Zenoah Chainsaw G500AVS User Manual

848C8193A4 (806)  
G
B
OWNER’S MANUAL  
CHAIN SAW  
G455AVS  
G500AVS  
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G455AVS / G500AVS  
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.  
WARNING!!!  
RISK OF DAMAGING HEARING  
Wear head, eye and ear protection.  
SOUND LEVEL  
VIBRATION LEVEL  
MODEL  
EN 608-ISO 7182  
2000/14/EC  
LwA  
guaranteed  
110 dB(A)  
110 dB(A)  
EN 608-ISO 7505  
LpA  
Front handle  
Rear handle  
G455AVS 45.0 cm3  
G500AVS 49.3 cm3  
102.5 dB(A)  
103.6 dB(A)  
6.5 m/s2  
5.5 m/s2  
7.7 m/s2  
7.2 m/s2  
APPROVAL NUMBER OF CE EXHAUST EMISSION REGULATION (2002/88/EC)  
G455AVS: e13*97/68SH2G3*2002/88*0101*01  
G500AVS: e13*97/68SH2G3*2002/88*0102*02  
GB-2  
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G
B
DECLARATION OF CONFORMITY TO MACHINES DIRECTIVE  
DECLARATION OF CONFORMITY TO MACHINES DIRECTIVE  
(Directive 98/37/EC, 89/336/EEC)  
and to the regulations governing transposition  
Internal control production  
(Directive 98/37/EC, 89/336/EEC)  
and to the regulations governing transposition  
Internal control production  
MANUFACTURER : Husqvarna Zenoah Co., Ltd.  
No. 9, 1-Chome  
MANUFACTURER : Husqvarna Zenoah Co., Ltd.  
No. 9, 1-Chome  
MINAMIDAI, KAWAGOE City  
SAITAMA, JAPAN  
MINAMIDAI, KAWAGOE City  
SAITAMA, JAPAN  
DECLARES THAT THE DESIGN OF THE MACHINE DESCRIBED BELOW :  
DECLARES THAT THE DESIGN OF THE MACHINE DESCRIBED BELOW :  
Model  
Serial no.  
Make  
:
:
:
G455AVS18  
800001 and up  
ZENOAH  
Model  
Serial no.  
Make  
:
:
:
G500AVS18  
800001 and up  
ZENOAH  
CONFORMS TO THE REQUIRMENTS OF THE MODIFIED MACHINES  
DIRECTIVE (Directive 98/37/EC, 89/336/EEC) AND TO THE NATIONAL  
REGULATIONS GOVERNING ITS TRANSPOSITION ABROAD : AND  
CONFORMS TO THE REQUIRMENTS OF THE MODIFIED MACHINES  
DIRECTIVE (Directive 98/37/EC, 89/336/EEC) AND TO THE NATIONAL  
REGULATIONS GOVERNING ITS TRANSPOSITION ABROAD : AND  
THAT IT HAS BEEN ISSUED WITH A “CE”CERTIFICATE, NO. 380-080-A-0025-  
12-94, BY THE CENTRE TECHNIQUE DU BOIS ET DE LAMEUBLEMENT  
(TECHNICAL CENTRE FOR WOOD AND FURNITURE), 10 AVENURE DE  
SAINT-MANDE, 75012 PARIS.  
THAT IT HAS BEEN ISSUED WITH A “CE”CERTIFICATE, NO. 380-080-A-0026-  
12-94, BY THE CENTRE TECHNIQUE DU BOIS ET DE LAMEUBLEMENT  
(TECHNICAL CENTRE FOR WOOD AND FURNITURE), 10 AVENURE DE  
SAINT-MANDE, 75012 PARIS.  
Signed in Saitama, Japan  
Signed in Saitama, Japan  
1st December 2007  
1st December 2007  
Masahiko GOUDA  
General Manager, Quality Assurance Department  
Masahiko GOUDA  
General Manager, Quality Assurance Department  
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. Disposal .................................................................................. 14  
11. Specifications ......................................................................... 15  
GB-3  
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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.  
