Zenoah G2500 User's Manual
Contents
1. 2 Put some of the gasoline into a clean approved fuel container 3 Pour in all of the oil and agitate well GB 10 REY 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 Putaclear 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 E FUELING THE UNIT 1 Untwist and remove the fuel cap Rest the cap ona 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 A WARNING 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 E 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 can2. Case 2 Lack of power Poor acceleration Rough idling Check fuel for water or substandard mix ture Check air filter and fuel filter for clog ging Check carburetor for inadequate ad justment Case 3 Oil does not come out Check oil for sub Replace standard quality gt P Check oil passage and ports for clog m Clean ging If the unit seems to need further service please consult with an authorized service shop in your area GB 17 G2500 G2500 OPS 11 Specifications Power unit G2500 G2500 OPS Displacement CIM Ji acca staccesp ncaessieansetinateicosaunnones 25 4 Fuel oo Mixture Gasoline 50 Two cycle oil 1 when using ZENOAH genuine oil Fuel tank Capacity CMS ceccccceeecceceeeeeeeeees 230 CNAIN OIF x ccrsereveieves meenttscduens Motor oil SAE 10W 30 OI TANK capacity CAV scsanslersiadsscviatdeasieeiade naGsiantess 160 CFE DUCTION aceite sactatveteniieniadiaeortaenimonwauins Diaphragm type OMIM Sy eh eaan Solid State Spark PU seere ee Champion RCJ 7Y Oil feeding system eee Mechanical pump EE SOC serrin aii 12 500 min Idle speed ooo ccceccccceccceueceeeneeeeanenenans 2 900 min G2500 Dimensions L x W x H mm 265 x 220 x 220 Dry weight Power UN OMV ING ariei ETE 2 9 POWET iseieerieeerrerrirerrrrerrrerrn 0 96 9 000 kw min G2500 OPS One push start Dimensions L x W x H mm aaan 205 X239 X 220 Dry weight Power nit o
3. operators fail to adopt a secure work position witch allows them to hold both handles of the saw This results in an increased risk of injury due to e not having a firm grip on the saw if it kicks back e a lack of control of the saw such that it is more liable to contact climbing lines and operators body par ticularly the left hand and arm e losing control from insecure work position resulting in contact with the saw unexpected movement dur ing operation of the saw Securing the work position for two handed use To allow the operator to hold the saw with both hands they should as general rule aim for secure work posi tion where they are operating the saw at e hip level when cutting horizontal sections e solar plexus level when cutting vertical sections Where the operator is working close into vertical stems with a low lateral forces on their work position then a good footing may be all that is needed to maintain a secure work position However as operators move away from the stem they will need to take steps to remove or counteract the increasing lateral forces by for example a re direct of the main line via a Supplementary anchor point or using an adjustable strop direct from the har ness to a Supplementary anchor point Gaining a good footing at the working position can be assisted by use of a temporary foot stirrup created from an endless sling Starting the saw in the tree When starting the saw in the tree t
4. and the trouble in starting After each 100 hours check and clean inside the muffler Recoil Starter For recoil maintenance when attaching or detaching the starter of One push start model the select lever should be in the position of the rear side G2500 One push start only e Don t pull the starter when detaching it from the unit It will cause machine defect or serious injury by touching rotat ing parts on your body part carelessly eo Select lever A WARNING Don t pull the starter when detaching it from the unit 8 Maintenance of Saw Chain and Guide Bar E Saw Chain A WARNING It is very important for smooth and safe operation to always keep the cutters sharp The cutters need to be sharpened when e Sawdust becomes powder like e You need extra force to Saw in e The cut path does not go straight e Vibration increases e Fuel consumption increases Cutter setting standards A WARNING Be sure to wear safety gloves Before filing e Make sure the saw chain is held securely e Make sure the engine is stopped e Use a round file of proper size for the chain Chain type 91VG 25AP File size 5 32 in 4 0 mm GB 16 Place the file on the cutter and push straight forward Keep the file position as illustrated lt 25AP gt After each cutter has been filed check the depth gauge and file it to the proper level as illustrated Make the shoulder round 025 0 64 m
