McCulloch TM502 User Manual

Gasoline Chain Saws

SAFETY

OPERATION

MAINTENANCE

USER MANUAL

Model : TM502

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

aiw

PN 9096-31C206

inted in

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 REMOVING & INSTALLING BAR & CHAIN . . . . . . . . . . . . .7

3-1.

Bar & Chain Removal and Installation 3-2. Before starting your saw 3-3. Guide Bar/Saw Chain/Clutch Cover Removal or 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

PART LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Mechanical Test

Operational Test

THE ENGINE

TING

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

mation

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

2 3

1-1.GENERAL IDENTIFICATION

1. GUIDE BAR

2. SAW CHAIN

3. SAW CHAIN ADJUSTMENT SCREW

4. SPARK ARRESTER SCREEN

5. CHAIN BRAKE

6. FRONT HANDLE

7. STARTER HANDLE

8. SPARK PLUG AIR CLEANER COVER

OP SWITCH

10. SAFETY

11. OIL TANK CAP

12.

TER CO

13.

ANK CAP

FUEL

14.

15. REAR HANDLE / BOOT LOOP CHOKE LEVER

16. BAR RET

17.

18. THROTTLE / TRIGGER CHAIN CA

19. CHAIN BRAKE

20.

21. SCREWDRIVER / WRENCH

Y CASE (A

CARR

22.

TE:

Study y

LEVER / HAND GUARD

TRIGGER

VER

AINING NUTS

TCHER

VER

ailable on some models)

w and be f

our sa

amiliar with its par

1-2. SAFETY FEATURES

Numbers preceding the descriptions correspond with the numbers on preceding page to help you locate the safety feature. 2 LOW KICKBACK SAW CHAIN helps significantly

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

4 SPARK ARRESTER SCREEN retains carbon and other

flammable particles over 0.023 inches (0.6mm) in size from engine exhaust flow. Compliance with local, state and federal laws and/or regulations governing the use of a spark arrester screen is the user’s responsibility. See Safety Precautions for additional information.

5 CHAIN BRAKE®LEVER / HAND GUARD protects the

operator’s left hand in the event it slips off the front handle while saw is running.

5 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®lever.

10 STOP SWITCH immediately stops the engine when

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

11 SAFETY TRIGGER prevents accidental acceleration of

the engine. Throttle trigger (19) cannot be squeezed unless the safety latch is depressed.

19 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.

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.

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

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

4 5

2 - SAFETY PRECAUTIONS

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 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

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.

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. Beware of kickback.

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

3. Avoid bar nose contact.

RECOMMENDED

4. Hold saw properly with both hands.

3 4

2-5A

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.

Wear safety boots to protect against electric shock.

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

6 7

3 - REMOVING & INSTALLING BAR & CHAIN

3-1. BAR & CHAIN REMOVAL AND

INSTALLATION

ou will need these tools to work on your chain saw:

1. Combination wrench-screwdriver (contained in your s kit or in lid of carry case).

user’

2. Heavy duty work gloves (user supplied).

3-2. BEFORE STARTING YOUR SAW

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 REMOVAL OR INSTALLATION

3-3B

3-3C

WARNING

Always wear protective gloves when handling chain.

CAUTION

To ensure the bar and chain receive oil, ONLY USE THE ORIGINAL STYLE BAR with the oil passage hole (A) as illustrated above (Figure 3-3A).

1. Make sure the CHAIN BRAKE

the DISENGAGED position (Figure 3-3B)

2. Remove the 2 bar retaining nuts (B). Remove the

CHAIN BRAKE guide bar plate (M). (Figure 3-3K) Carefully remo

4. Using a screwdriver, run the adjustment screw (D)

COUNTERCLOCKWISE until the TANG (E) (projecting prong) is to the end of its travel toward the clutch drum and sprocket (Figure 3-3D).

5. Place the slotted end of the guide bar over the 2 bar

bolts (F). Position the bar so that the adjustment TANG fits into the lower hole (G) on the guide bar (Figure 33E).

