Zenoah Chainsaw G3801 User Manual

115 39 06-38 (007)  
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OWNER’S MANUAL  
CHAIN SAW  
G3801  
G3801EZ  
Original Language  
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G3801/G3801EZ  
EXPLANATION OF SYMBOLS AND SAFETY WARNINGS  
Read operator's instruction  
book before operating this  
machine.  
Wear head, eye and ear  
protection.  
Use the chain saw  
with two hands.  
Warning! Danger of  
kickback.  
Read, understand and  
follow all warnings.  
Never touch hot surface.  
Contents  
1. For Safe Operation ................................................................... 3  
2. Explanation of Symbols on the Machine .................................. 5  
3. Installing Guide Bar and Saw Chain......................................... 6  
4. Fuel and Chain Oil .................................................................... 7  
5. Operating the Engine ............................................................... 8  
6. Sawing .................................................................................... 10  
7. Maintenance ........................................................................... 11  
8. Maintenance of Saw Chain and Guide Bar ............................ 12  
9. Troubleshooting Guide ........................................................... 13  
10. Disposal .................................................................................. 13  
11. Specifications ......................................................................... 14  
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1. For safe operation  
WARNING  
This chainsaw has been especially designed for tree  
maintenance and should therefore only be used by  
trained operators when working on trees.  
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1. Never operate a chain saw when you  
are fatigued, ill, or upset, or under the  
influence of medication that may  
make you drowsy, or if you are under  
the influence of alcohol or drugs.  
10. Keep all parts of your body away from  
the saw chain when the engine is run-  
ning.  
2. Use safety footwear, snug fitting  
clothing and eye, hearing and head  
protection devices.  
11. Before you start the engine, make  
sure the saw chain is not contacting  
anything.  
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 pressing a dull  
chain through wood will increase the  
vibrations transmitted to your hands.  
A saw with loose components or with  
damaged or worn AV buffers will also  
tend to have higher vibration levels.  
12. 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.  
13. Always inspect the chain saw before  
each use for worn, Ioose, or dam-  
aged parts. Never operate a chain  
saw that is damaged, improperly ad-  
justed, or is not completely and se-  
curely assembled. Be sure that the  
saw chain stops moving when the  
throttle control trigger is released.  
14. 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  
remove the clutch, structural damage  
to the flywheel could occur which  
could subsequently cause the fly-  
wheel to disintegrate.)  
4. Always use caution when handling  
fuel. Wipe up all spills and then move  
the chain saw at least 3 m from the  
fueling point before starting the en-  
gine.  
5. 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.  
6. Do not smoke while handling fuel or  
while operating the chain saw.  
15. Always shut off the engine before  
setting it down.  
7. Do not allow other persons to be near  
the chain saw when starting or cut-  
ting. 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 oper-  
ate the chain saw.  
16. Use extreme caution when cutting  
small size brush and saplings be-  
cause slender material may catch the  
saw chain and be whipped toward  
you or pull you off balance.  
17. When cutting a limb that is under ten-  
sion, be alert for spring- back so that  
you will not be struck when the ten-  
sion in the wood fibers is released.  
18. 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.  
19. Keep the handles dry, clean and free  
of oil or fuel mixture.  
8. Never start cutting until you have a  
clear work area, secure footing, and  
a planned retreat path from the fall-  
ing tree.  
9. Always hold the chain saw firmly with  
both hands when the engine is run-  
ning. Use a firm grip with thumb and  
fingers encircling the chain saw  
handles.  
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20. Operate the chain saw only in well  
ventilated areas. Never start or run  
the engine inside a closed room or  
building and potentially explosive at-  
mosphere. Exhaust fumes contain  
dangerous carbon monoxide.  
handle, and the left hand on the front  
handle, when the engine is running.  
Use a firm grip with thumbs and fin-  
gers encircling the chain saw  
handles. A firm grip will help you re-  
duce kickback and maintain control  
of the saw.  
21. Do not operate the chain saw in a tree  
unless specially trained to do so.  
(3) Make certain that the area in which  
you are cutting is free from obstruc-  
tions. 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.  
(5) Do not overreach or cut above shoul-  
der height.  
(6) Follow the manufacturer’s sharpening  
and maintenance instructions for the  
saw chain.  
(7) Only use replacement bars and  
chains specified by the manufacturer  
or the equivalent.  
22. Guard against kickback. Kickback 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 dan-  
gerous loss of control of the chain  
saw.  
23. When transporting your chain saw,  
make sure the appropriate guide bar  
scabbard is in place.  
24. Never touch the cover, guide bar, saw  
chain or nut with bare hands while  
the engine is in operation or immedi-  
ately after shutting down the engine.  
Doing so could result in serious burns  
because of high temperature.  
