Zenoah Chainsaw G3800 User Manual

848C4093A2 (601)  
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OWNER’S MANUAL  
CHAIN SAWS  
G3800  
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EXPLANATION OF SYMBOLS AND SAFETY WARNINGS  
Read operator's instruction  
Wear head, eye and ear  
book before operating this  
protection.  
machine.  
Use the chain saw  
with two hands.  
Warning! Danger of  
kickback.  
Read, understand and  
follow all warnings.  
WARNING!!!  
RISK OF DAMAGING HEARING  
IN NORMAL CONDITIONS OF USE, THIS MACHINE  
MAY INVOLVE A DAILY LEVEL OF PERSONAL EXPOSURE TO NOISE  
FOR THE OPERATOR EQUAL TO OR GREATER THAN  
85 dB(A)  
SOUND LEVEL  
VIBRATION LEVEL  
MODEL  
EN 608-ISO 7182  
2000/14/EC  
EN 608-ISO 7505  
LwA  
guaranteed  
110 dB(A)  
LpA  
Front handle  
3.8 m/s2  
Rear handle  
4.3 m/s2  
37.2 cm3  
98 dB(A)  
APPROVAL NUMBER OF CE EXHAUST EMISSION REGULATION (2002/88/EC)  
e13*97/68SH2G3*2002/88*0088*00  
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Contents  
1. For Safe Operation ................................................................... 4  
2. Explanation of Symbols on the Machine .................................. 6  
3. Installing Guide Bar and Saw Chain......................................... 7  
4. Fuel and Chain Oil .................................................................... 8  
5. Operating the Engine ............................................................... 9  
6. Sawing .................................................................................... 11  
7. Maintenance ........................................................................... 12  
8. Maintenance of Saw Chain and Guide Bar ............................ 13  
9. Troubleshooting Guide ........................................................... 14  
10. Specifications ......................................................................... 15  
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1. For safe operation  
1. Never operate a chain saw when  
you are fatigued, ill, or upset, or  
under the influence of medica-  
tion that may make you drowsy,  
or if you are under the influence  
of alcohol or drugs.  
9. Never start cutting until you have  
a clear work area, secure foot-  
ing, and a planned retreat path  
from the falling tree.  
2. Use safety footwear, snug fitting  
clothing and eye, hearing and  
head protection devices.  
10. Always hold the chain saw firmly  
with both hands when the engine  
is running. Use a firm grip with  
thumb and fingers encircling the  
chain saw handles.  
Use the vibration-proof glove.  
3. Keep the saw chain sharp and  
the saw, including the AV system,  
well maintained. A dull chain will  
increase cutting time, and press-  
ing a dull chain through wood will  
increase the vibrations transmit-  
ted to your hands. A saw with  
loose components or with dam-  
aged or worn AV buffers will also  
tend to have higher vibration lev-  
els.  
4. All the above mentioned precau-  
tions do not guarantee that you  
will not sustain whitefinger dis-  
ease or carpal tunnel syndrome.  
Therefore, continual and regular  
users should monitor closely the  
condition of their hands and fin-  
gers.  
11. Keep all parts of your body away  
from the saw chain when the en-  
gine is running.  
If any of the above symptoms ap-  
pear, seek medical advice imme-  
diately.  
12. Before you start the engine,  
make sure the saw chain is not  
contacting anything.  
5. Always use caution when han-  
dling fuel. Wipe up all spills and  
then move the chain saw at least  
3 m from the fueling point before  
starting the engine.  
6. Eliminate all sources of sparks or  
flame (i.e. smoking, open flames,  
or work that can cause sparks)  
in the areas where fuel is mixed,  
poured, or stored.  
13. 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.  
14. Always inspect the chain saw be-  
fore each use for worn, Ioose, or  
damaged parts. Never operate  
a chain saw that is damaged, im-  
properly adjusted, or is not com-  
pletely and securely assembled.  
Be sure that the saw chain stops  
moving when the throttle control  
trigger is released.  
