Zenoah G3802 User manual

GB-1
G3802/G3802EZ
G3802
G3802EZ
G
B
OWNER’S MANUAL
CHAIN SAW
Original Language
115 59 85-38 (306)
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GB-2
G3802/G3802EZ
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..........6
6. Installing Guide Bar and Saw Chain ................7
7. Fuel and chain oil.............................................8
8. Operating the Engine.......................................9
9. Sawing ...........................................................11
10. Maintenance ..................................................12
11. Maintenance of Saw Chain and Guide Bar....13
12. Troubleshooting Guide...................................14
13. Disposal .........................................................14
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
G3802/G3802EZ
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Power unit:
Displacement (cm3): ............................................. 37.2
Fuel: ................................................................ Mixture
When using market oil (JASO FB grade oil or ISO-L-
EGB grade oil)..........................GASOLINE 25: OIL 1
When using ZENOAH genuine oil, JASO FD grade oil
or ISO-L-EGD grade oil.............GASOLINE 50: OIL 1
Fuel tank capacity (ml): ......................................... 310
Chain oil: ................................ Motor oil SAE# 10W-30
Oil tank capacity (ml):............................................ 210
Carburetor: ...................Diaphragm type (Walbro WT)
Ignition system: ....................................Pointless (TCI)
Spark plug: ....................................Champion RCJ-7Y
Oil feeding system: ......Automatic pump with adjuster
Power:..........................................1.62/9500 (kw/min-1)
Max speed:............................................ 12,500 (min-1)
Idle speed:............................................... 2,900 (min-1)
Noise at Operator’s ear (Racing): ..................... 102dB
Sprocket (Teeth x Pitch):
for 91PX .............................................6T x 3/8” (9.53)
for 95VPX.......................................7T x 0.325” (8.26)
Dimensions (L x W x H)(mm): ............370 x 235 x 270
Dry weight (Power unit only) (kg):
G3802...................................................................4.2
G3802EZ ..............................................................4.4
Cutting head:
Guide bar
Type: .................................................. Sprocket nose
Size mm (in.):................................................400 (16)
Saw chain: Oregon 91PX
Pitch mm (in.): ............................................9,53 (3/8)
Gauge mm (in.): .......................................1.27 (0.05)
Saw chain: Oregon 95VPX
Pitch mm (in.): ........................................8.26 (0.325)
Gauge mm (in.): .......................................1.27 (0.05)
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.
(4) Warning! Kickback it’s dan-
ger.
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
G3802/G3802EZ
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 operation.
19. Keep the handles dry, clean and free
of oil or fuel mixture.
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G3802/G3802EZ
G
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(1) cover (2) guide bar
(3) saw chain (4) nut
20. Operate the chain saw only in well
ventilated areas. Never start or run
the engine inside a closed room or
building and potentially explosive
atmosphere. 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 cover, guide bar, saw
chain or nut with bare hands while
the engine is in operation or immedi-
ately after shutting down the engine.
Doing so could result in serious burns
because of high temperature.
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 manufac-
turer 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.
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GB-6
G3802/G3802EZ
5. Explanation of Symbols on the Machine
The port to fuel “MIX GASOLINE”
Position: Beside Fuel cap
Theporttollwithchainoil
Position: Beside Oil cap
Setting the switch to the “O” position, the engine stops immediately.
Position: Beside rocker switch
Starting the engine. If you pull out the choke knob (at the back-right of the
rear handle) to the point of the arrow, you can set the starting mode as fol-
lows:
•“START”position–startingmodewhentheengineiswarm.
•“CHOKE”position–startingmodewhentheengineiscold.
Position: Upper-right of the aircleaner cover
The screw under the “H” stamp is The High-speed adjustment screw.
The screw under the “L” stamp is The Slow-speed adjustment screw.
The screw at the left of the “T” stamp is the Idle adjustment screw.
Position: Rear left side of the cylinder cover
The indication regarding the operating mode.
•“sun”mark–normaloperatingmode
•“snow”mark–anti-freezemode
Position: Icing cap located on the right hand side of the cylinder cover.
If you turn the rod by screwdriver follow the arrow to the "MAX" position, the
chainoilowmore,andifyouturntothe"MIN"position,less.
Position: Bottom of the power unit
Shows the directions that the chain brake is released (white arrow) and
activated (black arrow).
Position: Front of the chain cover
For safe operation and maintenance, symbols are carved in relief on the
machine.
According to these indications, please be careful not to make any mistake.
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G3802/G3802EZ
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6. Installing Guide Bar and Saw Chain
3. Fit the chain cover to the power unit and fasten the
nutstongertightness.
4. While holding up the tip of the bar, adjust the chain
tension by turning the tensioner screw until the tie
straps just touch the bottom side of the bar rail.
Tighten
Tensioner screw
Loosen
5. Tighten the nuts securely with the bar tip held up
(12 ~ 15 N·m). Then check the chain for smooth
rotation and proper tension while moving it by hand.
If necessary, readjust with the chain cover loose.
6. Tighten the tensioner screw.
Note: A new chain will expand its length in the beginning of use.
Check and readjust the tension frequently as a loose chain can