5. 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 Re 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 cov ered 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 E CHAIN OIL Use motor oil SAE 10W 30 all year round or SAE 30 40 in Summer and SAE 20 in winter Do not use wasted or regenerated oil that can cause damage to the oil pump 5 Operating the Engine A WARNING 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 includ ing bar and chain are installed properly E STARTING THE ENGINE Normal start 1 Fill fuel and chain oil tanks respectively and tighten the caps securely Chain oil 2
6. right side of the rear handle and set it to the Run position After that move the select le ver to the rear side of the machine body indicated by label The starter is started to start the engine Run O Stop Engine stop switch r at F maa i l Fii EL AN enr N he j Pe as ee he sE F i Sell a ee ni i ti N pi T A Er r a Vi _ Ll b p ee A Li Label If the engine cannot be started by the above proce dure repeat the above operations again If the en gine cannot be started smoothly it may be neces sary to add warming up or readjust the engine Per form warming up enough and ask the distributor to readjust the engine E FOR SMOOTHER USE OF ONE PUSH START To use One push start more smoothly it is important to perform warming up longer than ever 1 When the outside temperature is 0 or more perform warming up for about 5 seconds with the throttle fully opened And leave the product for 5 minutes or less after the engine stops Then use the product With this the engine can be started more securely GB 12 2 When the outside temperature is below O C repeat the above warming up operation twice or more After the engine stops use the product in a shorter leaving time A WARNING e Be sure to perform warming up with the guide bar and the saw chain mounted e Keep clear of the saw chain as it will start rotatlng upon starting of engine e Before you start the engine make sur
7. 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 4 Cut at high engine speeds 5 Do not overreach or cut above shoulder height 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 G2500 G2500 OPS WORKING WITH TREE SERVICE CHAIN SAWS FROM A ROPE AND HARNESS This chapter sets out working practices to reduce the risk of injury from tree service chainsaws when working at height from a rope and harness While it may form the basis of guidance and training literature it should not be regarded as a substitute for formal training General requirements working at height Operators of tree service chainsaws working at height from a rope and harness should never work alone A competent ground worker trained in appropriate emer gency procedures should assist them Operators of tree service chainsaws for this work should be trained in general safe climbing and work position ing techniques and shall properly equipped with har nesses ropes strops karabiners and other equipment for maintaining secure and safe working
8. sharp edges Use thick pro tective 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 Fix the hanger on the rear of power unit by screw A WARNING When installing the chain cover be sure to fit the hook completely at the rear end of the cover 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 Tensioner screw 4 Mount the guide bar then fit the saw chain around the bar and sprocket Tighten 7 Tighten the nuts securely with the bar tip held up 11 8 14 7 N m 120 150 kg cm Then check the chain for smooth rotation and proper tension while moving it by hand If necessary readjust with the BES chain cover loose Pay attention to the correct direction of the saw chain Moving direction 8 Tighten the tensioner screw A WARNING 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 GB 9 G2500 G2500 OPS 4 Fuel and Chain Oil E FUEL A WARNING e 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 an
