Zenoah G2500 User manual

GB-1
G2500/G2500 OPS
G2500
G2500 OPS
(One-Push-Start)
G
B
OWNER’S MANUAL
CHAIN SAW
Original Language
115 59 93-38 (306)
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GB-2
G2500/G2500 OPS
⑧
⑦
④
③
⑫
⑬
①②
⑤
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⑨
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1. Parts location
Contents
1. Parts location ...................................................2
 2. Specication ....................................................3
3. Warning labels .................................................3
4. For safe operation ............................................4
5. Explanation of Symbols on the Machine..........8
6. Installing Guide Bar and Saw Chain ................9
7. Fuel and chain oil...........................................10
8. Operating the Engine.....................................11
9. Sawing ...........................................................14
10. Maintenance ..................................................15
11. Maintenance of Saw Chain and Guide Bar....17
12. Troubleshooting Guide...................................18
13. Disposal .........................................................18
1. Front guard
2. Starter knob
3. Air cleaner
4. Choke knob
5. Throttle interlock
6. Right handle
7. Throttle lever
8. Engine switch
9. Fuel tank
10. Oil tank
11. Left handle
12. Saw chain
13. Guide Bar
SAFETY FIRST
Instructions contained in warnings within this manual marked
with a symbol concern critical points which must be taken into
consideration to prevent possible serious bodily injury, and for
this reason you are requested to read all such instructions care-
fully and follow them without fail.
NOTES ON TYPES OF WARNINGS IN THE MANUAL
WARNING
This mark indicates instructions, which must be followed in order
to prevent accidents, which could lead to serious bodily injury
or death.
IMPORTANT
This mark indicates instructions, which must be followed, or it
leads to mechanical failure, breakdown, or damage.
NOTE
This mark indicates hints or directions useful in the use of the
product.
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GB-3
G2500/G2500 OPS
G
B
Power unit:
G2500/G2500 OPS
Displacement (cm3): ............................................. 25.4
Fuel: .................Mixture (Gasoline 50: Two-cycle oil 1)
(when using ZENOAH genuine oil)
Fuel tank capacity (cm3)........................................ 230
Chain oil: ................................ Motor oil SAE# 10W-30
Oil tank capacity (cm3).......................................... 160
Carburetor: ....................................... Diaphragm type
ignition system: ..........................................Solid State
Spark plug: .....................................Champion RCJ-7Y
Oil feeding system: ........................ Mechanical pump
Max speed:............................................ 12,500 (min-1)
Idle speed:............................................... 2,900 (min-1)
Power:............................. G2500 0.96/9,000 (kw/min-1)
G2500 ops 0.88/9,000 (kw/min-1)
Noise at Operator’s ear (Racing): ..................... 102dB
G2500
Dimensions (L x W x H)(mm): ............265 x 220 x 220
Dry weight
Power unit only (kg): ............................................... 2.9
G2500 OPS (One-push-start)
Dimensions (L x W x H)(mm): ............265 x 235 x 220
Dry weight
Power unit only (kg): ............................................... 3.1
Cutting head:
<Sprocket bar>
Sprocket: ................................................................6T
Chain speed at max. power:........................ 17.1 (m/s)
Guide bar
Type: .................................................. Sprocket nose
Size (in. (mm)): ...............................................10 (25)
Saw chain
Type: ....................................................Oregon 91PX
Pitch (in. (mm)): ..........................................3/8 (9.53)
Gauge (in. (mm)): ....................................0.05 (1.27)
<Hard nose bar>
Sprocket: ................................................................8T
Chain speed at max. power:........................ 15.2 (m/s)
Guide bar
Type: ..........................ZENOAH carving (Hard nose)
Size (in. (mm)): ...............................................10 (25)
Saw chain
Type: ....................................................Oregon 25AP
Pitch (in. (mm)): ..........................................1/4 (6.35)
Gauge (in. (mm)): ....................................0.05 (1.27)
Specicatiotnsaresubjecttochangewithoutnotice.
3. Warning labels on the machine
(1) Read operator's manual be-
fore operation this machine. (5) Warning/Attention.
(2) Wear head, eye and ear pro-
tection. (6) Never touch hot surface.
(3) Use the chain saw with two
hands.
(7) Use appropriate protections
for foot-leg and hand-arm.