15. All chain saw service, other than  
the items listed in the Owner’s  
Manual, should be performed by  
competent chain saw service  
personnel. (E.g., if improper tools  
are used to remove the flywheel,  
or if an improper tool is used to  
hold the flywheel in order to re-  
move the clutch, structural dam-  
7. Do not smoke while handling fuel  
or while operating the chain saw.  
8. Do not allow other persons to be  
near the chain saw when start-  
ing or cutting. Keep bystanders  
and animals out of the work area.  
Children, pets and bystanders  
should be a minimum of 10 m  
away when you start or operate  
the chain saw.  
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age to the flywheel could occur  
which could subsequently cause  
the flywheel to disintegrate.)  
16. Always shut off the engine be-  
fore setting it down.  
17. Use extreme caution when cut-  
ting small size brush and sap-  
lings because slender material  
may catch the saw chain and be  
whipped toward you or pull you  
off balance.  
18. When cutting a limb that is un-  
der tension, be alert for spring-  
back so that you will not be  
struck when the tension in the  
wood fibers is released.  
19. Never cut in high wind, bad  
weather, when visibility is poor or  
in very high or low temperatures.  
Always check the tree for dead  
branches which could fall during  
the felling operation.  
saw chain in the cut. Tip contact  
in some cases may cause a light-  
ning fast reverse reaction,kicking  
the guide bar up and back to-  
wards the operator. Pinching the  
saw chain along the top of the  
guide bar may push the guide  
bar rapidly back towards the op-  
erator. Either of these reactions  
may cause you to Iose control of  
the saw, which could result in  
serious personal injury.  
Do not rely exclusively on the  
safety devices built into your saw.  
As a chain saw user you should  
take several steps to keep cut-  
ting jobs free from accident or  
injury.  
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(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 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 kick-  
back and maintain control of the  
saw.  
20. Keep the handles dry, clean and  
free of oil or fuel mixture.  
21. Operate the chain saw only in  
well ventilated areas. Never start  
or run the engine inside a closed  
room or building. Exhaust fumes  
contain dangerous carbon mon-  
oxide.  
22. Do not operate the chain saw in  
a tree unless specially trained to  
do so.  
23. Guard against kickback. Kick-  
back is the upward motion of the  
guide bar which occurs when the  
saw chain at the nose of the  
guide bar contacts an object.  
Kickback can lead to dangerous  
loss of control of the chain saw.  
(3) Make certain 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.  
24. When transporting your chain  
saw, make sure the appropriate  
guide bar scabbard is in place.  
(5) Do not overreach or cut above  
shoulder height.  
KICKBACK SAFETY PRECAU-  
TIONS FOR CHAIN SAW USERS  
(6) Follow the manufacturer’s sharp-  
ening and maintenance instruc-  
tions for the saw chain.  
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  
(7) Only use replacement bars and  
chains specified by the manufac-  
turer or the equivalent.  
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2. Explanation of Symbols on the Machine  
For safe operation and maintenance, symbols are carved in relief on the  
machine.  
According to these indications, please be careful not to make any mistake.  
The port to refuel “MIX GASOLINE”  
Position: Fuel cap  
The port to top up chain oil  
Position: Oil cap  
Setting the switch to the “O” position, the engine stops immediately.  
Position: Rear-left of the unit  
Starting the engine. If you pull out the choke knob (at the back-right of  
the rear handle) to the point of the arrow, you can set the starting mode  
as follows:  
First-stage position – starting mode when the engine is warm.  
Second-stage position – starting mode when the engine is cold.  
Position: Upper-right of the aircleaner cover  
The screw under the “H” stamp is The High-speed adjustment screw.  
The screw under the “L” stamp is The Slow-speed adjustment screw.  
The screw at the left of the “T” stamp is the Idle adjustment screw.  
Position: Left side of the rear handle  
Shows the directions that the chain brake is released (white arrow) and  
activated (black arrow).  
