McCulloch Chainsaw 3516 Service Manual

The McCulloch Chainsaw 3516 is a 35cc, 16-inch gas-powered chainsaw designed for general-purpose cutting, limbing, and pruning. This manual covers essential safety procedures, technical specifications, routine maintenance, troubleshooting, and repair instructions to ensure safe and efficient operation. Below are key sections for safety, features, maintenance, operation, and troubleshooting.

Features at a Glance

Key components: 35cc 2-stroke engine, 16-inch Oregon bar and chain, automatic oiler, anti-vibration system, chain brake, primer bulb, and tool-less chain tensioning.

Safety Precautions

Always wear appropriate PPE: safety glasses, hearing protection, gloves, chainsaw chaps, and sturdy boots.

1. Inspect chainsaw before each use: Check for loose parts, chain tension, and sharpness.
2. Clear work area: Remove debris, ensure secure footing, and plan escape path.
3. Fuel safely: Mix gasoline and 2-stroke oil (50:1 ratio) in approved container; refuel in well-ventilated area with engine off and cool.
4. Operate with both hands: Maintain firm grip, thumbs wrapped around handles.
5. Never operate above shoulder height or on a ladder.

WARNING! Kickback can occur without warning. Keep chain sharp, maintain proper tension, and use reduced-kickback chain. Always engage chain brake when not cutting.

Specifications

• Engine Type: 35cc 2-stroke, single cylinder, air-cooled.
• Power Output: 2.0 HP @ 9000 RPM.
• Idle Speed: 2800 RPM.
• Max Engine Speed: 12,500 RPM.
• Fuel Mix: 50:1 (Unleaded 89 octane gasoline with JASO FD or ISO-L-EGD certified 2-stroke oil).
• Spark Plug: Champion RCJ7Y or equivalent, gap 0.025" (0.63mm).
• Chain Type: Oregon 91PX series, 55 drive links.
• Sound Level: 105 dB(A) at operator's ear.
• Warranty: 2-year limited warranty for residential use.

Assembly & Initial Setup

Unpack and inspect contents. Assembly requires bar, chain, and chain cover installation.

1. Attach guide bar: Place bar onto studs, align chain tensioning pin.
2. Install chain: Ensure cutting teeth face forward on top of bar. Fit chain over sprocket and into bar groove.
3. Secure clutch cover: Place cover over studs, hand-tighten nuts. Adjust chain tension (see section 8).
4. Fill fluids: Add fuel mix to tank. Fill bar and chain oil reservoir with SAE 30 or equivalent chainsaw oil.
5. Check controls: Verify throttle trigger, throttle lock, stop switch, and chain brake function properly.

CAUTION! Always wear cut-resistant gloves when handling chain. Ensure chain is properly seated on bar sprocket before tightening.

Controls and Components

Main Controls: Front Handle with throttle trigger and throttle lockout. Rear Handle with stop switch. Chain Brake lever (front hand guard). Primer Bulb. Choke Lever. Decompression Valve (if equipped).

Main Components: Engine Cylinder, Muffler, Air Filter Cover, Fuel Cap, Oil Cap, Chain Tensioning Screw, Spark Plug, Starter Rope Handle, Anti-Vibration Mounts.

Operation: Set choke for cold start, press primer bulb 5-6 times, engage throttle lockout, pull starter rope. Disengage choke once engine fires. Allow 30-second warm-up before cutting.

Starting & Operating Procedures

Cold Start: Engage chain brake. Set choke to full ON. Press primer bulb until fuel is visible. Pull starter rope sharply until engine fires (usually 3-5 pulls). Move choke to half position, pull again until engine starts. Open choke fully, allow to idle 30 seconds. Disengage chain brake to begin cutting.

1. Warm Start: No choke needed. Pull starter rope 1-3 times.
2. Cutting Technique: Use full throttle when cutting. Let chain do the work; avoid forcing. For bucking, support log; cut from top down. For limbing, cut branches from underside.
3. Shutdown: Allow engine to idle 30 seconds. Press stop switch to OFF.

Tip: Avoid "pinching" bar by planning cuts. Use wedges for large logs.

Routine Maintenance

Daily/Pre-use: Check chain tension, sharpness, and lubrication. Inspect air filter, clean if dirty. Check fuel and oil levels. Verify all fasteners are tight.

Weekly: Clean cooling fins, spark arrestor screen (if equipped). Check spark plug condition and gap. Inspect anti-vibration mounts for wear.

Monthly: Clean fuel filter in tank. Replace air filter if damaged. Grease clutch bearing (if applicable).

Seasonal: Drain fuel for long-term storage. Run engine dry of fuel. Remove chain, clean bar groove, soak chain in oil. Store in dry place.

WARNING! Always disconnect spark plug wire before performing maintenance.

Chain & Bar Care

Chain Tension: Proper tension when cold - chain should snap back when pulled from bar, with drive links not fully out of bar groove. Adjust via side tension screw with bar nuts loosened. Retighten nuts after adjustment.

1. Sharpening: Use round file (5/32" or 4.0mm) at 30° angle. File each cutter evenly, maintain same number of strokes. Check depth gauges with flat file.
2. Bar Maintenance: Clean bar groove weekly. Flip bar monthly for even wear. Dress bar rails with flat file if burred.
3. Lubrication: Ensure oiler port is clear. Use only chainsaw bar oil. Adjust oil flow (if adjustable) for cutting conditions.

CAUTION! A loose chain can derail; an over-tightened chain can break or damage sprocket.

Carburetor Adjustment

Factory settings: L (low speed) - 1-1/4 turns out. H (high speed) - 1 turn out. Idle speed screw - 1 turn out.

1. Warm up engine fully before adjustment.
2. Adjust idle speed: Turn idle screw to achieve 2800 RPM (chain should not move).
3. Adjust L screw: For smooth acceleration from idle without hesitation.
4. Adjust H screw: For maximum RPM (not exceeding 12,500 RPM).
5. Re-check idle after adjustments.

Note: Carburetor adjustment may require tachometer. Excessive leaning can cause engine damage.

Troubleshooting

Reset: For electronic ignition, disconnect spark plug wire for 30 seconds to reset module.

Service: For technical support, contact McCulloch at 1-800-521-5322 or visit www.mcculloch.com

Parts List & Exploded View

Refer to official McCulloch parts diagram for part numbers. Key replacement parts:

• Air Filter: Part # 530035119
• Spark Plug: Champion RCJ7Y or # 530035467
• Complete Chain: Oregon 91PX055G or # 530035588
• Guide Bar: 16" Oregon style # 530035592
• Fuel Filter: # 530035214
• Clutch Assembly: # 530035701
• Carburetor Kit: # 530035845
• Starter Rope: # 530035312

Note: Use only genuine McCulloch parts for warranty compliance.