9. the clutch and may cause trouble e At machine inspection prior to each job check the operating condition of the brake following the steps 1 Start the engine and grasp the handle securely with both hands 2 Pulling the throttle lever to maintain the chain opera tion push the brake lever left hand guard down toward the front using the back of your left hand 3 When the brake operates and the chain is stopped release the throttle lever 4 Release the brake Release Activate the brake E 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 a q Switch N e Itis not necessary to force the saw into the cut Ap ply only light pressure while running the engine at full throttle e 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 E GUARD AGAINST KICKBACK GB 13 G2500 G2500 OPS e This saw is equipped with a chain brake that will stop the chain in the event of kickback if operating prop erly You must check the chain brake operation before each usage by run ning the saw at full the throttle for 2 seconds and pushing the front hand guard forward The chain should stop immediately with the engine at full speed If the chain is slow to stop or does not stop re place the brake band and clutch drum before use e It is
10. touch the cylinder muffler or ignition plug etc during operation or right after stopping the engine e Before starting the engine check around the muffler and take off sawdust If you do not It will cause the overheating and a fire For preventing the trouble please keep clean around the muffler This engine is air cooled Dust clogging between the inlet port of the cooling air and cylinder fins will cause overheating of the engine Periodically check and clean the cylinder fins after removing the air cleaner and the cylinder cover IMPORTANT When installing the cylinder cover make sure that switch wires and grommets are positioned correctly in place GB 15 G2500 G2500 OPS 7 Muffler A WARNING If you do not attach the muffler correctly after engine starts the muffler will be loosen and the hightemperature exhaust gas spout After cleaning the muffler pay attention to fit up the muffler according to the explanation as follows 1 Muffler body muffler cover and baffle will be combined correctly ae 2 Be sure the gasket is not broken If it is broken change to the new one 3 Before tightening the screw rub the gross on it 4 After making a test run re tighten the screw TORQUE 6 9 7 8 N m 70 80 kg cm A WARNING Right after stopping the engine do not touch the muffler with one s bare hands It will cause to burn your hands If carbon clogs between the muffler it will cause the poor out put
11. 848C1B93A1 704 zenon OWNER S MANUAL J CHAIN SAWS G2500 G 2 5 0 0 O Pp S Before using our products please read this manual carefully to understand the One Push Start proper use of your unit G2500 G2500 OPS GB 2 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 Use appropriate protections for foot leg and hand arm Read understand and follow all warnings This saw is for trained tree service operators only Never touch hot surface gt gt G2500 WARNING RISK OF DAMAGING HEARING Wear head eye and ear protection G2500 OPS WARNING RISK OF DAMAGING HEARING Wear head eye and ear protection MODEL SOUND LEVEL VIBRATION LEVEL EN 608 ISO 7182 2000 14 EC EN608 ISO 7505 LpA Front handle Rear handle G2500 97 4 dB A 110 dB A 7 0 m s G2500 OPS 96 5 dB A 112 dB A 5 1 m s APPROVAL NUMBER OF CE EXHAUST EMISSION REGULATION 2002 88 EC 13 97 68SH2G3 2002 88 0085 03 DECLARATION OF CONFORMITY TO MACHINES DIRECTIVE Directive 98 37 EC 89 336 EEC and to the regulations governing transposition Internal control production MANUFACTURER ZENOAH CO LTD No 9 1 Chome MINAMIDAI KAWAGOE City SAITAMA JAPAN DECLARES THAT THE DESIGN OF THE MACHINE DESCRIBED BELOW Model
12. Continuously push the priming bulb until fuel comes in the bulb 3 Set the switch to I position l Throttle Switch interlock G2500 OPS e Move the select lever to the machine back side indicated by label until it is stopped and then set this lever to the recoil start mode select lever operating direction OPS Select lever Ry gis 4 Pull out the choke knob to the second stage position The choke will close and the throttle lever will then be set in the starting position When the engine is cool s When the engine is warm up xe After the engine starts G2500 G2500 OPS When restarting immediately after stopping the en gine set the Choke knob in the first stage position choke open and throttle lever in the starting posi tion 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 5 While holding the saw unit securely on the ground pull the starter rope vigorously A WARNING Do not start the engine while the chain saw hangs in one hand The saw chain may touch your body This in very dangerous 6 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 7 Allow the engine to warm up with the throttle lever pulle