Position: Front of the chain cover  
If you turn the rod by screwdriver follow the arrow to the "MAX" position,  
the chain oil flow more, and if you turn to the "MIN" position, less.  
Position: Bottom of the power unit  
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3. Installing Guide Bar and Saw Chain  
A standard saw unit package contains the items as illustrated.  
Power unit  
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Plug wrench  
Screwdriver for carburetor adjustment  
Bar protector  
Guide bar  
Saw chain  
Open the box and install the guide bar and the saw  
chain on the power unit as follows:  
4. Fit the chain cover to the power unit and fasten the  
nuts to finger tightness.  
5. While holding up the tip of the bar, adjust the chain  
tension by turning the tensioner screw until the tie  
straps just touch the bottom side of the bar rail.  
The saw chain has very sharp edges. Use  
thick protective gloves for safety.  
1. Pull the guard towards the front handle to check that  
the chain brake is not engaged.  
2. Loosen the nuts and remove the chain cover.  
3. Gear the chain to the sprocket and, while fitting the  
saw chain around the guide bar, mount the guide  
bar to the power unit. Adjust the position of the chain  
tensioner.  
Loosen  
Tighten  
Tensioner screw  
6. Tighten the nuts securely with the bar tip held up  
(12 ~ 15 N·m). Then check the chain for smooth ro-  
tation and proper tension while moving it by hand. If  
necessary, readjust with the chain cover loose.  
Tensioner nut  
Chain cover  
7. Tighten the tensioner screw.  
Note: Pay attention to the correct direction of the saw chain.  
Note: A new chain will expand its length in the beginning of use.  
Check and readjust the tension frequently as a loose chain can  
easily derail or cause rapid wear of itseif and the guide bar.  
Moving direction  
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4. Fuel and Chain Oil  
4. Pour in the rest of gasoline and agitate again for at  
least one minute. As some oils may be difficult to  
agitate depending on oil ingredients, sufficient agi-  
tation is necessary for the engine to last long. Be  
careful that, if the agitation is insufficient, there is an  
increased danger of early piston seizing due to ab-  
normally lean mixture.  
5. Put a clear indication on the outside of the container  
to avoid mixing up with gasoline or other contain-  
ers.  
6. Indicate the contents on outside of container for easy  
identification.  
FUEL  
Gasoline is very flammable. Avoid smoking or  
bringing any flame or sparks near fuel. Make sure  
to stop the engine and allow it cool before refuel-  
ing the unit. Select outdoor bare ground for fuel-  
ing and move at least 3 m (10 ft) away from the  
fueling point before starting the engine.  
FUELING THE UNIT  
1. Untwist and remove the fuel cap. Rest the cap on a  
dustless place.  
2. Put fuel into the fuel tank to 80% of the full capacity.  
3. Fasten the fuel cap securely and wipe up any fuel  
spillage around the unit.  
• The Komatsu Zenoah engines are lubricated by oil  
specially formulated for air-cooled 2-cycle gasoline  
engine use. If Komatsu Zenoah oil is not available,  
use an anti-oxidant added quality oil expressly labeled  
for air-cooled 2-cycle engine use (JASO FC GRADE  
OIL or ISO EGC GRADE).  
1. Select bare ground for fueling.  
2. Move at least 10 feet (3 meters) away from the fuel-  
ing point before starting the engine.  
3. Stop the engine before refueling the unit. At that time,  
be sure to sufficiently agitate the mixed gasoline in  
the container.  
• Do not use BIA or TCW (2-stroke water-cooling type)  
mixed oil.  
FOR YOUR ENGINE LIFE, AVOID:  
1. FUEL WITH NO OIL (RAW GASOLINE) – It will cause  
severe damage to the internal engine parts very  
quickly.  
2. GASOHOL – It can cause deterioration of rubber and/  
or plastic parts and disruption of engine lubrication.  
3. OIL FOR 4-CYCLE ENGINE USE – It can cause spark  
plug fouling, exhaust port blocking, or piston ring  
sticking.  