(4) Warning! Kickback it’s dan-
ger.
(8) This saw is for trained tree
service operators only.
Never remodel the product.
We won’t warrant the machine, if you use the
remodeled product or you don’t observe the
proper usage written in the manual.
If warning label peels off or becomes soiled and
impossible to read, you should contact the
dealer from which you purchased the product
to order new labels and affix them in the re-
quired location(s).
2. Specicaions
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GB-4
G2500/G2500 OPS
4. 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.
Whenusingthisproductforthersttime,beforebeginning
actual work, learn to handling it from skilled worker.
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inuence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 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.
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
ame(i.e.smoking,openames,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.
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.
8. Never start cutting until you have a
clear work area, secure footing, and
a planned retreat path from the falling
tree.
9. Alwaysholdthechainsawrmlywith
both hands when the engine is run-
ning.Usearmgripwiththumband
fingers encircling the chain saw
handles.
10. Keep all parts of your body away from
the saw chain when the engine is
running.
11. Before you start the engine, make
sure the saw chain is not contacting
anything.
12. Always carry the chain saw with the
engine stopped, the guide bar and
sawchaintotherear,andthemufer
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
adjusted, or is not completely and
securely 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ywheel,orifanimpropertoolis
usedtoholdtheywheelinorderto
remove the clutch, structural damage
to the ywheel could occur which
could subsequently cause the y-
wheel to disintegrate.)
15. Always shut off the engine before
setting it down.
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
tension, be alert for spring- back so
that you will not be struck when the
tension in the wood fibers is re-
leased.
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 opera-
tion.
19. Keep the handles dry, clean and free
of oil or fuel mixture.
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GB-5
G2500/G2500 OPS
G
B
(1)muferguard
(2) guide bar
(3) saw chain
20. 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 monoxide.
21. Do not operate the chain saw in a tree
unless specially trained to do so.
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danger-
ous 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 muffer guard, guide
bar, saw chain or nut with bare hands
while the engine is in operation or
immediately after shutting down the
engine. Doing so could result in seri-
ous burns because of high tempera-
ture.
KICKBACK SAFETY PRECAUTIONS
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 contact in some cases may cause
alightningfastreversereaction,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 to-
wards 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 sev-
eralstepstokeepcuttingjobsfree
fromaccidentorinjury.
(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
handle, and the left hand on the front
handle, when the engine is running.
Usearmgripwiththumbsandn-
gers encircling the chain saw han-
dles.Armgripwillhelpyoureduce
kickback and maintain control of the
saw.
(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speciedbythemanufacturer
or the equivalent.
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difcultypickingupsmallobjectssuch
as screws or nails;
• the vibration white nger could happen more fre-
quentlyandaffectmoreofyourngers.
FOR PROTECTING YOUR BODY FROM VIBRATION
Please observe the following matter, in order to
protect 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 vibra-
tion).
2. Check tools before using them to make sure they have
been properly maintained and repaired to avoid in-
creased vibration caused by faults or general wear.
3. Make sure cutting tools are kept sharp so that they
remainefcient.
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:
• 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ow;and massaging and
exercisingyourngers
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.
(1)
(2)
(3)
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GB-6
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 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tted
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.
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.
When moving the saw from any attachment point to
another, operators should ensure it is secured in the
new position before releasing it from the previous at-
tachment 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,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:
• nothavingarmgriponthesawifitkicksback;
• 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)
• 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 position
where they are operating the saw at:
• hiplevelwhencuttinghorizontalsections;
• 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 ex-
ample, a re-direct of the main line via a supplementary
anchorpointorusinganadjustablestropdirectfrom
the harness to a supplementary anchor point.
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GB-7
G2500/G2500 OPS
G
B
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, the operator
should:
a) apply the chain brake before starting;
b) hold saw on either the left or right of the body when
starting:
1) on the 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) on the 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
lowering a running saw onto its strop.
Operatorsshouldalwayscheckthesawhassufcient
fuel before undertaking critical cuts.
One-hand use of the chainsaw
Operators should not use tree service chainsaws one-
handed in place of unstable work positioning or in
preference to a handsaw when cutting small diameter
wood at the branch tips.