13. G2500 Serial no 110001 and up Make ZENOAH CONFORMS TO THE REQUIRMENTS OF THE MODIFIED MACHINES DIRECTIVE Directive 98 37 EC AND TO THE NATIONAL REGULATIONS GOVERNING ITS TRANSPOSITION ABROAD AND THAT IT HAS BEEN ISSUED WITH A CE CERTIFICATE NO M 0303 02 2737 BY THE ISTITUTO CERTIFICAZIONE EUROPEA PALAZZO DEL VESCOVO V GARIBALDI 20 40011 ANZOLA DELL EMILIA ITALY Signed in Saitama Japan 1st April 2007 Masahiko GOUDA General Manager Quality Assurance Department Contents G2500 G2500 OPS DECLARATION OF CONFORMITY TO MACHINES DIRECTIVE Directive 98 37 EC 89 336 EEC and to the regulations governing transposition Internal control production MANUFACTURER ZENOAH CO LTD No 9 1 Chome MINAMIDAI KAWAGOE City SAITAMA JAPAN DECLARES THAT THE DESIGN OF THE MACHINE DESCRIBED BELOW Model G2500 OPS Serial no 510001 and up Make ZENOAH CONFORMS TO THE REQUIRMENTS OF THE MODIFIED MACHINES DIRECTIVE Directive 98 37 EC AND TO THE NATIONAL REGULATIONS GOVERNING ITS TRANSPOSITION ABROAD AND THAT IT HAS BEEN ISSUED WITH A CE CERTIFICATE NO U3 2592658 01 BY TUV Rheinland Group TUV Rheinland InterCert kft Product Certification H 1061 Budapest Paulay Ede u 52 HUNGARY Signed in Saitama Japan 1st April 2007 Masahiko GOUDA General Manager Quality Assurance Department 1 Fo oale SUA ON gtecenades cotcesesteyoemnesecanedtauatecestaccee cemcane ee 4 2 Explanation of Sym
14. RRANTED PART IS DEFECTIVE IF THE DIAGNOSTIC WORK IS PERFORMED AT THE ZENOAH DEALER THE PURCHASER OR OWNER IS RESPONSIBLE FOR THE PERFORMANCE OF THE REQUIRED MAINTE NANCE AS DEFINED BY THE MANUFACTURER IN THE OWNER OPERATOR MANUAL ANY WARRANTED PART WHICH IS NOT SCHEDULED FOR REPLACEMENT AS REQUIRED MAINTENANCE OR WHICH IS SCHEDULED ONLY FOR REGULAR IN SPECTION TO THE EFFECT OF REPAIR OR REPLACE AS NECESSARY SHALL BE WARRANTED FOR THE WARRANTY PERIOD ANY WARRANTED PART WHICH IS SCHEDULED FOR REPLACEMENT AS REQUIRED MAINTENANCE SHALL BE WARRANTED FOR THE PERIOD OF TIME UP TO THE FIRST SCHEDULED RE PLACEMENT POINT FOR THE PART ANY REPLACEMENT PART THAT IS EQUIVALENT IN PERFORMANCE AND DULABILITY MAY BE USED IN NON WARRANTY MAINTENANCE OR REPAIRS AND G2500 G2500 OPS SHALL NOT REDUCE THE WARRANTY OBLIGATION OF THE COMPANY THE COMPANY IS LIABLE FOR DAMAGES TO OTHER ENGINE COMPONENTS CAUSED BY THE FAILURE OF A WARRANTED PART STILL UNDER WARRANTY THE WARRANTY DOES NOT APPLY TO THOSE UNITS WHICH HAVE BEEN DAMAGED BY NEGLI GENCE OF INSTRUCTION LISTED IN THE OWNER OPERATOR MANUAL FOR PROPER USE AND MAIN TENANCE OF THE UNITS ACCIDENT MISHANDLING ALTERATION ABUSE IMPROPER LUBRICATION USE OF ANY PARTS OR ACCESSORIES OTHER THAN THOSE SPECIFIED BY THE COMPANY OR OTHER CAUSES BEYOND THE COMPANY S CONTROL THIS WARRANTY DOES NOT COVER THOSE PARTS REPLACED BY NORMAL WEAR OR HARMLESS CHANGES IN THEIR APPEARANCE
15. THERE ARE NO OTHER EXPRESS WARRANTIES IMPLIED WARRANTIES INCLUDING THOSE OF MER CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED TO TWO 2 YEARS OF HOME USE ONE 1 YEAR FOR ANY OTHER USE FROM THE ORIGINAL DELIVERY DATE LIABILITIES FOR INCIDENTAL OR CONSEQUENTIAL DAMAGE UNDER ANY AND ALL WARRANTIES ARE EXCLUDED IF YOU NEED TO OBTAIN MORE INFORMATION PLEASE CALL YOUR NEAREST SERVICE CENTER OR CHECK PLEASE ZENOAH WEB SITE http www zenoah net GB 19
16. bols on the Machine cccececeeeeeee eens 8 3 Installing Guide Bar and Saw Chain cscicseconsancicoverasradtovesemvenan 9 4 Fuel and Chain Oil oo cccceccceceeee esses eeenesten estan cena eenaees 10 5 Operating the Engine a dscssaxeasdsccundeandatmrcavanindenendexeansiaddtendetacien 11 0 SAWING ccs bocessdectcidasdacdinbasncdanandd hodaceneesaaiandaan indadtaad sosddnadbanondaes 13 fe AVIAN ANG E ennn e E NOE 15 8 Maintenance of Saw Chain and Guide Bar aciceicene 16 9 TFOUBIESNOOUMG GUIJO sigs skesses nero noen AREER 17 LONE e o E E E E A EEA AE 17 Ty opo CHIC NOMS irer a 18 12 Limited Warranty ss snnsnnenusnrsrnerurrrerusrrerrerrerrerrerrerrerrerrerrerr 19 GB 3 G2500 G2500 OPS 1 For safe operation A WARNING This chainsaw has been especially designed for tree maintenance and should therefore only be used by trained operators when working on trees 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 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 co