4. Mixed fuels which have been left unused for a  
period of one month or more may clog the carbu-  
retor and result in the engine failing to operate prop-  
erly.  
5. In the case of storing the product for a long period  
of time, clean the fuel tank after rendering it empty.  
Next, activate the engine and empty the carburetor  
of the composite fuel.  
6. In the case of scrapping the used mixed oil con-  
tainer, scrap it only at an authorized repository site.  
RECOMMENDED MIXING RATIO  
GASOLINE 50 : OIL 1  
(when using ZENOAH genuine oil)  
Exhaust emission are controlled by the funda-  
mental engine parameters and components (eq.,  
carburation, ignition timing and port timing) with-  
out addition of any major hardware or the intro-  
duction of an inert material during combustion.  
• These engines are certified to operate on unleaded  
gasoline.  
• Make sure to use gasoline with a minimum octane  
number of 89RON (USA/Canada: 87AL).  
• If you use a gasoline of a lower octane value than  
prescribed, there is a danger that the engine tem-  
perature may rise and an engine problem such as  
piston seizing may consequently occur.  
• Unleaded gasoline is recommended to reduce the  
contamination of the air for the sake of your health  
and the environment.  
• Poor quality gasolines or oils may damage sealing  
rings, fuel lines or fuel tank of the engine.  
Note: As for details of quality assurance, read the description in  
the section Limited Warranty carefully. Moreover, normal wear and  
change in product with no functional influence are not covered by  
the warranty. Also, be careful that, if the usage in the instruction  
manual is not observed as to the mixed gasoline, etc. described  
therein, it may not be covered by the warranty.  
CHAIN OIL  
Use motor oil SAE #10W-30 all year round or SAE  
#30 ~ #40 in summer and SAE #20 in winter.  
HOW TO MIX FUEL  
• Pay attention to agitation.  
1. Measure out the quantities of gasoline and oil to be  
mixed.  
2. Put some of the gasoline into a clean, approved fuel  
container.  
3. Pour in all of the oil and agitate well.  
Note: Do not use wasted or regenerated oil that can cause damage  
to the oil pump.  
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5. Operating the Engine  
It is very dangerous to run a chainsaw that  
mounts broken parts or lacks any parts.  
Before starting engine, make sure that all the  
parts including bar and chain are installed  
properly.  
6. Allow the engine to warm up with the throttle lever  
pulled slightly.  
Keep clear of the saw chain as it will start  
rotatIng upon starting of engine.  
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CHECKING THE OIL SUPPLY  
STARTING THE ENGINE  
1. Fill fuel and chain oil tanks respectively, and tighten  
Make sure to set up the bar and the chain  
when checking the oil supply.  
the caps securely.  
If not, the rotating parts may be exposed. It is  
very dangerous.  
After starting the engine, run the chain at medium speed  
and see if chain oil is scattered off as shown in the figure.  
Fuel  
Chain oil  
Chain oil  
2. Set the switch to “I” position.  
Switch  
Throttle  
interlock  
The chain oil flow can be changed by inserting a screw-  
driver in the hole on bottom of the clutch side. Adjust  
according to your work conditions.  
Throttle lever  
3. Pull out the choke knob to the second-stage posi-  
tion. The choke will close and the throttle lever will  
then be set in the starting position.  
Choke knob  
Chain oil flow  
adjusting  
Rich  
Lean  
ADJUSTING THE CARBURETOR  
L needle  
H needle  
Idle adjusting  
screw  
Note: When restarting immediately after stopping the engine, set  
the Choke knob in the first-stage position (choke open and throttle  
lever in the starting position).  
The carburetor on your unit has been factory adjusted,  
but may require fine tuning due to a change in operat-  
ing conditions.  
Before adjusting the carburetor, make sure that the pro-  
vided air/fuel filters are clean and fresh and the fuel prop-  
erly mixed.  
Note: Once the choke knob has been pulled out, it will not return  
to the operating position even if you press down on it with your  
finger. When you wish to return the choke knob to the operating  
position, pull out the throttle lever instead.  
