McCulloch Mac 110 User manual

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MAC 110/115/120/130/140
OWNER'S MANUAL
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© U.S.A. 1982 - McCULLOCH CORPORATION
PRINTED IN U.S.A.
215489

2
TABLE OF CONTENTS
IDENTIFICATION 3
SAFETY INSTRUCTIONS 4
GENERAL CUTTING INSTRUCTIONS 6
FUEL AND LUBRICATION 7
Fuel 7
Mixing Fuel 7
Chain Lubrication 7
Fuel Mixture Table 7
INSTALLATION INSTRUCTIONS 8
Guide Bar. Saw Chain and CHAIN BRAKE 8
OPERATING INSTRUCTIONS 10
CHAIN BRAKE Operation 10
Starting and Stopping 11
Carburetor Adjustment 12
Breaking in a New Engine 12
Storing a Chain Saw 12
Removal from Storage 13
MAINTENANCE 14
Spark Plug 14
Fuel Tank Vent 14
Air Filter 14
Starter Cover and Cooling Fins 14
Muffler or Spark Arrester and Exhaust Port 15
CHAIN BRAKE Maintenance 16
Sprocket, Clutch, and Clutch Drum 16
Automatic Oiler Adjustment 16
Guide Bar Maintenance 17
CHAIN MAINTENANCE 18
Chain Tension 18
New Chain Break-In 18
Chain Lubrication 18
Chain Sharpening 18
Lowering Depth Gauges 18
PREVENTIVE MAINTENANCE 19
ACCESSORIES 19
Spark Arrester Screens 19
Spike Kit 19
NOTE: Throughout this manual, a number circled in black
indicates the illustration which corresponds to the text where
the number appears.

IDENTIFICATION
A. Guide Bar
M. Ignition/Stop Switch
B.
Saw Chain
N. Throttle Latch
C.
Fuel Tank Cap
O. Carburetor Controls
D.
Manual Oiler Lever
P.
Cho15.e Lever
E.
Throttle Trigger
Q.
CHAIN BRAKE Lever/Handguard
F.
Rear Handle
R. Oil Tank Cap
G.
Spark Plug Cover
S. Saw Chain Tension
H.
Air Cleaner Cover
Adjustment Screw
J.
Front Handle
T. CHAIN BRAKE Retaining Nuts
K. Starter Cover
u. CHAIN BRAKE
L. Starter Handle
VM
uHler
W. Safety Trigger
The serial number is attached to the bottom of the .saw. Make
a record of the serial number for identification in case the saw
is lost or stolen and keep the record in a safe place.
3

• DULL or LOOSE CHAIN.
~~--=-~-..;....~
• CUTTING ABOVE SHOULDER' HEIGHT.
• INATTENTION in holding or guiding saw while
cutting.
USE DEVICES such as low kickback chain, CHAIN
BRAKES, and handguards which reduce the hazards
associated with kickback.
DON'T FELL A TREE during high or changing winds.
USE WEDGES TO HELP CONTROL FELLING and pre-{.;\
vent binding the bar and chain in the cut.
0
BE SURE OF YOUR FOOTING and pre-plan a safe exit
from a falling tree or limbs. (])
DO NOT SET A HOT SAW DOWN in areas where flam-
mable material is present.
SAFETY INSTRUCTIONS
• ~ l.
READ YOUR OWNER'S MANUAL AND ALL SUP-
PLEMENTS (if any enclosed) thoroughly before
operating your saw. CD
Operation of a chain saw should be restricted to
mature, properly instructed individuals. DO NOT
ATTEMPT OPERATIONS BEYOND YOUR CAPACITY
OR EXPERIENCE.
WEAR CLOSE FITTING AND PROTECTIVE WORK
CLOTHING that is made to give protection, such as
(A) safety hat, (B) safety shield, safety goggles or
safety glasses, (C) safety work shoes, (D) heavy
duty work gloves, and (E) good grade ear plugs or
sound barriers. ®
DON'T USE ANY OTHER FUEL than that recom-
mended in your Owner's Manual.
REFUEL IN A SAFE PLACE. OPEN FUEL CAP SLOWLY
to release any pressure which may have formed
in fuel tank. Do not start a saw where you fuel it,
move at least 10 feet (3 meters) from fueling area
before starting. ®
DO NOT OVERFILL or spill fuel. If fuel has been
spilled on the unit, be certain the saw has dried
before starting it. Do not refuel a hot saw - allow it
to cool off. ®
DON'T SMOKE while fueling or operating the saw.@
DON'T WORK ALONE.
START YOUR SAW WITHOUT HELP. Don't start a
saw on your leg or knee. Never operate a chain saw
when you are fatigued. ®
KEEP ALL PARTS of your body and clothing away
from the saw chain when starting or running the
engine. Before you start the engine, make sure the
saw chain is not contacting anything. ®
BEWARE OF KICKBACK! Hold saw firmly with both
hands when engine is running; use a firm grip with
thumbs and fingers encircling the chain saw
handles and watch carefully what you cut. Kickback
(saw jumps or jerks, up or backward) can be caused
by:
• STRIKING LIMBS or other objects accidentally
with the tip of the saw while the chain is moving.
• STRIKING METAL, cement, or other hard material
near the wood, or buried in the wood.
• RUNNING ENGINE SLOWLY at start of, or during
cut.
4