17. d move at least 3 m 10 ft away from the fueling point before starting the engine iY reo 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 Do not use BIA or TCW 2 stroke water cooling type mixed oll E RECOMMENDED MIXING RATIO GASOLINE 50 OIL 1 lt when using ZENOAH genuine oil gt e 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 e These engines are certified to operate on unleaded gasoline e Make sure to use gasoline with a minimum octane number of 89RON USA Canada 87AL e f 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 E HOW TO MIX FUEL A WARNING e Pay attention to agitation 1 Measure out the quantities of gasoline and oil to be mixed
18. d slightly One push start G2500 OPS only A WARNING e Use One push start after performing warming up by Recoil Start in the status where the machine body is securely fixed You can not use OPS when the engine is cold e The starting performance of the engine depends on the adjustment of the engine Ask the distributor to adjust the engine if possible e Be careful not to set OPS in motion except when starting the engine If so it may lead to serious injury 1 Move the select lever to the front side of the machine body indicated by label until it is stopped and set this lever to the One push start mode GB 11 G2500 G2500 OPS 2 Put the machine body on the stable ground and make sure that there is no obstacle around the saw crossing portion Then while holding the front handle with the left hand and putting the right foot on the frame portion pull out the starter rope slowly The rope may be pulled out little by little several times A WARNING e When pulling out the rope large clanging is produced With this clanging stop pulling out the rope at once This sound notifies that One push start has been set e Don t pull out the rope excessively or don t pull it out without load by the starter only otherwise a starter failure will occur 3 Before starting the engine fix the engine securely and make sure that there is no obstacle around the saw chain Then push the top of the engine stop switch on the
19. e the saw chain is not contacting anything E CHECKING THE OIL SUPPLY A WARNING 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 After starting the engine run the chain at medium speed and see if chain oil is scattered off as shown in the fig ure The chain oil flow can be changed by inserting a screwdriver in the hole on bottom of the clutch side Adjust according to your work conditions Lean adjusting shaft 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 E ADJUSTING THE CARBURETOR Idle adjusting screw H needle L needle 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 When adjusting take the following steps RES Be sure to adjust the carburetor with the bar chain at tached H and L needles are restricted within the number of turn as shown below H needle 1 4 L needle 1 4 N Start the engine and allow it to warm up in low speed for a few minutes 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 cl
20. eaner cover H The screw under the H stamp is The High speed adjustment screw The screw under the L stamp is The Slow speed adjustment screw L The screw at the left of the T stamp is the Idle adjustment screw Position Left side of the rear handle activated black arrow 5 ap Shows the directions that the chain brake is released white arrow and O Position Front of the chain cover e If you turn the rod by screwdriver follow the arrow to the MAX position 4 the chain oil flow more and if you turn to the MIN position less Position Bottom of the power unit lt G2500 One push start only gt A Indicates the operation selecting position of the select lever for the One push start and Super e START at a start of the recoil B Indicates the operating direction of the select lever at a start of the engine by One push start Position Upper side portion of the recoil starter G2500 G2500 OPS 3 Installing Guide Bar and Saw Chain A standard saw unit package contains the items as illustrated Power unit Bar protector Guide bar Na Saw chain Na ie tr Screwdriver for carburetor adjustment Open the box and install the guide bar and the saw 5 Fit the chain tensioner nut into the lower hole of the chain on the power unit as follows guide bar then install the chain cover and fasten the mounting nut to finger tightness A WARNING 9 ane The saw chain has very
