shorten saw chain life, cause rapid dulling of chain, and lead to excessive wear of bar from overheating.Too little oil is evidenced by smoke or bar discoloration.

CHAIN SHARPENING:

Chain sharpening requires special tools to ensure that cutters are sharpened at the correct angle and depth. For the inexperienced chain saw user, we recommend that the saw chain be professionally sharpened by the nearest Authorized Service Center.If you feel comfortable sharpening your own saw chain, special tools are available from the nearest Authorized Service Center.

18 19

Bar Type (Oregon)

Bar Type (Carlton)

Chain

Gauge

Chain

Pitch

File

Size

0.05” 3/8” 5/32”

9 - TROUBLESHOOTING THE ENGINE 10 - ONE YEAR LIMITED WARRANTY

PROBLEM

Unit won’t start or starts but will not run.

Unit starts, but engine has low power.

Engine hesitates.

No power under load.

Runs erratically.

Smokes excessively.

PROBABLE CAUSE

Incorrect starting procedures.

Incorrect carburetor mixture adjustment setting.

Fouled spark plug

Fuel filter plugged.

Incorrect lever position on choke.

Dirty spark arrester screen.

Dirty air filter.

Incorrect carburetor mixture adjustment setting.

Incorrectly gapped spark plug.

Incorrect carburetor mixture adjustment setting.

Incorrect fuel mixture.

CORRECTIVE ACTION

ollow instructions in the User Manual.

Have carburetor adjusted by an Authorized Service Center.

Clean / gap or replace plug.

Replace fuel filter.

Move to RUN position.

Replace spark arrester screen.

Remove, clean and reinstall filter.

Have carburetor adjusted by an Authorized Service Center.

Clean / gap or replace plug.

Have carburetor adjusted by an Authorized Service Center.

Use properly mixed fuel (40:1 mixture).

1. DURATION

The duration of the warranty for this McCulloch product is as follows: ONE (1) YEAR from date of original purchase only when used for personal, family, household, farm or ranch, purposes, provided the unit is not used for rental purposes; NINETY (90) DAYS from date of original purchase when used for commercial, professional, institutional or rental purposes. This warranty gives you specific legal rights. You may also have other rights which vary from state to state. MCCULLOCH CORPORATION HEREBY DISCLAIMS ALL IMPLIED WARRANTIES AFTER THE APPLICABLE EXPIRATION DATES OF THIS EXPRESS LIMITED WARRANTY. (Some states do not allow limitations on how long an implied warranty lasts, so the above limitations may not apply to you.)

2. WHO GIVES THIS WARRANTY

McCulloch U.S.A 1-800-521-8559 10715 Springdale Avenue, Unit 2, Santa Fe Springs, CA 90670 USA

3. WHO RECEIVES THIS WARRANTY

A. The buyer (other than for purposes of resale) of the McCulloch Product. B. Any person to whom such product is lawfully transferred within the duration of the implied or written warranty applica-

ble to the product.

C. Any other person who is entitled by the terms of the warranty or under applicable state law to enforce against the

Warrantor the obligation of the warranty. (The above mentioned parties are hereinafter referred to as “User.”)

4. WHAT IS COVERED UNDER THIS WARRANTY

Any failure that occurs within the applicable duration of the warranty period that is the result of defects in materials or workmanship.

5. WHAT IS NOT COVERED UNDER THIS WARRANTY

A. Any incidental or consequential damages that may result from the failure or malfunction of the McCulloch product.

(Some states do not allow the exclusion or limitation of incidental or consequential damages, so these limitations may not apply to you.)

B. Any failure that results from an accident, User abuse, neglect or failure to operate the product in accordance with the

instructions provided in the User Manual(s) supplied with the product, or that results from improper servicing by an

unauthorized repair facility. C. Normal adjustments which are explained in the User Manual(s) provided with the product. D. Any component(s) or accessories not sold or manufactured by the Warrantor. E. Predelivery setup or assembly of units.

anty does not apply to accessories, normal maintenance or adjustment(s) of the product set forth in the User

arr

This w

Man

ual(s).

6. RESPONSIBILITIES OF THE WARRANTOR UNDER THIS WARRANTY

A. Repair or replace components which have failed within the duration of the applicable warranty period at no cost to the

User.

. Ensure that the authorized repair station is reimbursed for parts and labor costs incurred due to performance of a war-

anty policies and procedures

arr

mal w

umber

lished w

anty repair in accordance with estab

7. RESPONSIBILITIES OF THE USER UNDER THIS WARRANTY

A. The User must deliver or ship the McCulloch product covered under this warranty to the dealer from whom it was orig-

inally purchased or to the nearest Authorized Service Center. Proof of purchase is required. B. Freight costs, if any, will be borne by the user.

Use reasonable care in maintenance, operations and storage of the product as explained in the User Manual(s).

ARRANT

WHEN

B. Repair time which exceeds ten (10) days from the time the product was delivered to the servicing agent will extend

Repair of w

ing on the availability of replacement parts.

the warranty coverage by the number of days the product remains inoperable.

. If User does not receive satisfactory results from local servicing outlet, User must contact McCulloch Corporation, by

calling our toll-free telephone n

OR WILL PERFORM OBLIGATION UNDER THIS WARRANTY

le products will be scheduled according to the nor

antab

arr

w at the servicing location, depend-

k flo

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+ 25 hidden pages