WE STRONGLY RECOMMEND you do not attempt to
operate the saw while IN A TREE, ON A LADDER or
ON ANY OTHER UNSTABLE SURFACE. If you elect
to do so, be advised that these positions are
EXTREMELY DANGEROUS. ®
DON'T CUT IN AWKWARD POSITIONS (off-balance,
out-stretched arms, one-handed, etc.).
WHEN CUTTING A LIMB THAT IS UNDER TENSION
be alert for springback so that you will not be struck
when the tension is released. ®
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. ®
VIBRATION - Avoid prolonged operation of your
chain saw and rest periodically, especially if your
hands or arms start to have a loss of feeling, swell or
become difficult to move. These conditions can
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reduce your ability to control a saw.
EXHAUST FUMES - Do not operate your chain saw
in confined or poorly vented areas.
OBSERVE ALL LOCAL FIRE PREVENTION REGULA-
TIONS. We recommend that you keep a fire
extinguisher and shovel close at hand whenever you
cut in areas where dry grass, leaves or other flam-
mable materials are present.
NOTE: Spark arrester screens are available for
installation in your muffler where fire regulations
require them. Check local regulations for your
-special requirements.
NEVER OPERATE YOUR CHAIN SAW WITHOUT A
MUFFLER.
DO NOT CARRY THE SAW BY THE CHAIN BRAKE
LEVER.
WHEN TRANSPORTING YOUR CHAIN SAW, use the
appropriate guide bar scabbard.
TURN OFF YOUR SAW WHEN MOVING BETweEN
CUTS and before setting it down. Always carry the
chain saw with the engine stopped, the guide bar
and saw chain to the rear, and the muffler away from
your body. @>
DON'T TOUCH or try to stop a moving chain with
your hand. @
DON'T ALLOW ANY OTHER PERSON or ANIMAL
CLOSE to a running saw or where a tree is being cut
down. @
/ DON'T TOUCH or let your hand come in contact with
a hot muffler, spark arrester, or a spark plug wire.
Don't ru n the saw without a muffler, exhaust stack,
or a spark arrester. Keep screens and baffles clean.@
KEEP THE CHAIN SHARP and SNUG on the GUIDE
bar. @
DON'T ALLOW DIRT, FUEL or SAWDUST to build up
on the engine or outside of the saw.
KEEP ALL SCREWS and FASTENERS TIGHT. Never
operate a chain saw that is damaged, improperly
adjusted, or is not completely and securely assem-
bled. Be sure that the saw chain stops moving when
the throttle control trigger is released. Keep the
handles dry, clean and free of oil or fuel mixture. @
DON'T OPERATE YOUR CHAIN SAW unless the
chain stops when the engine idles. (Have
corrected. )
5

DIRECTION OF FALL
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GENERAL CUTTING INSTRUCTIONS
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This consumer chain saw is intended for general homeowner
use, and such general applications as clearing, pruning, and
cutting firewood.
Before using your saw, you should review the safety precau-
tions listed in your Owner's Manual, and all local regulations
for the operation of your saw. These precautions and regula-
tions are for your protection.
For all types of cutting, always hold saw firmly with both
hands, with thumbs and fingers encircling saw handles.
Cut at high engine speeds (full throttle) only. Don't run the
engine slowly at the start or during the cut.
Pre-plan a safe exit from a falling tree or limbs.
Cut wood only,
Test the operation of the CHAIN BRAKE before cutting,
FElLING
Direction of fall is controlled by the undercut. Type" A" is
easy to make and is commonly used for small trees. Type
"8" leaves butt end of log cut squarely across. Type "C"
is a variation of Type" A". The notch should be about 1/3
diameter of the tree. On felling cut, do not cut through to
notch. Uncut band of wood parallel to notch serves as a
hinge. Make cuts in order shown - 1, 2, 3 on "A".@
When diameter of wood being cut is greater than bar length,
make two cuts as shown.@
BUCKING
When bucking on a slope, always stand on the up hill side,
LOG SUPPORTED ALONG ENTIRE LENGTH: Cut from top
(overbuck), being careful to avoid cutting earth.@
LOG SUPPORTED ON ONE END: First cut from bottom (under-
buck) 1/3 diameter of log to avoid splintering. Second, over-
buck to meet first cut and avoid pinching. ®
LOG SUPPORTED ON BOTH ENDS: First overbuck 1/3 dia-
meter of log to avoid splintering. Second, underbuck to meet
first cut and avoid pinching, ®
LIM BING
Keep the log off the ground. Do not remove supporting limbs
until after the log is bucked into lengths, ®
6