21. extremely important that the chain brake be checked for proper operation before each use and that the chain be sharp in order to main OVO O O_O 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 ot serious per sonal injury due to kickback E FELLING A TREE La Felling direction a t 4 Notch cut 1D ae Q2 Felling cut 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 A WARNING When you fell a tree be sure to warn neighboring work ers of the danger Bucking and Limbing A WARNING e Always ensure your foothold Do not stand on the log e Be alert to the rolling over of a cut log Especially when working on a slope stand on the uphill side of the log e Follow the instructions in For Safe Operation 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 t
22. he guide bar from being caught in the cut GB 14 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 Cutting the limbs of Fallen Tree First check to which side the limb is bent Then make the initial cut from the bent side and finish by sawing from the opposite side A WARNING Be alert to the springing back of a cut limb Pruning of Standing Tree Cut up from the bottom finish down from the top A WARNING e Do not use an unstable foothold or ladder e Do not overreach e Do not cut above shoulder height e Always use both your hands to hold the saw 7 Maintenance Before cleaning the inspecting or repairing the unit make sure that engine has stopped and is cool Disconnect the spark plug to prevent accidental starting E MAINTENANCE AFTER EACH USE 1 Air filter Loosen the knob and remove the air cleaner cover Take off the filter elements and tap off attached sawdust When they are extremely dirty shakewash with gasoline Dry them completely before reinstalling 2 Oiling port Dismount the guide bar and check the oiling port for clogging Oiling port 3 Guide bar When the guide bar is dismounted remove sawdust in the bar groove and
23. he operator should a apply the chain brake before starting b hold saw on either the left or right of the body when starting 1 onthe left side hold the saw with either the left hand on the front handle or the right hand on the rear handle and thrust the saw away from the body while holding the pull starter cord in the other hand 2 onthe right side hold the saw with the right hand on either handle and thrust the saw away from the body while holding the pull starter cord in the left hand The chain brake should always be engaged before low ering a running saw onto its strop Operators should always check the saw has sufficient fuel before undertaking critical cuts G2500 G2500 OPS One hand use of the chainsaw Operators should not use tree service chainsaws one handed in place of unstable work positioning or in pref erence to a handsaw when cutting small diameter wood at the branch tips Tree service chainsaws should only be used one handed where e the operator cannot gain a work position enabling two handed use and e they need to support their working position with one hand and e the saw is being used at full stretch at right angles to and out of line with the operator s body p Operators should never e cut with the kickback zone at the tip of the chainsaw guide bar e hold and cut sections e attempt to catch falling sections Freeing a trapped saw If the saw should become trapped during c
24. l 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 Always shut off the engine be fore setting it down 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 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 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 Keep the handles dry clean and free of oil or fuel mixture 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 Do not operate the chain saw in a tree unless specially trained to do so 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 When transp
25. m Cees 1 Depth gauge standard 5 ae 7 A WARNING Be sure to round off the front edge to reduce the chance of kickback or tie strap breakage Make sure every cutter has the same length and edge angles as illustrated Cutter length i t 1 30 Filing angle rope ED Side plate angle ad 0 6 o Top plate cutting angle E Guide Bar e Reverse the bar occasionally to prevent partial wear e The bar rail should always be square Check for wear of the bar rail Apply a ruler to the bar and the out G2500 G2500 OPS side of a cutter If a gap is observed between them the rail is normal Otherwise the bar rail is worn such a bar needs to be corrected or replaced ig AK Ruler Chain tilts A WARNING This saw is equipped with one of the following low kickback bar chain combinations Zenoah Part Number Bar Size Guide Bar Saw Chain Drum 10 2479 92110 2475 52210 2475 51110 10 2479 92120 3622 52210 2841 51110 9 Troubleshooting Guide Case 1 Starting failure A WARNING Make sure the icing prevention system is not work ing Check fuel for water Replace with proper or substandard mix fel ture Check for engine flooding gt Remove and dry the spark plug Then pull the starter again with no choke Check spark ignition ma o with a new 10 Disposal When disposing your machine fuel or oil for the machine be sure to allow your local regulations
