Mac 3516 Chainsaw Service Manual PDF

The Mac 3516 Chainsaw is a professional-grade gasoline-powered chainsaw designed for demanding cutting tasks. This service manual provides comprehensive information for maintenance, troubleshooting, repair, and safety procedures. Below are key sections covering safety warnings, specifications, maintenance schedules, engine service, fuel system, cutting equipment, troubleshooting, and parts diagrams.

1. Safety Warnings & Precautions 2. Specifications 3. Maintenance Schedule 4. Engine Service 5. Fuel & Lubrication System 6. Cutting Equipment & Bar 7. Ignition System 8. Carburetor Adjustment 9. Troubleshooting Guide 10. Parts Diagrams & List 11. Warranty & Support

Safety Warnings & Precautions

Essential safety information to prevent serious injury or death during operation, maintenance, and repair.

Hazard	Precaution
Kickback	Always use a reduced-kickback bar and chain. Hold saw firmly with both hands.
Fuel Handling	Refuel in well-ventilated area, engine off and cool. Use approved fuel containers.
Chain Contact	Ensure chain brake is functional. Wear cut-resistant chaps and safety boots.
Hot Surfaces	Allow engine and muffler to cool before performing maintenance.
Falling Branches	Be aware of your surroundings. Wear a hard hat during felling operations.
Carbon Monoxide	Never operate in an enclosed or poorly ventilated area.
Sharpening	Disconnect spark plug wire. Use proper filing tools and guides.
Electrical	Ignition system produces high voltage. Avoid contact when engine is running.

Specifications

Model: Mac 3516
Engine Type: 2-stroke, air-cooled gasoline engine
Displacement: 51.7 cc (3.16 cu. in.)
Power Output: 3.2 HP @ 9,500 RPM
Fuel Tank Capacity: 0.55 L (18.6 fl. oz.)
Oil Tank Capacity: 0.26 L (8.8 fl. oz.)
Recommended Bar Lengths: 16" to 20"
Chain Pitch/Gauge: 0.325" / .058" or .063"
Ignition System: Electronic, solid-state
Carburetor: Walbro or Zama diaphragm type
Weight (Powerhead): 5.9 kg (13 lbs.)

Maintenance Schedule

Regular maintenance is critical for performance, longevity, and safety.

Before Each Use: Check chain tension and sharpness, inspect bar for wear, verify throttle and chain brake operation, check for loose fasteners.
Every 10 Operating Hours: Clean air filter, check spark plug condition, clean external surfaces and cooling fins.
Every 20 Operating Hours: Clean spark arrestor screen (if equipped), inspect fuel filter and line, check anti-vibration elements.
Every 50 Operating Hours: Replace air filter, clean carburetor fuel filter, inspect clutch and sprocket.
Seasonal/Annual: Deep clean entire saw, replace fuel filter, check all gaskets and seals, inspect piston through exhaust port.

WARNING! Always disconnect the spark plug boot before performing any maintenance.

Engine Service

Procedures for cylinder, piston, crankshaft, and bearings.

Cylinder & Piston Inspection: Remove muffler to view piston and cylinder walls. Look for scoring, scratches, or excessive carbon buildup.
Compression Test: Use compression gauge. Minimum acceptable compression is 110 PSI. Low compression indicates worn rings, piston, or cylinder.
Crankcase Seals: Check for leaks by pressurizing crankcase. Leaking seals cause air leaks and poor engine performance.
Decompression Valve: If equipped, ensure it seals properly when closed.
Engine Reassembly: Use new gaskets and seals. Torque cylinder bolts to manufacturer specification (typically 10-12 Nm).

Fuel & Lubrication System

Fuel mix ratio, tank cleaning, oiler system service.

Fuel Mixture: Use high-quality 89+ octane gasoline mixed with a 2-stroke oil at a 50:1 ratio (20ml oil per 1 liter of gas). Use oil certified for air-cooled 2-stroke engines.