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.  
2. Use safety footwear, snug fitting  
clothing and eye, hearing and  
head protection devices.  
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.  
11. Keep all parts of your body away  
from the saw chain when the en-  
gine is running.  
4. All the above mentioned precau-  
tions do not guarantee that you  
will not sustain whitefinger  
diseaseor carpal tunnel syn-  
drome. Therefore, continual and  
regular users should monitor  
closely the condition of their  
hands and fingers. If any of the  
above symptoms appear, seek  
medical advice immediately.  
12. Before you start the engine,  
make sure the saw chain is not  
contacting anything.  
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, loose, 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-  
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.  
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.  
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.  
GB-4  
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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.  
tion, 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 lose 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 ac-  
cident or injury.  
G
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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.  
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.  
(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.  
(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.  
24. When transporting your chain  
saw, make sure the appropriate  
guide bar scabbard is in place.  
(4) Cut at high engine speeds.  
(5) Do not overreach or cut above  
shoulder height.  
KICKBACK SAFETY PRECAU-  
TIONS FOR CHAIN SAW USERS  
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 con-  
tact in some cases may cause  
a lightning fast reverse reac-  
(6) Follow the manufacturer’s sharp-  
ening and maintenance instruc-  
tions for the saw chain.  
(7) Only use replacement bars and  
chains specified by the manufac-  
turer or the equivalent.  
GB-5  
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2. Explanation of Symbols on the Machine  
WARNING  
• 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 “ | ” position, the engine starts.  
Setting the switch to the “O” position, the engine stops immediately.  
Position: Rear-left of the unit  
(d) Choke will close when pulling the choke knob.  
Position: Choke knob  
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 ar-  
row).  
Position: Front of the chain cover  
GB-6  
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3. Installing Guide Bar and Saw Chain  
A standard saw unit package contains the items as illustrated.  
Power unit  
G
B
Screwdriver for  
carburetor adjustment  
Plug wrench  
Bar protector  
Guide bar  
Spike and mountaing screws  
Saw chain  
Open the box and install the guide bar and the saw  
chain on the power unit as follows:  
5. Fit the chain cover to the power unit and fasten the  
nuts to finger tightness.  
WARNING  
6. 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) Tensioner  
screw  
(2) Loosen  
(3) Tighten  
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. Install the attached spike to the power unit.  
7. 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.  
4. 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 chain  
tensioner nut on the chain cover to the lower hole of  
guide bar.  
8. Tighten the tensioner screw.  
NOTE  
(1) Hole  
(2) Tensioner nut  
(3) Chain cover  
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 itself and  
the guide bar.  
NOTE  
Pay attention to the correct direction of the saw chain.  
Moving direction  
GB-7  
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4. Fuel and Chain Oil  
FUEL  
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.  
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.  
5. Put a clear indication on the outside of the container  
to avoid mixing up with gasoline or other containers.  
6. Indicate the contents on outside of container for easy  
identification.  
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.  
WARNING  
• 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).  
1. Select flat and bare ground for fueling.  
2. Move at least 10 feet (3 meters) away from the  
fueling 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, nor-  
mal wear and change in product with no functional in-  
fluence are not covered by the warranty. Also, be care-  
ful that, if the usage in the instruction manual is not ob-  
served as to the mixed gasoline, etc. described therein,  
it may not be covered by the warranty.  
HOW TO MIX FUEL  
WARNING  
CHAIN OIL  
Use motor oil SAE #10W-30 all year round or SAE  
#30 ~ #40 in summer and SAE #20 in winter.  
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.  
NOTE  
3. Pour in all of the oil and agitate well.  
4. Pour in the rest of gasoline and agitate again for at  
least one minute. As some oils may be difficult to  
GB-8  
Do not use wasted or regenerated oil that can cause  
damage to the oil pump.  