26. mponents 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 yr If any of the above symptoms ap NEF pear seek medical advice imme a 4 diately Way 5 Always use caution when han nE dling fuel Wipe up all spills and 3 m 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 Donot 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 9 Never start cutting until you have a Clear work area secure foot ing and a planned retreat path from the falling tree 10 Ti 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 Keep all parts of your body away from the saw chain when the en gine is runni
27. ng 12 14 15 16 Before you start the engine make sure the saw chain is not contacting anything This product is provided with a centrifugal clutch Accordingly the saw chain starts to rotate the moment the choke knob is set to the START position first step to start the engine At the start put the machine body on the flat ground and pull the starter rope while holding the machine body securely so that the saw chain cannot touch the ground and sur rounding obstacles Don t pull the starter rope while pulling the throttle lever Start while pulling in the status where the chain saw is hung with one hand Doing this operation is strictly prohibited If the saw chain continues to ro tate stop the engine and then readjust the idle adjustment screw after confirming that there is no hitch on the throttle lever motion 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 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 2 1 muffler guard 2 guide bar 3 saw chain 18 20 All chain saw service other than the items listed in the Owner s Manua
28. nly KQ sereceserenseeiniierseniii sesiet 3 1 PON TE a E 0 88 9 000 kw min GB 18 Cutting head lt Sprocket bar gt OC CE ecg pecdeecqe tats deer anni eguse nec seeaeiecunanoen cane 6T Chain speed at Max POWEF o n 17 1 m s Guide bar WPS EEEE SEA Sprocket nose oe MOM sctees ave ceuteciacerseceledatrsetectae cet 10 25 saw chain WYO CS serra en Oregon 91VG PUL VJs IE e neee EE n 3 8 9 53 Gauge in MM ieiccimnteerivvaddectsweceterees 0051 27 lt Hard nose bar gt O a E 8I Chain speed at Max DOWEL ss cc 15 2 m s Guide bar TYDE saeun ZENOAH carving Hard nose Aze CIN A CNT oreren E 10 25 Saw chain e e E E EEES Oregon 25AP Piten m MMI conse nits scdestontaseda nateaoteenbeass 1 4 6 35 Gauge N M seeitdireismarenute cide duabincitewetow OOS T27 G2500 series are equipped with Chain Brake Specifications are subject to change wihout notice 12 Limited warranty Should any failure occur on the product under normal operating conditions within the applicable warranty pe riod the failed part will be replaced or repaired free of charge by a ZENOAH authorized dealer WARRANTY PERIOD 1 year 6 months if used profes sionally and 30 days if used for rental purpose from the date of initial purchase THE PURCHASER SHALL BEAR COSTS OF TRANS PORTING THE UNIT TO AND FROM THE ZENOAH DEALER THE PURCHASER SHALL NOT BE CHARGED FOR DI AGNOSTIC LABOR WHICH LEADS TO THE DETERMI NATION THAT A WA
29. ockwise Make a test cut and adjust the H needle for best cutting power not for maximum speed Q E CHAIN BRAKE The chain brake is a device which stops the chain in stantaneously if the chain saw recoils due to kickback Normally the brake is activated automatically by inertial force It can also be activated manually by pushing the brake lever left hand guard down toward the front When the brake operates a yellow cone pops up from the base of the brake lever Releasing the Brake Pull the brake lever up toward the left hand handle until it clicks into place 6 Sawing 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 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 G2500 G2500 OPS A WARNING e When the brake operates release the throttle lever to slow down the engine speed Continuous opera tion with the brake engaged will generate heat from