easily derail or cause rapid wear of itseif and the guide bar.
A standard saw unit package contains the items as illustrated.
Open the box and install the guide bar and the saw
chain on the power unit as follows:
The saw chain has very sharp edges. Use
thick protective gloves for safety.
1. Loosen the nuts and remove the chain cover.
2. Gearthechaintothesprocketand,whilettingthe
saw chain around the guide bar, mount the guide
bar to the power unit. Adjust the position of the chain
tensioner nut.
Tensioner nut
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/S16) +
Slotted driver)
Screwdriver for carburetor adjustment
(Slotted driver)
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GB-8
G3802/G3802EZ
7. Fuel and Chain Oil
■FUEL
WARNING
• Gasoline is very ammable.Avoid smoking or
bringinganyameorsparksnearfuel.Makesure
to stop the engine and allow it cool before refuel-
ing 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
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 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 25 : OIL 1
When Using Market Oil (JASO FB grade oil or
ISO-L-EGB grade oil)
GASOLINE 50 : OIL 1
When using ZENOAH genuine oil, JASO FD grade
oil or ISO-L-EGD grade oil
• Exhaust emission are controlled by the funda-
mental engine parameters and components (eq.,
carburation, ignition timing and port timing) with-
out addition of any major hardware or the introduc-
tion of an inert material during combustion.
• Theseenginesarecertiedtooperateonunleaded
gasoline.
• Make sure to use gasoline with a minimum octane
number of 89RON (USA/Canada: 87AL).
• If you use a gasoline of a lower octane value than
prescribed, there is a danger that the engine tem-
perature may rise and an engine problem such as
piston seizing may consequently occur.
• Unleaded gasoline is recommended to reduce the
contamination of the air for the sake of your health and
the environment.
• Poor quality gasolines or oils may damage sealing
rings, fuel lines or fuel tank of the engine.
■HOW TO MIX FUEL
•Payattentiontoagitation.
1. Measure out the quantities of gasoline and oil to be
mixed.
2. Put some of the gasoline into a clean, approved fuel
container.
3. Pour in all of the oil and agitate well.
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agi-
tation 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 ab-
normally 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
identi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atandbaregroundforfueling.
2. Move at least 10 feet (3 meters) away from the fueling
point before starting the engine.
3. Stop the engine before refueling the unit. At that time,
besuretosufcientlyagitatethemixedgasolinein
the container.
■FOR YOUR ENGINE LIFE, AVOID:
1. FUELWITHNOOIL(RAWGASOLINE)–Itwillcause
severe damage to the internal engine parts very
quickly.
2.
GASOHOL–Itcancausedeteriorationofrubberand/
or plastic parts and disruption of engine lubrication.
3. OILFOR4-CYCLEENGINEUSE–Itcancausespark
plug fouling, exhaust port blocking, or piston ring
sticking.
4. Mixed fuels which have been left unused for a
period of one month or more may clog the carbu-
retor and result in the engine failing to operate prop-
erly.
5. In the case of storing the product for a long period
of time, clean the fuel tank after rendering it empty.
Next, activate the engine and empty the carburetor
of the composite fuel.
6. In the case of scrapping the used mixed oil 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 influence are not covered by
the warranty. Also, be careful that, if the usage in the instruction
manual is not observed as to the mixed gasoline, etc. described
therein, it may not be covered by the warranty.
■CHAIN OIL
Use motor oil SAE #10W-30 all year round or SAE
#30 ~ #40 in summer and SAE #20 in winter.
Note: Do not use wasted or regenerated oil that can cause damage
to the oil pump.
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8. Operating the Engine
6. Whenenginehasignited,rstpushinthechokeknob
to “START” position and then pull the starter again to
start the engine.
7. Allow the engine to warm up with the throttle lever
pulled slightly.
At once pulling throttle lever out, the choke knob is
automatically returned to the “RUN” position.
Keep clear of the saw chain as it will start
rotatIng upon starting of engine.
■CHECKING THE OIL SUPPLY
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g-
ure.
Chain oil
Thechainoilowcanbechangedbyinsertingascrew-
driver in the hole on bottom of the clutch side. Adjust
according to your work conditions.
Rich
Lean
Chain oil flow
adjusting
Note: The oil tank should become nearly empty by the time fuel is
used up. Be sure to refill the oil tank every time when refueling the
saw.
■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operating
conditions.
Before adjusting the carburetor, make sure that the pro-
vided 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 attached.
It is very dangerous to run a chainsaw that
mounts broken parts or lacks any parts.
Before starting engine, make sure that all the parts
including bar and chain are installed properly.
■STARTING THE ENGINE
1. Fill fuel and chain oil tanks respectively, and tighten
the caps securely.
Chain oil
Fuel
2. Set the switch to “I” position.
3. Continuously push the priming bulb until fuel comes
in the bulb.
Switch
Throttle lever
Throttle
interlock
Priming bulb
4. Pull out the choke knob to “CHOKE” position. The
choke will close and the throttle lever will then be
set in the starting position.
Choke knob
CHOKE START RUN
Note: When restarting immediately after stopping the engine, set
the Choke knob in “START” position (choke open and throttle lever
in the starting position).
Note: Once the choke knob has been pulled out, it will not return
to “RUN” position even if you press down on it with your finger.
When you wish to return the choke knob to “RUN” position, pull
out the throttle lever instead.
5. While holding the saw unit securely on the ground,
pull the starter rope vigorously.
Do not start the engine while the chain saw
hangs in one hand. The saw chain may touch
your body. This in very dangerous.
01-G3802･3802EZ_GB_306＿三.indd 9 13.6.25 5:26:41 PM