FUEL AND LUBRICATION
FUEL
Use only regular grade leaded gasoline. Do not use highly
leaded. unleaded or low lead gasolines Chain saw fuel is a
mixture of gasoline and lUbricating oil. The correct ratio of
gasoline to oil is very important. Follow the ratios in the Fuel
Mixture Table. McCulloch 40: 1 Two-Cycle Custom Lubricant
is recommended. If not available. use a good grade SAE 40
two-cycle oil at a ratio of 20 to 1.
MIXING FUEL
Mix fuel in a container equipped with a flexible spout and
strainer. Pour half of the gasoline and all of the oil into the
container. Shake the container vigorouslyl Add the rest of the
gasoline and shake container vigorously again. Thoroughly
mixed fuel makes your saw run better.
CAUTION: Fuel additives or special starting fluids should not
be used because seals and other rubber composition parts
may be damaged.
CHAIN LUBRICATION
Always refill the chain oil tank each time the fuel tank is re-
filled. We recommend using 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. If McCulloch Chain, Bar and Sprocket Oil is not
available, use SAE 30 non-additive motor oil at temperatures
above 40° F(5° C) and SAE 10 non-additive motor oil at
lower temperatures ..
FUEL MIXTURE TABLE
Gasoline
McCulloch 40:1 Ratio SAE 40 Two-Cycle Oil
Custom Lubricant 20: 1 Ratio
l, U. S. Gal. 1. 6 oz. 48 ml
(ee)
3.2 oz.
95 ml (ee)
1U.S. Gal. 3.2 oz.
95 ml
(ee)
6.4 oz.
190 ml (ee)
5 U. S. Gal. 16.0 oz.
475 ml (ee)
32.0 oz.
950 ml (ee)
1 Liter 0.9 oz. 25 ml
.(ee) 1. 7
oz.
50 ml (ee)
5 Liter 4.3 oz.
125 ml
(eel
8.5 oz. 250 ml (ee)
20 Li ter 17.0 oz. 500 ml (ee 34.0 oz. 1000 ml (ee)
1Imp. Gal.
4.3 oz.
125 ml
(ee)
8.6 oz. 250 ml (ee)
2Imp. Gal. 8.6 oz.
250 ml
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17.1 oz. 500 ml ~eel
5Imp. Gal. 21.4 oz.
625 ml
42.8 oz. 1250 ml ce
Mixing
40 parts gasoline to
20 parts gasoline to
Procedure
1 part lubricant
1 part lubricant
1 ml =lcc
7

INSTALLATION INSTRUCTIONS
GUIDE BAR, SAW CHAIN AND CHAIN BRAKE INSTALLATION
CAUTION: Do not attempt to start or run the engine until the
BAR, SAW CHAIN and CHAIN BRAKE have been installed.
WARNING: Handle the CHAIN BRAKE carefully when it is
removed from the saw because it is under tension.
1. Remove the upper retaining nut and bolt, and the lower
retaining nut. Remove the CHAIN BRAKE. This is only
necessary when the CHAI N BRAKE is assembled on the
unit. @
2. Slide the slotted end of the bar over the bar mounting
bolt and push it back toward the sprocket as far as it
will go.@
3. Spread the chain out in a loop with the cutting edges of
the chain pointing clockwise around the loop.
4. Tilt the top of the chain away from you so that you can
slide it edgewise over the top of the drum (under the
saw housing and sawdust deflector).@
5. Guide the chain around and behind the drum (between
the drum and the muffler) and onto the sprocket.@
6. Move the chain back and forth to make sure it is in
proper mesh with the sprocket and lined up with the
bar groove.@
7. Guide the chain center links into the bar groove all the
way around the bar. Pull the nose of the bar out to take
up all the slack in the chain. @
8. Make certain the CHAIN BRAKE lever is pulled back to
the disengaged position (chain can move).@
9. Install the CHAIN BRAKE, being certain the brake band
is fitted carefully around the outside of the clutch drum,
and the CHAI N BRAKE lever is set properly onto the
CHAI N BRAKE. @
CAUTION: THE CHAIN BRAKE CAN BE CRACKED OR
BROKEN if carelessly installed. The chain tension adjust-
ment nut (tang) must be properly positioned in the
adjustment hole in the bar before tightening the lower
retaining nut. There should be no large gaps between
the CHAI N BRAKE and the saw housing, and the front
should fit snug against the bar. ®
10. Turn the chain tension adjustment screw in or out to
align the nut with the bar hole. ®
11. Install the lower retaining nut finger tight.
12. Hold the nose of the bar up and turn the adjustment
screw clockwise to tension the chain. It should be a
snug fit all around the bar. @
NOTE: The chain has the proper tension when, with the
bar locked in the uppermost position, it has a snug fit all
around and will pull around the bar easily by hand. No
droop or sag of the chain is permitted.
,
13. Holding the nose of the bar up tighten the lower retain-
ing nut securely.
14. Install the retaining bolt and nut to the brake lever and
tighten securely.
8
®