30. orting your chain saw make sure the appropriate guide bar scabbard is in place Never touch the muffler guard guide bar or saw chain with bare hands while the engine Is in op eration or immediately after shut ting down the engine Doing so could result in serious burns be cause of high temperature G2500 G2500 OPS KICKBACK SAFETY PRECAU TIONS FOR CHAIN SAW US ERS A 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 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 lose control of the saw which could result in se rious 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 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
31. positions for both themselves and the saw Preparing to use the saw in the tree The chainsaw should checked fuelled started and warmed up by the ground worker before it is sent up to the operator in the tree The chainsaw should be fitted with a suitable strop for attaching to the operator s har ness a choke the strop around the attachment point on the rear of the saw A b provide suitable karabiners to allow indirect i e via the strop and direct attachment i e at the attach ment point on the saw of saw to the operators har ness c ensure the saw is securely attached when it is being sent up to the operator d ensure the saw it secured to the harness before it is disconnected from the means of ascent GB 6 The saw should only be attached to the recommended attachment points on the harness These may be at mid point front or rear or at the sides Where possible attaching the saw to centre rear mid point will keep it clear of climbing lines and support its weight centrally down the operator s spine gt PF geet W lia When moving the saw from any attachment point to an other operators should ensure it is secured in the new position before releasing it from the previous attachment point Using the chainsaw in the tree An analysis of accidents with these saws during tree service operations shows the primary cause as being inappropriate one handed use of the saw In the vast majority of accidents
32. the oiling port lt Type sprocket nose gt Grease the nose sprocket from the feeding port on the tip of the bar Grease port _ Sprocket _ Giling port 4 Others Check for fuel leakage and loose fastenings and damage to major parts especially handle joints and guide bar mounting If any defects are found make sure to have them repaired before operating the saw again E PERIODICAL SERVICE POINTS 1 Cylinder fins 1 Remove the starter case 2 Remove sawdust between the cylinder fins 3 Clean the valute area 2 Fuel filter Fuel filter b Wash the filter with gasoline Replace with new one if clogged with dirt completely G2500 G2500 OPS A WARNING When returning the filter use a pinch not to be folded the suc tion pipe 3 Oil filter 1 With a wire hook take out the oil filter from the feeding port Oil filter 2 Wash the filter with gasoline A WARNING When returning the filter use a pinch not to be folded the suc tion pipe 4 Spark plug 0 6 0 7mm Champion RCJ 7Y Clean the electrodes with a wire brush and reset the gap to 0 6 mm as necessary 5 Sprocket Check for cracks and for excessive wear interfering with the chain drive If the wear is considerable replace it with new one Never fit a new chain on a worn sprocket or a worn chain on anew sprocket 6 Way of the cooling air A WARNING e The engine metal parts can burn your skin Never
33. utting op erators should e switch off the saw and attach It securely to the tree inboard i e towards the truck side of the cut or toa separate tool line e pull the saw from the kerf whilst lifting the branch as necessary e if necessary use a handsaw or second chain saw to release the trapped saw by cutting a minimum of 30 cm away from the trapped saw Whether a handsaw or a chainsaw is used to free a stuck saw the release cuts should always be outboard to ward the tips of the branch in order to prevent the saw being taken with the section and further complicating the situation GB 7 G2500 G2500 OPS 2 Explanation of Symbols on the Machine A 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 b ie Position Fuel cap Co The port to top up chain oil Position Oil cap setting the switch to the O position the engine stops immediately O Position Front at the top of the rear handle NI Starting the engine If you pull out the choke knob at the back right of Ar the rear handle to the point of the arrow you can set the starting mode W as follows CHOKE e First stage position starting mode when the engine is warm Wy START e Second stage position starting mode when the engine is cold op RUN Position Upper right of the aircl
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