GB-10
G3802/G3802EZ
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 number
of turn as shown below.
H needle : 13/8± 1/4
L needle : 11/4± 1/4
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 cut-
ting power, not for maximum speed.
■CHAIN BRAKE
This machine is equipped with an automatic brake to
stop saw chain rotation upon occurrence of kickback
during saw cutting. The brake is automatically operated
byinertialforce,whichactsontheweightttedinside
the front guard.
This brake can also be operated manually with the front
guard turned down to the guide bar.
To release the brake, pull up the front guard toward the
front handle till a “click” sound is heard.
[Caution]
Besuretoconrmbrakeoperationduringdailyinspec-
tion.
How to confirm:
1) Turn off the engine.
2) Holding the chain saw horizontally, release your hand
from the front handle, hit the tip of the guide bar to a
stumporapieceofwood,andconrmbrakeopera-
tion. Operating level varies by bar size.
In case the brake is not effective, ask our dealer for in-
spection and repairs.
If the engine keeps rotating at high speed with the brake
engaged, the clutch will overheat causing trouble.
When the brake engages during operation, immediately
release the throttle lever to stop the engine.
■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
Carburetor anti-freeze mechanism
Operatingchainsawsintemperaturesof0–5°Cattimes
of high humidity may result in ice forming within the
carburetor, and this in turn may cause the output power
of the engine to be reduced or for the engine to fail to
operate smoothly.
This product has accordingly been designed with a
ventilation hatch on the right side of the surface of the
cylinder cover to allow warm air to be supplied to the
engine and to thereby prevent icing from occurring.
Under normal circumstances the product should be used
in the normal operating mode, i.e., in the mode to which
it is set at the time of shipment. However when the pos-
sibility exists that icing may occur, the unit should be set
to operate in the anti-freeze mode before use. Please
switch between modes in the repair specialty store.
Normal operating mode Anti-freeze mode
Cylinder cover
“Sunshine” mark “Snow” mark
Continuing to use the product in the anti-
freeze mode even when temperatures have
risen and returned to normal, may result in
the engine failing to start properly or in the
engine failing to operate at its normal speed,
and for this reason you should always be sure
to return the unit to the normal operating mode
if there is no danger of icing occurring.
■
HOW TO SWITCH BETWEEN OPERATING MODES
1. Set the switch to the “O” position to stop the en-
gine.
2. Removetheaircleanercover,removetheairlter,
and then remove the choke knob from the cylinder
cover.
3. Loosen the screws holding the cylinder cover in place
(i.e., the three screws on the inside and the one screw
on the outside of the cover), and then remove the
cylinder cover.
4. Presswithyourngerdownontheicingcaplocated
on the right-hand side of the cylinder cover to remove
the icing cap.
5. Adjust the icing cap so that the ‘snow’ mark faces
upwards and then return it to its original position in
the cylinder cover.
6. Fix the cylinder cover back into its original position,
and then x all other parts back into their proper
positions.
Choke knob
Cylinder cover
Icing cap
01-G3802･3802EZ_GB_306＿三.indd 10 13.6.25 5:26:41 PM