9

OPERATING INSTRUCTIONS
CHAIN BRAKE OPERATION
Your chain saw is equipped with a CHAIN BRAKE that
reduces the possibility of injury due to "kickback." The
brake is actuated if pressure is applied against the lever
when. as in the event of "kickback," the operator's hand
strikes the lever. When the brake is actuated, chain move-
ment stops abruptly.
CAUTION: Purpose of the CHAIN BRAKE is to reduce the
possibility of injury due to "kickback" but it can not provide
the measure of protection intended if the saw is operated
carelessly.
The CHAIN BRAKE is disengaged (the chain can move) when
the brake lever is pulled back and locked. ®
The CHAIN BRAKE is engaged (chain is stopped) when the
brake lever is in the forward position. @
When the brake has been tripped and engaged (chain stops)
immediately release the throttle trigger to prevent damage to
engine or clutch.
If the CHAI N BRAKE has been actuated and the engine is
idling, grasp the brake lever firmly and pull back to the locked
position while controlling the saw with a hand grasping the
rear handle. Be careful not to squeeze the throttle trigger.
NOTE: Do not attempt to start or operate the engine with the
brake engaged (chain is stopped). Do not allow the engine to
idle for long periods of time when the brake is engaged as
this tends to build up heat in the sprocket bearing.
Before cutting with your saw, test the CHAIN BRAKE as
follows:
1. Place the saw on a firm flat surface.
2. Follow the correct procedures to start the engine.
3. Grasp the rear handle firmly with the right hand. @
4. With the left hand, hold the front handle (not the CHAIN
BRAKE lever) firmly.@
5. Squeeze the throttle trigger so that the chain begins to
move, then activate (push forward) the CHAIN BRAKE
lever. @
CAUTION: Activate the CHAIN BRAKE SLOWLY and ®
DELIBERATELY. Be careful to keep chain from touching 34
surface: don't let saw tip forward.
10

6. The chain should stop abruptly. When it does, release
the throttle trigger immediately.
NOTE: If the chain does not stop, turn off the engine and
check to be sure the CHAI N BRAKE is properly installed.
If the installation is correct, take the saw to your McCulloch
dealer for repair or replacement of the CHAIN BRAKE
assembly.
The CHAIN BRAKE lever (hand-guard) provides the best pro-
tection against kickback when the saw is held at the top of the
front handle. As the left hand moves around the front handle
(toward the bottom of the saw) the CHAIN BRAKE becomes
increasingly difficult to activate. However, the CHAI N BRAKE
lever will act as a hand-guard if the saw is being held at any
point on the front handle. ®
DO NOT HOLD THE SAW BY THE CHAIN BRAKE LEVER.
STARTING AND STOPPING
Pre-start Checks
1. Fill the fuel tank with correct fuel mixture. Be certain not
to spill fuel on the saw and, if you do, allow saw to dry
out thoroughly before attempting to start or operate.
2. Fill the chain oil tank with the correct chain oil and pump
manual oiler until oil is seen at top of bar just forward of
the CHAIN BRAKE. ®®
3. Make sure the chain has correct tension and the bar is
tight on saw.
To Start
1. Place saw on firm flat surface.
2. Push red ignition/stop switch up to the "ON" position.
3. Turn the choke lever counter-clockwise (cold or vapor
locked engine only).
4. Depress the safety trigger as you grasp the rear handle
and squeeze the throttle trigger tightly. Hold down the
throttle latch.@
5. Release trigger.
6. Release throttle latch button (button should stay
depressed) .
7. Grip front handle firmly (not brake lever). @
. r .
11