Tree service chainsaws should only be used one-
handed where:
• the operator cannot gain a work position enabling
two-handed use; and
• theyneedtosupporttheirworkingpositionwithone
hand; and
• thesawisbeingusedatfullstretch,atrightangles
to and out of line with the operator’s body.
Operators should never:
• cutwiththekickbackzoneatthetipofthechainsaw
guide bar
• ‘holdandcut’sections
• attempttocatchfallingsections.
Freeing a trapped saw
If the saw should become trapped during cutting, op-
erators should:
• switchoffthesawandattachitsecurelytothetree
inboard (i.e. towards the truck side) of the cut or to a
separate tool line;
• pullthesawfromthekerfwhilstliftingthebranchas
necessary;
• 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
(toward the tips of the branch), in order to prevent the
saw being taken with the section and further complicat-
ing the situation.
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GB-8
G2500/G2500 OPS
5. Explanation of Symbols on the Machine
• Forsafeoperationandmaintenance,symbolsarecarvedinreliefonthemachine.
According to these indications, please be careful not to make any mistake.
The port to refuel “MIX GASOLINE”
Position: Fuel cap
The port to top up chain oil
Position: Oil cap
Setting the switch to the “O” position, the engine stops immediately.
Position: Front at the top of the rear handle
Starting the engine. If you pull out the choke knob (at the back-right of the
rear handle) to the point of the arrow, you can set the starting mode as
follows:
•
First-stage position – starting mode when the engine is warm.
• Second-stage position – starting mode when the engine is cold.
Position: Upper-right of the aircleaner cover
Thescrewunderthe“H”stampisTheHigh-speedadjustmentscrew.
Thescrewunderthe“L”stampisTheSlow-speedadjustmentscrew.
Thescrewattheleftofthe“T”stampistheIdleadjustmentscrew.
Position: Left side of the rear handle
Shows the directions that the chain brake is released (white arrow) and
activated (black arrow).
Position:: Front of the chain cover
If you turn the rod by screwdriver follow the arrow to the “MAX” position,
thechainoilowmore,andifyouturntothe“MIN”position,less.
Position: Bottom of the power unit
<G2500 OPS>
Shows the direction of the select lever for the OPS (one-push-start) and
“Super e-start”.
Position: Upper side of the recoil starter
WARNING
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GB-9
G2500/G2500 OPS
G
B
6. Installing Guide Bar and Saw Chain
A standard saw unit package contains the items as illustrated.
5. Fit the chain tensioner nut into the lower hole of the
guide bar, then install the chain cover, and fasten the
mountingnuttongertightness.
WARNING
Wheninstallingthechaincover,besuretot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
Loosen
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chain
cover loose.
Tighten
8. Tighten the tensioner screw.
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.
Open the box and install the guide bar and the saw chain
on the power unit as follows:
WARNING
The saw chain has very sharp edges. Use thick protec-
tive 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.
4. Mounttheguidebarthentthesawchainaroundthe
bar and sprocket.
Chain tensioner nut
Hole
Chain cover
NOTE
Pay attention to the correct direction of the saw chain.
Moving direction
Power unit
Bar protector
Guide bar
Saw chain
Plug wrench
(Hexagon socket (S13/S19) +
Slotted driver)
Screwdriver for
carburetor adjustment
(Slotted driver)
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GB-10
G2500/G2500 OPS
7. Fuel and Chain Oil
■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 refueling the unit. Select outdoor
bare ground for fueling and move at least 3 m (10 ft) away
from the fueling point before starting the engine.
• TheZenoah engines arelubricated by oilspecially formu-
lated for air-cooled 2-cycle gasoline engine use. If Zenoah oil
is not available, use an anti-oxidant added quality oil ex-
pressly labeled for air-cooled 2-cycle engine use (JASO FD
GRADE OIL or ISO-L-EGD GRADE).
• DonotuseBIAorTCW(2-strokewater-coolingtype)mixed
oil.
■RECOMMENDED MIXING RATIO
GASOLINE 50 : OIL 1
<when using ZENOAH genuine oil>
(JASO FD GRADE OIL or ISO-L-EGD GRADE)
• Exhaust emission are controlled by the fundamental en-
gine parameters and components (eq., carburation, igni-
tion timing and port timing) without addition of any major
hardware or the introduction of an inert material during
combustion.
• Theseengines are certied to operate onunleaded gaso-
line.