6. Spread chain out in a loop with cutting edges (H) point-

ing CLOCKWISE around loop (Figure 3-3F).

cover (C) (Figure 3-3C). Remove outer

e chain & bar.

lever is pulled back into

3-3D

3-3E

3-3A

3-3F

3 - REMOVING & INSTALLING BAR & CHAIN

7. Slip the chain around the sprocket (J) behind the clutch

Make sure the links fit between the sprocket teeth

(K). (Figure 3-3G).

8. Guide the drive links into the groove (L) and around the

end of the bar (Figure 3-3G).

9. The chain will be tight so you will have to rotate the

clutch clockwise by hand so the chain engages the bar sprocket (Figure 3-3H).

10. Inspect to insure that tang (E) is in the adjustment hole

on the bar (Figure 3-3J).

11. Replace the outer guide bar plate (M) so the bent

edges (top and bottom) are directed away from the chain (Figure 3-3K)

12. Install the CHAIN BRAKE

sure the chain does not slip off of the bar. Install the 2 nuts hand tight and follow tension adjustment instructions in Section 3-4.

NOTE: The guide bar retaining nuts are installed only hand tight at this point because saw chain adjustment is required.

cover (Figure 3-3K). Make

3-3K

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.

CAUTION

A new saw chain stretches, requiring adjustment after as few as 5 cuts. This is normal with a new chain, and the interval between future adjustments will lengthen quickly.

WARNING

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

3-3G

3-3H

3-3J

CAUTION

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

3-4A

3 - REMOVING & INSTALLING BAR & CHAIN

TO ADJUST SAW CHAIN:

1. Loosen the bar retaining nuts (Figure 3-3C). Hold nose

of guide bar up and turn adjustment screw (D) CLOCKWISE to increase chain tension. TERCLOCKWISE will decrease amount of tension on chain. Ensure the chain fits snugly all the way around the guide bar (Figure 3-4B).

2. After making adjustment, and while still holding nose of

bar in the uppermost position, tighten the bar retaining nuts securely. Chain has proper tension when it has a snug fit all around and can be pulled around by gloved hand.

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 2 bar retaining nuts so they are finger tight.

Decrease tension by turning the bar adjustment screw 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 screw CLOCKWISE.

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

in the uppermost position and tighten the 2 bar retaining nuts securely.

Turning screw COUN-

To Test CHAIN BRAKE®:

1. The CHAIN BRAKE®is DISENGAGED (chain can move) when BRAKE LEVER IS PULLED BACK AND LOCKED (Figure 3-5A).

2. The CHAIN BRAKE®is ENGAGED (chain is stopped) when brake lever is in forward 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.

3-5A

3-4B

3-5. CHAIN BRAKE®MECHANICAL TEST

Your chain saw is equipped with a CHAIN BRAKE®that reduces possibility of injur activated if pressure is applied against brake lever when, as in the event of kickback, operator’s hand strikes the

ver. When the brake is actuated, chain movement stops

le abruptly.

y due to kic

kback. The brake is

WARNING

The purpose of the CHAIN BRAKE®is to reduce the possibility of injur the intended measure of protection if the saw is operated carelessly. Always test the CHAIN BRAKE®before using your saw and periodically while on the job.

y due to kickback; however, it cannot provide

3-5B

4 - FUEL AND LUBRICATION

4-1. FUEL

Use regular g Factory Parts 40:1 custom 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 Factory Parts

Custom 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 Factory Parts 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

FUEL MIXING TABLE

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 satisfactorily 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 Factory Parts 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.

Oil Only

Gasoline and Oil Mix 40:1

10 11

5 - OPERATING INSTRUCTIONS

5-1. ENGINE PRE-START CHECKS

WARNING

Never start or operate the saw unless the bar and chain are

ly installed.

proper

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).

is disengaged (C)

5-2A

Horizontal position

5-1A

5-2.TO START ENGINE

1. Slide the STOP switch down (Figure 5-2A).

2. Rotate the choke lever up to the horizontal position

(Figure 5-2B).

3. Pump primer bulb 10 times (Figure 5-2C).

4. Pull starter rope 4-6 times, engine should start (Figure

5-2D).