8. Pull the starter handle slowly until you feel the starter
engage, then pull with a smooth, rapid, short-stroke
motion. Allow the starter rope to rewind slowly. (Never
let the starter rope snap back from the extended posi-
tion). Repeat until engine starts. @
9. Turn the choke lever clockwise after engine first fires.
10. Squeeze the throttle trigger slightly to release the throttle
latch button.
11. Use the choke and throttle trigger to keep the engine
running until it is warmed up. Do not run the engine at
full throttle unless you are cutting wood ..
12. To stop the engine push the stop switch down to the
"STOP" position.
Starting Vapor Locked Engine
Vapor lock occurs in the carburetors of engines which have
become extremely hot from lengthy continuous use and/or
from use in extremely hot weather. After the.engine has been
shut off for a short time it may not start again due to the vapor
lock.
To re-start an engine that is vapor locked, perform steps 1
through 8 of the normal starting procedure.
When the engine starts, immediately move the choke lever
about halfway forward while alternately squeezing and releas-
ing the throttle trigger as required to keep the engine running.
Slowly move the choke lever to the open position and continue
to squeeze and release the throttle trigger until the engine
- runs smoothly.
CARBURETOR ADJUSTMENT ®
. Carburetor adjustment is critical and if done carelessly can
damage the carburetor and engine.
NOTE: Before making any adjustments make sure the air
filter is clean. Very often a dirty air filter will make the
engine operate as though the carburetor needed adjustment.
Cleaning the filter may correct the problem.
1. Carefully turn the low and high speed mixture needles
clockwise until resistance is felt. Do not turn the needles
in too tight or you can damage the needle tips and their
seats. Then open (turn counterclockwise) each needle 1114
turn.
2. Start the engine and let it warm up at low speed. If the
engine will not idle without stopping, turn the idle speed
screw clockwise until it does.
3. Accelerate the engine several times, adjusting the low
speed mixture needle to obtain a smooth. rap~d accel-
eration without hesitation or falter. If the needle IS turned
in too far, the engine will hesitate or falter when acceler-
ated. If the needle is turned out too far. the engine will run
rough and smoke heavily when accelerated.
4. Adjust the high speed needle for best power under load.
Do not judge by the sound; judge by the way the saw cuts.
Final position of the high speed needle will usually be
between 1114 and 1112.
5. Check idle operation again. It may be necessary to re-
adjust slightly for smooth idle and acceleration.
12
A Choke Lever (Open Position)
B Choke Lever (Closed Position)
C Idle Speed Screw
D High Speed Mixtwe Needle
E Low Speed Mixtwe Needle
F Throttle Latch
BREAKING IN A NEW ENGINE
Breaking in a new chain saw engine is very important. Run
your engine for its first few minutes at one-third throttle.
Increase speed to about half-throttle and run for a few min-
utes longer. Cut a few limbs or small logs at first. Check
chain tension frequently and use the manual oiler button often.
It is advisable to use a slightly richer fuel mixture during the
break-in period. Turn the high speed mixture needle about
one-eighth turn counterclockwise from the normal preliminary
starting position. On carburetors with a fixed high speed jet,
turn the low speed mixture needle one-eighth turn counter-
clockwise from the preliminary setting. After about an hour's
operation, turn the adjusted needle back one-eighth turn
clockwise.
STORING A CHAIN SAW
When storing the saw for short periods or transporting it
with fuel in the tank, always keep the saw level and with the
fuel cap up to avoid leakage from the tank or cap vent.
Never store a chain saw for over 30 days without performing
the following procedures:
1. Drain the fuel tank in a safe prea. @

2. Start the saw and run at idle speed until the engine stops.
This will remove most of the fuel from the fuel system.
3. Remove the spark plug with a spark plug wrench and pour
a teaspoonful of oil through the spark plug hole into the
combustion chamber. Pull the starter rope slowly several
times to distribute the oil throughout the engine. Replace
the spark plug tightly. @
4. Remove and clean the bar and chain (use gloves when
handling chain). @
5. Store the chain in a container with oil covering the chain.
6. Apply a heavy film of oil over the entire bar including the
groove for the chain. Cover with heavy paper, cloth or
plastic.
7. Clean the outside surfaces of the saw.
®
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8. Cover the saw with a protective cloth or plastic, and store
the saw and bar in a dry place. Always store away from
possible source of ignition such as furnaces, heaters, etc.
9. Ideally the saw should be operated for a short period of
time (5 minutes) every 30 days. Follow the usual starting
instructions.
REMOVAL FROM STORAGE
Remove the spark plug with a spark plug wrench. Pull the
starter rope briskly to clear the cylinder of excess oil. Clean
and gap the spark plug or install a new spark plug. Fill the
fuel tank with the correct fuel mixture and fill the chain oil
tank with McCulloch Chain, Bar and Sprocket Oil.
A Hint For Easier Starting
A newly manufactured saw or one which has been in storage
may sometimes be difficult to start. This is because for ship-
ping purposes one of the manufacturing processes removes
all fuel from the fuel tank, fuel lines and carburetor after the
engine is tested. Proper storage and long storage periods also
result in removing or evaporating all fuel from the engine.
Under these circumstances, it can be easier to start the
engine in the following manner: Remove the air filter cover
and air filter. Prime the engine by injecting about half a tea-
spoon of the proper fuel mixture through the carburetor air
@intake. (An oil can filled with the proper fuel mixture is ideal
for this purpose.) Take care not to flood the engine and do
not spill fuel into the airbox. It usually takes two or three
pulls of the starter rope to draw the fuel into the combustion
chamber and start the engine. It may be necessary to start
the engine two or three times in this manner before the en-
gine will run on its own fuel system. As soon as the engine
is running on its own fuel system, stop the engine and replace
the air filter and air filter cover. Never do any cutting with
the air filter and air filter cover off the engine.
NOTE: DO NOT USE THIS METHOD FOR REGULAR STARTING!
13