• 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 temperature may rise and
an engine problem such as piston seizing may consequent-
ly occur.
• Unleadedgasolineisrecommendedtoreducethecontamina-
tion of the air for the sake of your health and the environ-
ment.
• Poorqualitygasolinesoroilsmaydamagesealingrings,fuel
lines or fuel tank of the engine.
■HOW TO MIX FUEL
WARNING
•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 con-
tainer.
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difculttoagitatedepending
on oil ingredients, sufcient agitation is necessary for the
enginetolastlong.Becarefulthat,iftheagitationisinsuf-
cient, there is an increased danger of early piston seizing
due to abnormally lean mixture.
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 iden-
tication.
■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
1. Select 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 sufciently agitate the mixed gasoline in the con-
tainer.
■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 carburetor and result in
the engine failing to operate properly.
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 container, scrap
it only at an authorized repository site.
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inuencearenotcovered
by the warranty. Also, be careful that, if the usage in the instruc-
tion manual is not observed as to the mixed gasoline, etc. de-
scribed therein, it may not be covered by the warranty.
■Supplying chain oil
WARNING
Running the equipment for long hours with its chain oil run out
will accelerate the wear and tear of the chain and guide bar,
possibly resulting further in a chain cut and even in a fatal ac-
cident leading to death.
1. Forchainoil,useatypethatissufcientlyviscousandad-
equately lubricating under the summer-use conditions and
another type that shows similar performance under the
winter-use conditions.
2. The use of Zonoah genuine chain oil is recommended to
make your chain saws last as long as possible. If no genu-
ine chain oil is available, please use commercially available
chain oil, which is commonly used.
Caution
Using waste oil, recycled oil, or anything similar causes a break-
down and also proves harmful to the human body and environ-
ment. Please do not under any circumstances use any such
material.
IMPORTANT
Use chain oil of vegetable origin. Before storing it for a long
period, remove the chain oil from the blade and chain groove
and clean them. If not, the chain may become rusted. Chain
rust will cause the chain to become rigid or to become viscous
at the tip.
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G2500/G2500 OPS
G
B
8. Operating the Engine
NOTE
When restarting immediately after stopping the engine,
settheChokeknobintherst-stageposition(chokeopen
and throttle lever in the starting position).
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nger.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.
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,rstpushinthechokeknob
to the rst-stage position and then pull the starter
again to start the engine.
7. Allow the engine to warm up with the throttle lever
pulled slightly.
(G2500 OPS : OPS “one-push-start”)
WARNING
• UseOne-push-startafterperformingwarming-upby
Recoil Start in the status where the machine body is
securelyxed.YoucannotuseOPSwhentheengine
is cold.
• Thestartingperformanceoftheenginedependson
theadjustmentoftheengine.Askthedistributorto
adjusttheengineifpossible.
• BecarefulnottosetOPSinmotionexceptwhenstart-
ingtheengine.Ifso,itmayleadtoseriousinjury.
1. Set the select lever to the OPS mode as shown in the
label, to the direction of front side until it stops.
WARNING
It is very dangerous to run a chainsaw that mounts bro-
ken parts or lacks any parts.
Before starting engine, make sure that all the parts includ-
ing bar and chain are installed properly.
■STARTING THE ENGINE
1. Fill fuel and chain oil tanks respectively, and tighten
the caps securely.
Chain oil
Fuel
2. Continuously push the priming bulb until fuel comes
in the bulb.
3. Set the switch to “I” position.
Throttle
interlock
Throttle lever
Switch
(G2500 OPS : “Super e-start”)
• Setthe selectlever tothe “Supere-start” modeas
shown in the label, to the direction of rear side until it
stops.
Select lever
“Super e-start” mode
Label
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.
Choke
knob
When the engine is cool
When the engine is warm up
After the engine starts
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G2500/G2500 OPS
2. Put the machine body on the stable ground and make
sure that there is no obstacle around the saw-cross-
ing 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.
NOTE
The rope may be pulled out little by little several times.
WARNING
• When pulling out the rope, large clanging is pro-
duced. With this clanging, stop pulling out the rope
atonce.ThissoundnotiesthatOne-push-starthas
been set.
• 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,x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 right side of the rear handle and set it
to the “Run” position. After that, move the select lever
to the rear side of the machine body indicated by
label. The starter is started to start the engine.