5. If engine failed to start, rotate choke lever down to ver-

tical position then repeat step 4 (Figure 5-2D).

6. When engine starts, warm up 10 sec. Then depress

safety/throttle trigger.The automatic choke will disengage when tr

7. Release throttle trigger for idle. TO STOP: Slide stop switch up.

igger is pulled (Figure 5-2E).

Vertical position

5-2B

5-2C

5-2D

ANT IDLING INFORMA

IMPOR

In some cases due to operating conditions (altitude, temper to the idle speed.

After warm up - See the section 5-2, step 8 - If unit does not Idle after restarting 2 times, follow these steps to adjust idle.

1. Idle adjustment access (A) - the symbol "T" (for throttle)

2. Using a Phillips or slotted screwdriver - turn screw 1/4

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

ature etc.) y

is belo

to 1/2 tur properly (Figure 5-2G).

our chain sa

w the adjustment hole (Figure 5-2F).

n clockwise (to the right). Unit should then idle

w may need a slight adjustment

TION

5-2F

utomatic

5-2E

5-2G

5 - OPERATING INSTRUCTIONS

5-3. RE-STARTING A WARM ENGINE (LESS THAN 10 MINUTES SINCE STOPPING)

1. Make sure the switch is in the ON position.

2. Move the choke lever to horizontal position.

3. Depress the primer bulb 10 times.

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

start.

5. The automatic choke will disengage when trigger is

pulled.

6. Release the throttle trigger for idle.

5-4.TO STOP ENGINE

1. Release trigger and allow engine to return to idle

speed. Move STOP switch up to stop engine.

TE:For emergency stopping, simply activate CHAIN

BRAKE®and move STOP switch up.

INERTIA CHAIN BRAKE®ACTION :

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

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:

1. Place saw on a clear, firm, flat surface.

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

5. Squeeze the throttle trigger to 1/3 throttle, then imme-

diately activate the CHAIN BRAKE®lever (C) (Figure 55A).

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

5-5A

5-6.SAW CHAIN / BAR LUBRICATION

Adequate lubrication of the saw chain is essential at all times to minimize friction with the guide bar. Never starve the bar and chain of oil. Running the saw with 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.

NOTE: 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 minutes of operation.

5-7.AUTOMATIC OILER

Your chain saw is equipped with an automatic gear driven oiler system. The oiler automatically delivers the proper amount of oil to the bar and chain. As the engine speed increases, so does the oil flow to the bar pad. The amount of oil flowing to the bar and chain may be changed by turning the adjustment screw (A) as shown in Figure 5-7A.Turn the screw clockwise to DECREASE oil flow and counterclockwise to INCREASE the flow.

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®to the DISENGAGED position.

5-7A

12 13

6 - GENERAL CUTTING INSTRUCTIONS

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.

GENERAL GUIDELINES FOR FELLING TREES:

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

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

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-

guidebar 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.

6-1C

6-1D

6 - GENERAL CUTTING 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 (over-

k), 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.

6-3A

6-4A

14 15

7 - MAINTENANCE INSTRUCTIONS

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

ITEM

SCREWS / NUTS / BOLTS

AIR FILTER

FUEL FILTER / OIL FILTER

SPARK PLUG

SPARK ARRESTER SCREEN

FUEL HOSES

ACTION

INSPECT / TIGHTEN

CLEAN OR REPLACE

REPLACE

CLEAN / ADJUST / REPLACE

INSPECT

REPLACE AS REQUIRED

INSPECT

*REPLA

CE AS REQ

UIRED

EACH USE

✔

HOURS OF

OPERATION

✔

CHAIN BRAKE®COMPONENTS

*Recommended f

or Maintenance b

INSPECT

*REPLA

uthor

y a A

CE AS REQ

ed Ser

UIRED

vice Center

echnician.

✔

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 the top cover (A) and lift out air filter (B) (Figure 7-2A).

2. Clean air filter. Wash filter in clean, warm, soapy water. Rinse in clear, cool water. Air dry completely.

NOTE: It is advisable to have a supply of spare filters.