.. '
MAINTENANCE
All chain saw service, other than the items listed here in
your Owner's Manual maintenance instructions, should be
performed by your authorized McCulloch Servicing Dealer.
.Keep the saw, bar and chain clean. Do not allow the filters,
muffler, and cylinder fins to become plugged or covered with
sawdust, dirt or other foreign material. Never put dirty fuel
or chain oil into the saw.
SPARK PLUG
~
For efficient operation of the saw engine, the spark plug
must be kept clean and properly gapped.
1. Push ignition stop switch to "OFF" position .
. '·t
, 2., Disconnect the black rubber connector on end of the wire
@from spark plug by twisting and pulling at the same time.
3. Remove spark plug with spark plug wrench. Do not use
any other tool.
4. Clean electrodes with emery cloth or fine sandpaper. Blow
all dust away. Do not use a grit-type cleaning machine.
Wear eye protection during this oper.ation. @
5. Adjust the electrode air gap to 0.025 in. (0.635 mm) by
bending side electrode only. @
6. Re-install spark plug and black rubber spark plug connec-
tor on end of ignition wire.
7. For replacement spark plugs of different heat ranges, see
your McCulloch dealer.
FUEL TANK VENT
The fuel tank or fuel cap is vented to prevent bUild-up of
either pressure or vacuum in the tank. Both conditions will
affect operation of the engine. The vent can become plugged
through the use of dirty fuel or dirt falling into the fuel tank
during refueling operations. If pressure or vacuum develops,
have your McCulloch dealer service the saw.
AIR FILTER
Never operate the saw without the air filter, or dust and dirt
will be sucked into the engine and damage it. The air filter
must be kept clean.
To clean the air filter:
1. Remove the air filter cover by loosening the screw. ®
2. Lift off the air filter and blow it clean with low air pressure
or wash it in fuel mix. Dry in open air and away from open
flame. ®
3. Reinstall the filter in its original position, centered within
the ring of small locating studs.
4. Reinstall the cover. Slide the edge on the forward end
under the flange of the starter cover, then press the rear
end of the filter cover down until it snaps into position,
'smooth and even all around the edges, and tighten retain-
ing screw.
STARTER COVER AND COOLING FINS
The air inlet openings of the starter cover and the cylinder
14

cooling fins must be kept clean or the engine will become
overheated during cutting operations. Cooling fins are easily
cleaned after removing the starter cover and the muffler.
1. Remove the starter cover and clean out the openings. Use
a small wooden scraper to remove dirt and sawdust
packe into the mesh. Use a soft bristle brush to finish .'
cleaning the cover. Make sure the starter shaft turns
fr~ely and easily. ®
2. Scrape all dirt, grass, wood chips, etc. from the cooling
fins on the cylinder head. Use a thin scraper or astiff
brush.~ :
3. Clean the vanes on the flywheel and the other parts of the
engine that became visible when the starter cover was
removed.
4. When re-installing the starter cover, pull the starter rope
slowly so the starter can engage the flywheel properly.
MUFFLER OR SPARK ARRESTER AND EXHAUST PORT
Periodically it is advisable to remove, clean and inspect the
spark arrester or muffler. At the same time, any carbon
should be removed from the exhaust port. Operating the saw
with a dirty or defective spark arrester can lead to damage to
the engine. Never run the engine without a spark arrester or
muffler.
1. Remove the muffler or cover and spark arrester screen if
utilized.
2. Clean away all carbon deposits with a scraper blade, wire
brush, or by washing with a good solvent. Replace any
broken or damaged element.
3. While the muffler or spark arrester is removed from the
saw, examine the exhaust port for evidence of carbon
around the port. Clean the port as follows:
A. Pull the starter rope slowly until the piston covers the
port completely.
B. Use a wooden scraper and clean in and around the
port. Do not use any metal or sharp-edged tool that
might slip and scratch the piston or rings. ®
C. After cleaning, turn the saw exhaust side down and
blow loose particles away with compressed air. Protect
your eyes during the operation.
15

CHAIN BRAKE MAINTENANCE
Ttle clutch D(.lIm and CHAIN BRAKE should be kept as clean
and free of sawdust as possible to allow free movement and
full contact of the brake band. And. as the thickness of the
brake band is important to the effectiveness of the CHAI N
BRAKE. it should be inspected daily for any signs of measur-
• able wear or for any noticeable variation in the thickness of
ihe band. The inspection can be part of the daily preventive
maintenance program of rotating the guide bar for longest
service life (See Preventive Maintenance Schedule). If such
wear is noted the brake band should be replaced by your
McCulloch Servicing Dealer. ®
Your McCulloch Servicing Dealer has wear specifications for
the band and will be happy to advise you regarding the need
to replace the band.
SPROCKET, CLUTCH AND CLUTCH DRUM
You should always install a new sprocket when a new chain is
installed. A damaged or worn sprocket must be replaced with
a new one. The saw should never be operated with
excessive clutch slippage. Evidence of slippage is shown
when the chain moves very slowly or stops and the engine
continues to run. This will result in a rapid and damaging
heat build-up in the clutch and the clutch drum. If the clutch
begins to slip, the saw should be taken to a McCulloch Dealer
for servicing.
SPROCKET REPLACEMENT
1. Disconnect spark plug wire.
2. Remove spark plug using spark plug wrench.
3. Remove the CHAIN BRAKE assembly, bar and chain, and
the starter housing.
4. Lock the crankshaft by holding a V2 inch socket wrench on
the flywheel nut to act as a back-up to the V2 inch socket
wrench on the clutch nut. @@
5. Remove the clutch nut by turning it clockwise, then remove
the dust plate and clutch. @
6. Remove the sprocket and drum assembly and the sprocket
bearing. Lubricate the bearing with a good grade of non-
fibrous chassis grease whenever replacing the bearing or .
the sprocket and drum assembly.
7. Install the bearing, the sprocket and drum assembly, the
clutch, the dust plate and clutch nut.
8. Lock the crankshaft as explained in step 4 above. Tighten
the clutch nut securely by turning it in a counterclockwise
direction.
CAUTION: Do not use excessive force when tightening the
clutch nut. Too much force will loosen the flywheel nut. If
the flywheel nut is loosened during this procedure, see
your McCulloch dealer for corrective maintenance.
The clutch and clutch drum should be kept as clean and free
of sawdust as possible. If sawdust is allowed to build up the
clutch may drag causing the chain to move while the saw is
idling.
AUTOMATIC OILER ADJUSTMENT
The automatic oiler is adjusted at the factory for average cut-
ting conditions. Oil flow may be adjusted, however, for special
conditions or individual requirements. Turn the adjustment
screw clockwise to reduce oil flow and counterclockwise to
increase it. ®
16