I (Run) O (Stop) Engine stop switch
Select lever
Label
NOTE
If the engine cannot be started by the above procedure,
repeat the above operations again. If the engine cannot
be started smoothly, it may be necessary to add warm-
ing-up or readjust the engine.  Perform warming-up
enoughandaskthedistributortoreadjusttheengine.
■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.
2. When the outside temperature is below 0°C, repeat
the above warming-up operation twice or more. After
the engine stops, use the product in a shorter leaving
time.
WARNING
• Besuretoperformwarming-upwiththeguidebar
and the saw chain mounted.
• KeepclearofthesawchainasitwillstartrotatIng
upon starting of engine.
• Beforeyoustarttheengine,makesurethesawchain
is not contacting anything.
■CHECKING THE OIL SUPPLY
WARNING
Make sure to set up the bar and the chain when check-
ing the oil supply.
If not, the rotating parts may be exposed. It is very dan-
gerous.
After starting the engine, run the chain at medium speed
andseeifchainoilisscatteredoffasshownintheg-
ure.
Chain oil
Thechainoilowcanbechangedbyinsertinga
screwdriver in the hole on bottom of the clutch side.
Adjustaccordingtoyourworkconditions.
Rich
Chain oil flow
adjusting shaft
Lean
The oil tank should become nearly empty by the time
fuelisusedup.Besuretorelltheoiltankeverytime
when refueling the saw.
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GB-13
G2500/G2500 OPS
G
B
■ADJUSTING THE CARBURETOR
L needle
H needle
Idle adjusting
screw
Thecarburetoronyourunithasbeenfactoryadjusted,
butmayrequirenetuningduetoachangeinoperat-
ing conditions.
Before adjusting the carburetor, make sure that the
providedair/fuelltersarecleanandfreshandthefuel
properly mixed.
Whenadjusting,takethefollowingsteps:
NOTE
Besuretoadjustthecarburetorwiththebarchainat-
tached.
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-
ber of turn as shown below.
H needle : 1 1/8
L needle : 1 5/8
2. Start the engine and allow it to warm up in low speed
for a few minutes.
3.Turn L needle slowly clockwise to nd 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.
■CHAIN BRAKE
The chain brake is a device which stops the chain in-
stantaneously if the chain saw recoils due to kick-
back.
Normally, the brake is activated automatically by iner-
tialforce. It can also be activated manually by pushing
thebrake 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.
WARNING
• 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
the clutch and may cause trouble.
• 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.
■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.
Switch
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GB-14
G2500/G2500 OPS
9. Sawing
WARNING
• Before proceeding to your
job, read the section “For Safe
Operation”. It is recommend-
ed 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 regula-
tions would not be respected.
Do not use the chain saw as a
lever for lifting, moving or
splitting objects. Do not lock
it over fixed stands. It is for-
bidden to hitch tools or ap-
plications to the PTO other
than those specified by the
manufacturer.
• Itisnotnecessarytoforcethesawintothecut.
Apply only light pressure while running the en-
gine 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.
■GUARD AGAINST KICKBACK
• 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 I -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, replace the brake
band and clutch drum before use.
• Itisextremelyimportantthatthechain
brake be checked for proper opera-
tion before each use and that the
chain be sharp in order to maintain
the kickback safety level of this saw.
Removal of the safety devices, inad-
equate maintenance, or incorrect
replacement of the bar or chain may
increase the risk ot serious personal
injuryduetokickback.
■FELLING A TREE
Felling direction
Notch cut 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.
WARNING
• Whenyoufellatree,besuretowarnneighboring
workers of the danger.
Bucking and Limbing
WARNING
• Alwaysensureyourfoothold.Donotstandonthe
log.
• Bealerttotherollingoverofacutlog.Especially
when working on a slope, stand on the uphill side
of the log.
• 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nishcuttingfromthe
opposite side of the bending direction to prevent the
guide bar from being caught in the cut.
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GB-15
G2500/G2500 OPS
G
B
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nish
by sawing down from the top. In area B, saw down from
thetopone-thirdandnish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nishbysawingfrom
the opposite side.
WARNING
Be alert to the springing back of a cut limb.
Pruning of Standing Tree
Cutupfromthebottom,nishdownfromthetop.