WORSE EFFECTS OF VIBRATION  
If you continue to use high-vibration tools these  
symptoms will probably get worse, for example:  
the numbness in your hands could become perma-  
nent and you won’t be able to feel things at all;  
you will have difficulty picking up small objects such  
as screws or nails;  
(1) cover  
(2) guide bar  
(4) nut  
the vibration white finger could happen more fre-  
quently and affect more of your fingers.  
(3) saw chain  
KICKBACK SAFETY PRECAUTIONS  
FOR CHAIN SAW USERS  
FOR PROTECTING YOUR BODY FROM VIBRATION  
Please observe the following matter, in order to pro-  
tect the health of your body.  
1. Always use the right tool for each job (to do the job  
more quickly and expose you to less hand-arm vi-  
bration).  
2. Check tools before using them to make sure they  
have been properly maintained and repaired to avoid  
increased vibration caused by faults or general wear.  
3. Make sure cutting tools are kept sharp so that they  
remain efficient.  
4. Reduce the amount of time you use a tool in one go,  
by doing other jobs in between.  
5. Avoid gripping or forcing a tool or workpiece more  
than you have to.  
6. Store tools so that they do not have very cold handles  
when next used.  
7. Encourage good blood circulation by:  
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 saw chain in the cut.  
Tip contact in some cases may cause  
a
l i g h t n i n g f a s t r e v e r s e  
reaction,kicking the guide bar up and  
back towards the operator. Pinching  
the saw chain along the top of the  
guide bar may push the guide bar  
rapidly back towards the operator.  
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 cutting jobs free from  
accident or injury.  
keeping warm and dry (when necessary, wear  
gloves, a hat, waterproofs and use heating pads if  
available);  
giving up or cutting down on smoking because  
smoking reduces blood flow; and massaging and  
exercising your fingers  
(1) With a basic understanding of kick-  
back 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  
DISPOSAL  
When you dispose of the machine, do not disas-  
semble the machine.  
When you dispose of the machine, fuel, chain oil,  
be sure to follow your local regulations.  
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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.  
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The port to fuel “MIX GASOLINE”  
Position: Beside Fuel cap  
The port to fill with chain oil  
Position: Beside Oil cap  
Setting the switch to the “O” position, the engine stops immediately.  
Position: Beside rocker switch  
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:  
• “START” position – starting mode when the engine is warm.  
• “CHOKE” 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: Rear left side of the cylinder cover  
The indication regarding the operating mode.  
• “sun” mark–normal operating mode  
• “snow” mark–anti-freeze mode  
Position: Icing cap located on the right hand side of the cylinder 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  
Plug wrench  
(Hexagon socket (S13/S16) +  
Slotted driver)  
Screwdriver for carburetor adjustment  
(Slotted driver)  
Bar protector  
Guide bar  
Saw chain  
Open the box and install the guide bar and the saw  
chain on the power unit as follows:  
3. Fit the chain cover to the power unit and fasten the  
nuts to finger tightness.  
4. 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. Loosen the nuts and remove the chain cover.  
2. 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 nut.  
Loosen  
Tighten  
Tensioner screw  
5. 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  
6. 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  
WARNING  
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.  
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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 Zenoah engines are lubricated by oil specially  
formulated for air-cooled 2-cycle gasoline engine use.  
If 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).  
WARNING  
1. Select flat and 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  
6. When engine has ignited, first push in the choke knob  
to “START” position and then pull the starter again  
to start the engine.  
7. Allow the engine to warm up with the throttle lever  
pulled slightly.  
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.  
At once pulling throttle lever out, the choke knob is  
automatically returned to the “RUN” position.  
STARTING THE ENGINE  
1. Fill fuel and chain oil tanks respectively, and tighten  
the caps securely.  
Keep clear of the saw chain as it will start  
rotatIng upon starting of engine.  
Fuel  
CHECKING THE OIL SUPPLY  
Chain oil  
Make sure to set up the bar and the chain when  
checking the oil supply.  
If not, the rotating parts may be exposed. It is very  
dangerous.  
2. Set the switch to “I” position.  
3. Continuously push the priming bulb until fuel comes  
in the bulb.  
After starting the engine, run the chain at medium speed  
and see if chain oil is scattered off as shown in the fig-  
ure.  
Priming bulb  
Throttle  
interlock  
Switch  
Chain oil  
Throttle lever  
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.  
4. Pull out the choke knob to “CHOKE” position. The  
choke will close and the throttle lever will then be  
set in the starting position.  
Choke knob  
CHOKE  
START  
RUN  
Rich  
Chain oil flow  
adjusting  
Lean  
Note: The oil tank should become nearly empty by the time fuel is  
used up. Be sure to refill the oil tank every time when refueling the  
saw.  
Note: When restarting immediately after stopping the engine, set  
the Choke knob in “START” position (choke open and throttle le-  
ver in the starting position).  