Do not turn the adjustm~nt screw more than 1/4 ~urn at a
time. Check oil flow after each adjustment. When more oil is
needed for short periods, it is better to use the R1ahual oiler-
as a supplement and make no adjustment to the automatic
oiler screw.
GUIDE BAR MAINTENANCE
Bar wear: Turn bar over frequently (at regular intervals) to
ensure even wear on top and bottom of bar.
Bar groove: Bar groove should be cleaned every time chain
is removed. Run depth gauge tang or similarly sized instru-
ment along the groove until all residue is cleared. ®
Oil Passages: Oil passages at base of bar should be cleaned
periodically to ensure proper lubrication of chain and bar
groove. This can be done with depth gauge tang or any
instrument small enough to insert into passages. @
NOTE: New McCulloch depth gauges are designed with a
tang which is ideally suited for cleaning bar groove and oil
passages.
The condition of the oil passages should be checked before
each use of the saw. While running the saw, press manual
oiler button a few times. If passages are clear, the chain
will give off a spray of oil.
Lubrication of Sprocket Tip: For most non-professional usage
the sprocket tip will not require lubrication. However, lubrica-
tion is necessary for professional usage and under the follow-
ing circumstances:
1. Continuous cutting of dry or highly abrasive wood.
2. Continuous boring cuts.
3. Continuous cutting with the bar tip.
4. Continuous cutting in wet or snowy conditions.
Under these circumstances lubricati.on is recommended after ') :.
one hour of hard usage or after three (3) tanks of gas are ' ,
consumed.
NOTE: Thoroughly clean bar tip before lubrication.
Three methods of lubrication for the sprocket tip may be used:
1. Needle Nose Grease Gun: Clean lubrication hole. Using a
general purpose chassis lubricant of No. 1 consistency,
force grease into lubrication hole on one side of bar while
covering the lubrication hole on the other side. Rotate
sprocket and apply grease until it appears at edge of
sprocket. Repeat on other side of bar. @
NOTE: Lubri-Gun, piN 68090, is recommended by
McCulloch Corporation for applying grease to sprocket tip.
Its small nozzle is necessary for efficient application of
grease to sprocket tip.
2. Oil Can: Squirt the appropriate weight motor oil (SAE 10 in
cold weather, SAE 30 in hot weather) into lubrication hole
while turning sprocket. Repeat on other side of bar.
3. Oil Soak: Fill a small container with clean oil and sub-
merge bar tip in oil. Rotate sprocket several revolutions.
Bar tip may be submerged overnight for maximum
lubrication.
17