GB-11
G3802/G3802EZ
G
B
9. Sawing
WARNING
• Beforeproceedingtoyourjob,
read the section “For Safe Op-
eration”. It is recommended to
first practice sawing easy logs.
This also helps you get accus-
tomed to your unit.
• Alwaysfollowthesafetyregula-
tions. The chain saw must only
be used for cutting wood. It is
forbidden to cut other types of
material. Vibrations and kick-
back vary with different materi-
als and the requirements of the
safety regulations would not be
respected. Do not use the chain
saw as a lever for lifting, mov-
ing or splitting objects. Do not
lock it over fixed stands. It is
forbidden to hitch tools or ap-
plications to the PTO other than
those specified by the manufac-
turer.
• Itisnotnecessarytoforcethesawintothecut.
Apply only light pressure while running the en-
gine at full throttle.
• When`e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 to 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.
01-G3802･3802EZ_GB_306＿三.indd 11 13.6.25 5:26:42 PM

GB-12
G3802/G3802EZ
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bottom.
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, finish 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
Dust on the cleaner surface can be removed by tapping
a corner of the cleaner against a hard surface. To clean
dirt in the meshes, split the cleaner into halves and brush
in gasoline. When using compressed air, blow from the
inside.
To assemble the cleaner halves, press the rim until it
clicks.
NOTE
Wheninstallingthemainlter,makesurethatthegrooves
onthelteredgearecorrectlytwiththeprojectionson
the cylinder cover.
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.
Grease the nose sprocket from the feeding port on the
tip of the bar.
Grease port
Sprocket
Oiling 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.
■PERIODICAL SERVICE POINTS
1. Cylinder fins
Dustcloggingbetweenthecylindernswillcauseover-
heating of the engine. Periodically check and clean the
cylindernsintherepairspecialtystore.
01-G3802･3802EZ_GB_306＿三.indd 12 13.6.25 5:26:43 PM

GB-13
G3802/G3802EZ
G
B
4. Spark plug
0.65 mm Champion : RCJ-7Y
NGK : BPM7Y or BPM7A
Clean the electrodes with a wire brush and reset the gap
to 0.65 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.
Placetheleonthecutterandpushstraightforward.
Keepthelepositionasillustrated.
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)
2. Fuel filter
(a)Usingawirehook,takeoutthelterfromthellerport.
Fuel filter
(b)Disassemble the lter and wash with gasoline, or
replace with a new one if needed.
Note:
• Afterremovingthelter,useapinchtoholdtheendofthesuctionpipe.
• Whenassemblingthelter,takecarenottoallowlterbersordust
inside the suction pipe.
3. Oil tank
Withawirehook,takeouttheoillterthroughtheller
portandcleaningasoline.Whenputtingthelterback
into the tank, make sure that it comes to the front right
corner. Also clean off dirt in the tank.
Oil filter
11. Maintenance of Saw Chain and Guide Bar
■Saw Chain
It is very important for smooth and safe op-
eration 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:
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 95VPX
File size: 5/32in (4.0mm) 3/16in (4.8mm)
01-G3802･3802EZ_GB_306＿三.indd 13 13.6.25 5:26:43 PM

GB-14
G3802/G3802EZ
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 kick-
back bar/chain combinations:
Zenoah Part Number
Saw Model Chain Type Guide Bar Saw Chain
G3802/G3802EZ 91PX 3608-52113 580703504
G3802/G3802EZ 95VPX 2939-52111 577266101
12. Troubleshooting Guide
Case 1. Starting failure
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.
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
Top plate cutting angle
■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
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.
󰾲
󰾯
󰾯
01-G3802･3802EZ_GB_306＿三.indd 14 13.6.25 5:26:43 PM

GB-15
G3802/G3802EZ
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-G3802･3802EZ_GB_306＿三.indd 15 13.6.25 5:26:44 PM

01-G3802･3802EZ_GB_306＿三.indd 16 13.6.25 5:26:44 PM