WARNING
•Donotuseanunstablefootholdorladder.
•Donotoverreach.
•Donotcutaboveshoulderheight.
•Alwaysusebothyourhandstoholdthesaw.
10. Maintenance
WARNING
Before cleaning, the inspecting or repairing the unit,
make sure that engine has stopped and is cool. Discon-
nect the spark plug to prevent accidental starting.
■MAINTENANCE AFTER EACH USE
1. Air filter
Loosen the knob and remove the air cleaner cover. Take
offthelter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 the oiling port.
<Type : sprocket nose>
Grease the nose sprocket from the feeding port on the
tip of the bar.
Grease port
Oiling port Sprocket
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.
■PERIODICAL SERVICE POINTS
1. Cylinder fins
Reriodicallycheckandcleanthecylindernsintherepair
specialty store.
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GB-16
G2500/G2500 OPS
2. Fuel filter
(a)Usinga wirehook, take outthelterfromtheller
port.
Fuel filter
(b)Washthelterwithgasoline.
Replace with new one if clogged with dirt completely.
WARNING
Whenreturningthelter,useapinchnottobefoldedthe
suction pipe.
3. Oil filter
1. Withawirehook,takeouttheoillterfromthefeeding
port.
Oil filter
2. Washthelterwithgasoline.
WARNING
Whenreturningthelter,useapinchnottobefoldedthe
suction pipe.
4. Spark plug
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tanewchainonawornsprocket,
or a worn chain on a new sprocket.
6. Way of the cooling air
WARNING
• Theenginemetalpartscanburnyourskin.Nevertouch
thecylinder,muferorignitionplugetc.duringopera-
tion or right after stopping the engine.
• Beforestartingtheengine,checkaroundthemufer
and take off sawdust. If you do not, it will cause the
overheating and a re. For preventing the trouble,
pleasekeepcleanaroundthemufer.
This engine is air-cooled. Dust clogging between the
inletportofthecoolingairandcylindernswillcause
overheating of the engine. Periodically check and clean
thecylindernsintherepairspecialtystore.
7. Muffler
WARNING
Ifyou donot attachthe mufercorrectly,after engine
starts,themuferwillbeloosenandthehightemperature
exhaustgasspout.Aftercleaningthemufer,payatten-
tiontotupthemuferaccordingtotheexplanationas
follows.
1. Muferbody,mufercoverandbafewillbecombined
correctly.
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)
WARNING
Rightafterstoppingtheengine,donottouchthemufer
with one’s bare hands. It will cause to burn your hands.
If carbon clogs between the mufer, it will cause the
poor-output and the trouble in starting. After each 100
hours,checkandcleaninsidethemufer.
8. 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).
• Don’tpullthestarterwhendetachingitfromtheunit.
Itwillcausemachinedefectorseriousinjurybytouch-
ing rotating parts on your body part carelessly.
Set direction
Select lever
WARNING
Don’t pull the starter when detaching it from the unit.
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GB-17
G2500/G2500 OPS
G
B
11. Maintenance of Saw Chain and Guide Bar
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
Filing angle
Side plate angle
(25AP) 85°
(91PX) 80°
Top plate cutting angle
(91PX) 55°
(25AP) 60°
■Guide Bar
• Reverse the bar occasionally to prevent partial
wear.
• Thebarrailshouldalwaysbesquare.Checkforwear
of the bar rail. Apply a ruler to the bar and the outside
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.
Ruler
Gap
No gap
Chain tilts
WARNING:
This saw is equipped with one of the following low
kickback bar/chain combinations:
Zenoah Part Number
Bar Size Guide Bar Saw Chain
10 2475-52111 580703501 (91PX)
10 2475-52121 3622-52210 (25AP)
■Saw Chain
WARNING
It is very important for smooth and safe operation to
always keep the cutters sharp.
The cutters need to be sharpened when:
• Sawdustbecomespowder-like.
• Youneedextraforcetosawin.
• Thecutpathdoesnotgostraight.
• Vibrationincreases.
• Fuelconsumptionincreases.
Cutter setting standards:
WARNING
Be sure to wear safety gloves.
Beforeling:
• Makesurethesawchainisheldsecurely.
• Makesuretheengineisstopped.
• Usearoundleofpropersizeforthechain.