Fuel System Cleaning: Drain old fuel. Remove and clean fuel tank, replace fuel filter in tank, inspect fuel lines for cracks.
Automatic Oiler: Check oil output by running saw at high RPM over light-colored surface. Adjust oil flow screw if accessible.
Bar & Chain Lubrication: Always use proper bar and chain oil. Check oil passage in bar for clogs.

CAUTION! Never use straight gasoline or automotive motor oil. This will cause immediate engine seizure.

Cutting Equipment & Bar

Guide bar maintenance, chain sharpening, sprocket service.

Bar Maintenance: Clean bar groove regularly. Flip bar weekly for even wear. Dress bar rails with a flat file if burred.
Chain Sharpening: Use correct round file size (typically 4.0mm or 5/32"). Maintain correct filing angle (usually 30°). Ensure all cutters are filed to equal length.
Drive Sprocket: Inspect for wear. Replace if teeth are hooked or significantly worn. Use matching rim sprocket type (e.g., 7-tooth).
Chain Tension: Proper tension: snug against bar but pullable by hand. Re-tighten when chain is cool after initial use.

Ignition System

Spark plug gap, coil air gap, module testing.

Component	Specification/Test
Spark Plug	NGK BPMR7A or equivalent. Gap: 0.020" (0.5mm).
Ignition Coil Air Gap	Set between 0.010" - 0.012" (0.25 - 0.30mm) using a feeler gauge.
Module Test	Check for spark with tester. No spark indicates faulty coil, module, or stop switch wire.
Stop Switch	Test for continuity. Wire should be grounded to stop engine.

Carburetor Adjustment

Standard settings and adjustment procedure for H, L, and T screws.

Initial Settings (Screws seated lightly then opened):

L (Low Speed): 1-1/4 turns out
H (High Speed): 1 turn out
T (Idle Speed): 1 turn out

Start engine and warm up for 5 minutes.
Set idle speed (T) so chain just stops moving.
Adjust L screw for fastest, smoothest idle, then richen slightly (turn out 1/8 turn).
Adjust H screw for maximum RPM without exceeding safe limit (consult tachometer). Do not lean out excessively.
Re-check idle speed and finalize.

WARNING! An overly lean H adjustment will cause engine overheating and seizure.

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
Engine won't start	No spark, flooded, fuel issue	Check spark, plug condition. Dry plug if flooded. Verify fresh fuel, clean carb.
Engine starts then dies	Clogged fuel filter, carb adjustment, air leak	Replace fuel filter. Adjust L screw. Check crankcase seals & intake boot.
Lacks power under load	Clogged air filter, bad fuel, exhaust blocked	Clean/replace air filter. Use fresh mix. Clean spark arrestor.
Chain doesn't oil	Empty oil tank, clogged passages, faulty pump	Fill tank. Clean bar oil hole and tank filter. Inspect oil line and pump.
Excessive vibration	Loose components, unbalanced chain, bad AV mounts	Tighten all fasteners. Sharpen chain evenly. Replace anti-vibration buffers.
Chain won't stop moving at idle	Idle speed too high, clutch springs worn	Adjust idle screw (T). Inspect clutch drum and springs for wear.

Parts Diagrams & List

Exploded views and part numbers for major assemblies (available in full PDF manual).

Group 1: Cylinder & Piston Assembly
Group 2: Crankshaft & Bearings
Group 3: Carburetor & Air Filter
Group 4: Ignition & Rewind Starter
Group 5: Clutch, Sprocket & Chain Brake
Group 6: Fuel & Oil Tanks
Group 7: Handle & Anti-Vibration System
Group 8: Guide Bar & Chain

Note: Always use genuine Mac parts or OEM-equivalent quality parts for repair.

Warranty & Support

Limited warranty covering defects in materials and workmanship. Proof of purchase required.

Service Contacts:

Customer Support: 1-800-XXX-XXXX
Technical Manuals & Updates: www.macchainsaws.com/support
Authorized Service Centers: Visit website for locator.

Disclaimer: This manual is for reference. The manufacturer is not liable for injury or damage resulting from improper repair. Complex repairs should be performed by qualified technicians.