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5. Operating the Engine  
WARNING  
WARNING  
• Keep clear of the saw chain as it will start rotating  
upon starting of 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.  
G
B
CHECKING THE OIL SUPPLY  
WARNING  
STARTING THE ENGINE  
1. Fill fuel and chain oil tanks respectively, and tighten  
the caps securely.  
• 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.  
(1) Chain oil  
(2) Fuel  
After starting the engine, run the chain at medium speed  
and see if chain oil is scattered off as shown in the figure.  
2. Set the switch to “I” position.  
Cha
Switch  
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.  
3. Pull out the choke knob to the closed position.  
Chain oil flow  
adjusting  
M I N  
M A X  
knob  
NOTE  
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.  
When restarting immediately after stopping the engine,  
leave the choke knob at the open position.  
4. While holding the saw unit securely on the ground,  
pull the starter rope vigorously.  
ADJUSTING THE CARBURETOR  
(1) L needle  
(2) H needle  
(3) Idle adjusting screw  
WARNING  
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.  
5. When engine has ignited first, pull the throttle lever  
to return the choke knob to the open position and  
then pull the starter again to start the engine.  
When adjusting, take the following steps:  
NOTE  
6. Allow the engine to warm up with the throttle lever  
pulled slightly.  
Be sure to adjust the carburetor with the bar chain at-  
tached.  
GB-9  
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1. H and L needles are restricted within the number of  
turn as shown below.  
STOPPING THE ENGINE  
1. Release the throttle lever to allow the engine to idle  
for a few minutes.  
G455AVS G500AVS  
2. Set the switch to the “O” (STOP) position.  
H needle :  
L needle :  
-1/4  
-1/4  
-1/4  
-1/4  
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 car-  
buretor, and this in turn may cause the output power of  
the engine to be reduced or for the engine to fail to op-  
erate smoothly.  
This product has accordingly been designed with a ven-  
tilation hatch on the right side of the surface of the cylin-  
der cover to allow warm air to be supplied to the engine  
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.  
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.  
CHAIN BRAKE  
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.  
To release the brake, pull up the front guard toward the  
front handle till a “click” sound is heard.  
(4) Normal operating mode  
(5) Anti-freeze mode  
(6) Screen  
(1) Air cleaner cover  
(2) Shutter plate  
(3) Screw  
WARNING  
• 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 prop-  
erly 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.  
[Caution]  
Be sure to confirm brake operation during daily inspec-  
tion.  
How to confirm:  
1) Turn off the engine.  
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.  
HOWTO SWITCH BETWEEN OPERATING MODES  
Snow protector  
1. Flip the engine switch to turn off the engine.  
2. Remove the air cleaner cover from the cylinder cover  
3. Loosen a screw and remove the screen on the back  
of the air cleaner cover.  
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.  
4. Turn the screen a half and reinstall to the cover.  
When using the saw with the anti-freeze mode, frequently  
check the screen and keep it clean of saw dust.  
NOTE  
When using the unit at times when it is snowing. Zenoah  
recommends that you also use a snow protector effec-  
tive in preventing the air filter from freezing (e.g., the  
separately-sold Z2881-98610 snow protector).  
GB-10  
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6. Sawing  
gine at full speed. If the chain is slow  
to stop or does not stop, replace the  
brake band and clutch drum before  
use.  
WARNING  
Before proceeding to your job,  
read the section “For Safe Op-  
eration”. It is recommended to  
first practice sawing easy logs.  
This also helps you get accus-  
tomed to your unit.  
G
It is extremely important that the  
chain brake be checked for proper B  
operation before each use and that  
the chain be sharp in order to main-  
tain the kickback safety level of this  
saw. Removal of the safety devices,  
inadequate maintenance, or incor-  
rect replacement of the bar or chain  
may increase the risk to serious per-  
sonal injury due to kickback.  
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 lever for  
lifting, moving or splitting ob-