ADJUSTING THE CARBURETOR  
Note: Once the choke knob has been pulled out, it will not return  
to “RUN” position even if you press down on it with your finger.  
When you wish to return the choke knob to “RUN” position, pull  
out the throttle lever instead.  
L needle  
Idle adjusting screw  
H needle  
5. While holding the saw unit securely on the ground,  
pull the starter rope vigorously.  
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.  
Do not start the engine while the chain saw  
hangs in one hand. The saw chain may touch  
your body. This in very dangerous.  
When adjusting, take the following steps:  
Note: Be sure to adjust the carburetor with the bar chain attached.  
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HOW TO SWITCH BETWEEN OPERATING MODES  
1. Stop engine and screw L needle until it stops. Never  
force. Then set it back the initial number of turns as  
shown below. H needle is restricted within the num-  
1. Set the switch to the “O” position to stop the engine.  
2. Remove the air cleaner cover, 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 cylinder cover.  
4. Press with your finger down on the icing cap located  
on the right-hand side of the cylinder cover to re-  
move the icing cap.  
5. Adjust the icing cap so that the ‘snow’ mark faces  
upwards and then return it to its original position in  
the cylinder cover.  
ber of turn as shown below.  
1
H needle : 13/8  
L needle : 11/4  
/
4
4
1
/
2. Start the engine and allow it to warm up in low speed  
for a few minutes.  
G
B
3. Turn L needle slowly clockwise to find a position  
where idling speed is maximum, then set the needle  
back a quarter (1/4) turn counterclockwise.  
4. 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.  
5. Make a test cut and adjust the H needle for best  
cutting power, not for maximum speed.  
6. Fix the cylinder cover back into its original position,  
and then fix all other parts back into their proper  
positions.  
STOPPING THE ENGINE  
1. Release the throttle lever to allow the engine to idle  
for a few minutes.  
2. Set the switch to the “O” (STOP) position.  
Choke knob  
Switch  
Cylinder cover  
Carburetor anti-freeze mechanism  
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 ventila-  
tion hatch on the right side of the surface of the cylinder cover  
to allow warm air to be supplied to the engine and to thereby  
prevent icing from occurring.  
Icing cap  
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. Please switch between modes  
in the repair specialty store.  
Normal operating mode  
Anti-freeze mode  
Cylinder cover  
“Sunshine” mark  
“Snow” mark  
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.  
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6. Sawing  
FELLING A TREE  
Before proceeding to your job,  
read the section “For Safe  
Operation”. It is recommended  
to first practice sawing easy  
logs. This also helps you get  
accustomed to your unit.  
Felling directio
ling cut  
Notch cu
Always follow the safety regu-  
lations. The chain saw must  
only be used for cutting wood.  
It is forbidden to cut other  
types of material. Vibrations  
and kickback vary with differ-  
ent materials and the require-  
ments of the safety regulations  
would not be respected. Do  
not use the chain saw as a le-  
ver for lifting, moving or split-  
ting objects. Do not lock it over  
fixed stands. It is forbidden to  
hitch tools or applications to  
the PTO other than those  
specified by the manufacturer.  
1. Decide the felling direction considering the wind,  
lean of the tree, location of heavy branches, ease of  
completing the task after felling and other factors.  
2. While clearing the area around the tree, arrange a  
good foothold and retreat path.  
3. Make a notch cut one-third of the way into the tree  
on the felling side.  
4. Make a felling cut from the opposite side of the notch  
and at a level slightly higher than the bottom of the  
notch.  
When you fell a tree, be sure to warn neigh-  
boring workers of the danger.  
Bucking and Limbing  
• Always ensure your foothold. Do not stand  
on the log.  
• Be alert to the rolling over of a cut log. Es-  
pecially when working on a slope, stand  
on the uphill side of the log.  
It is not necessary to force the saw into the  
cut. Apply only light pressure while running the  
engine at full throttle.  
When the saw chain is caught in the cut, do  
not attempt to pull it out by force, but use a  
wedge or a lever to open the way.  
If the guide bar and saw chain becomes  
caught in wood while operating it, stop the  
engine.  
Do not pry the handle with excessive force.  
Use a wedge to remove the chain instead.  
• Follow the instructions in “For Safe Opera-  
tion” to avoid kickback of the saw.  
Before starting work, check the direction of bending  
force inside the log to be cut. Always finish cutting from  
the opposite side of the bending direction to prevent  
the guide bar from being caught in the cut.  
A log lying on the ground  
Saw down halfway, then roll the log over and cut from  
the opposite side.  
A log hanging off the ground  
In area A, saw up from the bottom one-third and finish  
by sawing down from the top. In area B, saw down from  
the top one-third and finish by sawing up from the bot-  
tom.  
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