CHAIN MAINTENANCE
How you care for your chain saw determines the kind of
service you will get from it.
The use of McCulloch Depth Gauge Tools and a McCulloch
File Guide is recommended.
Chain should be kept clean and sharp for maximum cutting
efficiency.
CAUTION: Always wear protective gloves when handling
chain.
1. Top Plate
2. Side Plate
3. Depth Gauge
4. Gullet
®
®
~
I 80
0
I
./
@
4. Repeat sharpening stroke until tooth is sharp. Drop file
into gullet and clean out with a few light strokes. Do not
touch cutting edge of the tooth.
5. Sharpen all teeth on one side of chain. before sharpening
teeth on the other side. Use same number of strokes on
each tooth to help keep all teeth the same length.
LOWERING DEPTH GAUGES
1. Place depth gauge tool over two cutter teeth with depth
gauge on first cutter projecting through desired clearance
of depth gauge tool. @
2. Remove projecting part of depth gauge with a flat file. @
3. After lowering all depth gauges, round off their leading
edges. Maintain same profile as on original depth gauge.
4. Always place depth gauge to be filed at same place on
bar when lowering depth gauges.
McCulloch saw chain is a precision manufactured cutting
attachment and requires regular inspection and care to main-
tain peak cutting efficiency. Touch up sharpening may be
required once or twice during a day's wood cutting. In some
areas where sand or other abrasives have become embedded
in the bark of trees, cutter teeth dull more rapidly and more
frequent sharpening may be required.
1. Chain can be sharpened on saw or place the chain in a
chain-filing vise.
2. Use a 5/32 inch (3.9 mm) round file and a file guide
marked for a30° top filing angle. @
3. Hold the file at the correct top filing angle, apply pressure
against the face of the tooth, and push the file toward the
outside of the tooth. Release pressure on the cutting edge
on the return stroke.@
CHAIN TENSION
Check the chain tension frequently and adjust as often as
necessary to keep chain snug on the bar,·but loose enough
to be pulled around the bar by hand.
Over a' per10d of time the moving parts of saw chain
become worn which results in what is referred to as "chain
stretch".
When it is no longer possible to obtain the correct
chain tension adjustment, a link will have to be removed to
shorten the chain. See your McCulloch Servicing Dealer to
have this repair performed.
NEW CHAIN BREAK-IN
1. Run chain at low speed without cutting for 5 minutes.
Push manual oiler button every 10 to 15 seconds to pro-
vide extra oil.
2. After 5 minutes, shut off engine and recheck and adjust
chain tension.
3. Keep the chain well lubricated.
4. After 10 minutes, shut off engine and check chain tension.
Adjust if necessary. Repeat chain tension check often
during the first few hours of cutting.
CHAIN LUBRICATION
Make sure manual and automatic oiler are working. Keep oiler
tank filled with clean McCulloch Chain, Bar and Sprocket Oil.
Use plenty of oil on chain when cutting. Never let chain run
dry on the bar. In abrasive wood, use extra oil.
CHAIN SHARPENING ®
18

PREVENTIVE MAINTENANCE
A goo e maintenance program of regular inspection
and ca - ncrease life and improve performance of your
McCu cain saw. This maintenance check chart is a
guide s ch a program. Cleaning, adjustment, and parts
replace ent may, under certain conditions be required at
more equent intervals than those indicated·. The chain oiler
mus e kept constantly in good operating condition and the
cain must be kept snug on the bar.
• After the first 7 days or 15 hours of operations, whichever
comes earliest, take your saw back to your nearest McCulloch
Servicing Dealer for an inspection and checkup. He will be
pleased to help you establish a preventive maintenance pro-
gram to suit your needs. The recommended first 7 -day or
15-hour checkup and a follow-up of regular, periodic check-
ups and tune-ups at your McCulloch Dealer's shop wil be
minimal in cos and will assure long, satisfactory service
from your McClulloch chain saw.
PREVENTIVE MAINTENANCE CHECK CHART
FREQUENCY
>- 0
>-
...J
...J
:::t:
C
>- :lIl:
~
W
...J WZ
a:
ITEM
MAINTENANCE
C( w0en
0
;:
:!: e:t
SCRFWS NUTS BOLTS
INSPECT & TIGHTEN
•
CONTROLS
INSPECT
•
AIR FILTER
CLEAN
•
REPLACE
•
SAWOUST GUARO
CLEAN
•
CHAIN
INSPECT & SHARPEN
•
RAil
CLEAN & TURN
•
SHOCK MOUNTS
INSPECT
•
REPLACE"
•
SPROCKET
INSPECT
•
REPLACE
•
FUEL FILTER
CLEAN
•
OIL SCREEN
CLEAN
•
MUFFLER
CLEAN
•
SPARK PLUG
r LEAN & ADJUST
•
REPLACE
•
CYLINDER FINS
CLEAN
•
STARTER ROPE INSPECT
•
REPLACE"
•
CARBURETOR CLEAN"
•
FUEL TANK CLEAN
•
BREAKER POINTS CLEAN & ADJUST"
•
LAMINATION GAP
CLEAN & ADJUST"
•
EXHAUST PORTS
CLEAN"
•
FUEL, OIL & PRESSURE
••
HOSFS
CHECK"
CARBURETOR DIAPHRAGM REPLACE ONCE A YEAR"
CRANKSHAFT SEALS REPLACE ONCE A YEAR"
"Recommended for maintenance by an authorized McCulloch Dealer.
ACCESSORIES
SPARK ARRESTER SCREENS @
An accessory spark arrester screen is available from your
McCulloch dealer for installation on the saw muffler under the
muffler cover. Local regulations may require the accessory
screen for fire prevention or other special cutting conditions.
SPIKE KIT ®
Spikes, which act as wood grippers and fulcrum points for
cutting control, are accessory items available from your
McCulloch dealer.
19

"McCULLOCH
•MANUFACTURING •
SALES
•
SERVICE •
McCULLOCH CORPORATION
P.O. BOX 92180, LOS ANGElES, CALIFORNIA 90009