Chain type: 91PX / 25AP
File size: 5/32 in (4.0 mm)
Placetheleonthecutterandpushstraightforward.
Keepthelepositionasillustrated.
<91PX>
Aftereachcutterhasbeenled,checkthedepthgauge
andleittotheproperlevelasillustrated.
Appropriate gauge checker
Make the shoulder round
Depth gauge standard
0.025″(0.64 mm)
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GB-18
G2500/G2500 OPS
12. Troubleshooting Guide
Case 1. Starting failure
WARNING
• Make sure the icing prevention system is not working.
Case 2. Lack of power/Poor acceleration/
Rough idling
Case 3. Oil does not come out
If the unit seems to need further service, please consult
with an authorized service shop in your area.
13. 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.
Check fuel for water
or substandard mix-
ture.
Check for engine
ooding.
Check spark ignition.
Replace with proper
fuel.
Remove and dry the
spark plug.
Then pull the starter
again with no choke.
Replace with a new
plug.
󰾲
󰾲
󰾯
󰾯
󰾯
Check fuel for water or
substandard mixture.
Check air filter and
fuel filter for clog-
ging.
Check carburetor for
inadequate adjust-
ment.
Replace with proper
fuel.
Clean.
Readjust speed nee-
dles.
󰾲
󰾲
󰾯
󰾯
󰾯
Check oil for substan-
dard quality.
Check oil passage
and ports for clog-
ging.
Replace.
Clean.
󰾲
󰾯
󰾯
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GB-19
G2500/G2500 OPS
G
B
Limited warranty
Should any failure occur on the product under normal
operating conditions within the applicable warranty
period, the failed part will be replaced or repaired free
of charge by a ZENOAH authorized dealer.
WARRANTY PERIOD: Six (6) months after purchased
byend-usersubjectto12monthsfromproducedmonth.
(30 days If used for rental purpose)
THE PURCHASER SHALL BEAR COSTS OF TRANS-
PORTING THE UNIT TO AND FROM THE ZENOAH
DEALER.
THE PURCHASER SHALL NOT BE CHARGED FOR
DIAGNOSTIC LABOR WHICH LEADS TO THE DETER-
MINATION THAT A WARRANTED 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
INSPECTION TO THE EFFECT OF REPAIR OR “RE-
PLACE AS NECESSARY” SHALL BE WARRANTED FOR
THE WARRANTY PERIOD. ANY WARRANTED PART
WHICH IS SCHEDULED FOR REPLACEMENT AS RE-
QUIRED MAINTENANCE SHALL BE WARRANTED FOR
THE PERIOD OF TIME UP TO THE FIRST SCHEDULED
REPLACEMENT POINT FOR THE PART.
ANY REPLACEMENT PART THAT IS EQUIVALENT IN
PERFORMANCE AND DURABILITY MAY BE USED IN
NON-WARRANTY MAINTENANCE OR REPAIRS, AND
SHALL NOT REDUCE THE WARRANTY OBLIGATION
OF THE COMPANY.
THE COMPANY IS LIABLE FOR DAMAGES TO OTHER
ENGINE COMPONENTS CAUSED BY THE FAIRURE
OF A WARRANTED PARTS STILL UNDER WARRAN-
TY.
THE WARRANTY DOES NOT APPLY TO THOSE UNITS
WHICH HAVE BEEN DAMAGED BY NEGLIGENCE OF
INSTRUCTION LISTED IN THE OWNER/OPERATOR
MANUAL FOR PROPER USE AND MAINTENANCE OF
THE UNITS ACCIDENT MISHANDLING, ALTERATION,
ABUSE, IMPROPER LUBRICATION, USE OF ANY
PARTS OR ACCESSARIES 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.
THERE ARE NO OTHER EXPRESS WARRANTIES.
ANY IMPLIED WARRANTY is limited to the duration of
the limited warranty. Otherwise, this limited warranty is
in lieu of all other expressed or implied warranties, in-
cluding any warranty of FITNESS FOR A PARTICULAR
PURPOSE OR USE and any implied warranty MER-
CHANTABILITY otherwise applicable to this product.
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
01-G2500･G2500 ops_GB_306＿四.indd 19 13.7.4 5:43:58 PM

01-G2500･G2500 ops_GB_306＿四.indd 20 13.7.4 5:43:58 PM