3. Install air filter. Install top cover. Make sure cover fits properly. Tighten the cover retaining screws securely.

WARNING

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

7-2A

7-3.FUEL FILTER

CAUTION

Never operate your saw without a fuel filter. The fuel filter should be replaced after each 20 hours of use. Drain fuel tank completely before changing filter.

e air box cover and air filter as shown in Section

Remo

1. 7-2.

2. Disconnect fuel hose (A) from carburetor fitting

3. Pull fuel filter (C) out of tank with a bent wire (D) or long needle nosed pliers. Disconnect filter and discard.

NOTE: Do not pull hose completely out of tank.

4. Install a new fuel filter on hose and pull hose/filter assembly back into tank so filter is positioned in front right corner.

5. Reconnect fuel hose (A) to carburetor fitting (B). Replace air filter and air box cover (Figure 7-3A).

6. Fill tank with fresh fuel / oil mixture. Install fuel cap.

7-4.OIL FILTER

NOTE: Drain oil tank before changing filter

1. Disconnect oil hose (A) from pump fitting (B).

2. Use a wire with a hook (C) and pull oil filter (D) from tank. Remove filter and hose completely.

3. Insert a length of hose into tank and pull it through filler opening

4. Install a new filter on hose and pull hose back into tank so filter is positioned in bottom of tank.

5. Cut hose to fit and push it on to oil pump fitting (Figure 7-4A).

7-4A

7-5.SPARK ARRESTER SCREEN (Figure 7-5A)

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

1. Remove 2 muffler retaining nuts (E), Lock plate (F) and muffler cover(G).

2. Remove spark arrester screen (H) from the metal baffle (J). Replace screen with new one.

3. Reassemble the muffler components and tighten nuts securely.

7-5A

7-3A

16 17

7 - MAINTENANCE INSTRUCTIONS

7-6.SPARK PLUG

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

1. Push STOP switch up.

2. Remove top Cover. Disconnect the wire connector from the spark plug by pulling and twisting at the same time (Figure 7-6A).

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

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

5. Reinstall a new spark plug.

NOTE: A resistor spark plug must be used for replacement (McCulloch part no. 9295-320001 champion RDJ8J or equivalent). NOTE: This spark ignition system meets all requirements of the Canadian Interferen-Causing Equipment Regulations.

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.

7-8A

7-9.REMOVING A UNIT FROM STORAGE

Before starting, empty oil from combustion chamber.

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.

7-6A

7-7.CARBURETOR ADJUSTMENT

The carburetor was pre-set at the factory for optimum performance. If further adjustments are necessary, please take

our unit to the nearest Authorized Service Center.

7-8.STORING A CHAIN SAW

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.

CAUTION

Never store a chain saw for longer than 30 days without perf

orming the following procedures.

1. Remove the fuel tank cap slowly to release any pressure in tank.

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

e fuel from carb

remo

w the engine to cool (appro

Allo

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

our 1 teaspoon of clean 2-cycle oil into the combus-

5. tion chamber coat internal components. Replace spark plug (Figure 7-8A).

Carefully dr

Pull star

ain the fuel tank.

uretor.

5 min

ter rope slo

utes).

wly se

eral times to

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 lubricate 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 proce-

dure 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.

8-2. 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 Factory Parts 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

8 - BAR / CHAIN MAINTENANCE

8-3.CHAIN REPLACEMENT INFORMATION

Bar Length Drive Links

16” Bar 66 DL 18” Bar 72 DL 20” Bar 78 DL

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

9 - TROUBLESHOOTING THE ENGINE

PROBLEM

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

Unit starts, but engine has low power.

Engine hesitates.

No power under load.

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.

CORRECTIVE ACTION

Follow 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 spar

ve, clean and reinstall filter.

Remo

Have carburetor adjusted by an Authorized Service Center.

k arrester screen.

Runs erratically.

Smokes excessively.

Incorrectly gapped spark plug.

Incorrect carburetor mixture adjustment setting.

Incorrect fuel mixture.

Clean / gap or replace plug.

Have carburetor adjusted by an Authorized Service Center.

Use properly mixed fuel (40:1 mixture).

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