4. While holding the saw unit securely on the ground,  
pull the starter rope vigorously.  
When adjusting, take the following steps:  
Note: Be sure to adjust the carburetor with the bar chain attached.  
1. H and L needles are restricted within the number of  
turn as shown below.  
H needle : -1/4  
L needle : -1/4  
2. Start the engine and allow it to warm up in low speed  
for a few minutes.  
3. Turn the idle adjusting screw (T) counterclockwise  
so that the saw chain does not turn. If the idling  
speed is too slow, turn the screw clockwise.  
4. Make a test cut and adjust the H needle for best  
cutting power, not for maximum speed.  
Do not start the engine while the chain saw  
hangs in one hand. The saw chain may touch  
your body. This is very dangerous.  
5. When engine has ignited, first push in the choke knob  
to the first-stage position and then pull the starter  
again to start the engine.  
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CHAIN BRAKE  
Carburetor anti-freeze mechanism  
This machine is equipped with an automatic brake to  
stop saw chain rotation upon occurrence of kickback  
during saw cutting. The brake is automatically operated  
by inertial force, which acts on the weight fitted inside  
the front guard.  
This brake can also be operated manually with the front  
guard turned down to the guide bar.  
Operating chain saws in temperatures of 0 – 5°C at times of  
high humidity may result in ice forming within the carburetor,  
and this in turn may cause the output power of the engine to  
be reduced or for the engine to fail to operate smoothly.  
This product has accordingly been designed with a ven-  
tilation hatch on the right side of the surface of the cyl-  
inder cover to allow warm air to be supplied to the en-  
gine and to thereby prevent icing from occurring.  
Under normal circumstances the product should be  
used in the normal operating mode, i.e., in the mode to  
which it is set at the time of shipment. However when  
the possibility exists that icing may occur, the unit should  
be set to operate in the anti-freeze mode before use.  
To release the brake, pull up the front guard toward the  
front handle till a “click” sound is heard.  
Anti-freeze mode  
Normal operating mode  
Cylinder cover  
[Caution]  
Be sure to confirm brake operation during daily inspec-  
tion.  
“Snow” mark  
“Sunshine” mark  
How to confirm:  
1) Turn off the engine.  
Continuing to use the product in the anti-freeze  
mode even when temperatures have risen and  
returned to normal, may result in the engine  
failing to start properly or in the engine failing  
to operate at its normal speed, and for this  
reason you should always be sure to return  
the unit to the normal operating mode if there  
is no danger of icing occurring.  
2) Holding the chain saw horizontally, release your hand  
from the front handle, hit the tip of the guide bar to a  
stump or a piece of wood, and confirm brake op-  
eration. Operating level varies by bar size.  
HOW TO SWITCH BETWEEN OPERATING MODES  
Choke knob  
In case the brake is not effective, ask our dealer for  
inspection and repairs.  
If the engine keeps rotating at high speed with the brake  
engaged, the clutch will overheat causing trouble.  
When the brake engages during operation, immediately  
release the throttle lever to stop the engine.  
Cylinder cover  
STOPPING THE ENGINE  
1. Release the throttle lever to allow the engine to idle  
for a few minutes.  
Icing cap  
2. Set the switch to the “O” (STOP) position.  
1. Flip the engine switch to turn off the engine.  
2. Remove the cover to the air filter, remove the air filter,  
and then remove the choke knob from the cylinder cover.  
3. Loosen the screws holding the cylinder cover in place  
(i.e., the three screws on the inside and the one screw  
on the outside of the cover), and then remove the cylin-  
der cover.  
switch  
4. Press with your finger down on the icing cap located on  
the right-hand side of the cylinder cover to remove the  
icing cap.  
5. Adjust the icing cap so that the “snow” mark faces up-  
wards and then return it to its original position in the  
cylinder cover.  
6. Fix the cylinder cover back into its original position, and  
then fix all other parts back into their proper positions.  
GB-10  
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