Mac Cat 440 Chainsaw Manual

The Mac Cat 440 is a professional-grade gasoline-powered chainsaw featuring a 44cc 2-stroke engine, 18-inch guide bar, automatic chain oiling system, anti-vibration handles, inertia-activated chain brake, quick-release air filter, and decompression valve for easier starting. Below are key sections for safety, features, assembly, operation, maintenance, and troubleshooting.

Features at a Glance

Key components: 44cc 2-stroke engine, 18-inch guide bar and chain, front hand guard with chain brake, rear handle with throttle trigger, fuel and oil tanks, side-access chain tensioner, and decompression valve.

Safety Information

Always wear protective gear: helmet, eye protection, hearing protection, gloves, chainsaw chaps, and steel-toe boots.

1. Clear work area of obstacles and bystanders.
2. Inspect chainsaw before each use: chain sharpness, tension, and lubrication.
3. Hold chainsaw firmly with both hands: left hand on front handle, right on rear.
4. Never operate above shoulder height or on unstable surfaces.
5. Shut off engine before adjusting or transporting.

WARNING! Kickback can occur suddenly; always grip handle firmly and avoid contact with bar tip. Keep chain brake functional.

Assembly & Preparation

Unpack and inspect all parts. Assemble on a clean, flat surface.

1. Attach guide bar: Place bar onto studs, align chain drive links with sprocket, adjust tension.
2. Install chain: Ensure cutting teeth face forward on top of bar.
3. Fill fuel tank: Use fresh 50:1 gasoline/oil mixture (89 octane minimum).
4. Fill oil tank: Use quality bar and chain oil.
5. Check chain tension: Chain should snap back when pulled from bar.

CAUTION! Do not force parts. Ensure all fasteners are tightened securely.

Specifications

• Engine: 44cc 2-stroke, air-cooled.
• Power Output: 2.4 kW (3.2 hp) at 9,500 RPM.
• Maximum Engine Speed: 13,500 RPM.
• Fuel Mix Ratio: 50:1 (unleaded gasoline to 2-stroke oil).
• Ignition System: Electronic, magneto.
• Spark Plug: NGK BPMR7A, gap 0.020 inch (0.5 mm).
• Chain Oil: Automatic pump with manual override.
• Sound Power Level: 112 dB(A).
• Vibration Level: Front handle 4.2 m/s², rear handle 2.8 m/s².

Controls and Components

Main Controls: Throttle trigger, throttle trigger lockout, stop switch, choke control, decompression valve, chain brake lever, master control lever (combined choke/stop/run).

Components: Front handle with chain brake, rear handle, fuel tank cap, oil tank cap, air filter cover, spark plug cover, muffler, side-mounted chain tensioner, bar nut cover.

Operation: Master control lever positions: STOP (◼), RUN (I), CHOKE (🐔). Chain brake engaged by pushing front hand guard forward. Decompression valve reduces cylinder pressure for easier starting.

Starting & Operating

Cold Start Procedure:

1. Place chainsaw on firm ground, clear of debris.
2. Engage chain brake by pushing hand guard forward.
3. Set master control lever to CHOKE position.
4. Press decompression valve (if equipped).
5. Pull starter rope briskly 3-5 times until engine fires.
6. Move lever to RUN position.
7. Pull starter rope until engine starts.
8. Disengage chain brake before cutting.

Tip: Warm start: Use RUN position only. Avoid flooding by not overusing choke.

Chain & Bar Maintenance

Regular maintenance ensures optimal performance and safety.

1. Chain Sharpening: Use round file (5/32 inch) at 30° angle. File each cutter evenly.
2. Chain Tension: Adjust when chain sags from bar. Loosen bar nuts, turn tensioning screw.
3. Bar Maintenance: Clean bar groove weekly. Flip bar monthly for even wear.
4. Lubrication: Check oil flow before each use. Adjust oil pump via screw if needed.
5. Depth Gauges: File down to 0.025 inch (0.65 mm) below cutter top.

WARNING! Always wear cut-resistant gloves when handling chain. Ensure engine is off and cool.

Engine Maintenance

Air Filter: Clean every 5 operating hours. Remove foam filter, wash in warm soapy water, dry, re-oil lightly.

Spark Plug: Check every 10 hours. Clean electrode, adjust gap to 0.020 inch. Replace if worn.

Fuel Filter: Replace annually. Access inside fuel tank via suction hose.

Carburetor Adjustment: Factory set; only adjust if necessary using H (high) and L (low) screws.

Muffler: Clean spark arrestor screen every 20 hours to prevent overheating.

Storage & Transport

Long-term Storage:

1. Drain fuel tank and run engine until it stops.
2. Remove chain, clean, and soak in oil.
3. Clean entire saw, especially cooling fins and air filter.
4. Store in dry, cool place, bar and chain separately.

Transport: Always engage chain brake. Use scabbard over bar. Secure in vehicle to prevent movement.

CAUTION! Gasoline is flammable; store in approved container away from heat sources.

Warranty Information

Mac Cat 440 includes a 2-year limited warranty for residential use and 1-year for commercial use. Warranty covers defects in materials and workmanship. Not covered: normal wear, misuse, improper maintenance, or use of non-genuine parts. For warranty claims, contact authorized service center with proof of purchase. For support, visit www.maccat.com or call 1-800-555-0440.

Troubleshooting

Service: For repairs, use only genuine Mac Cat parts. Authorized service: 1-800-555-0440; www.maccat.com