Instruction/ maintenance manual of the product EXZ2500S-BC, EX-BC, EX-LRT, EX-PS, EX-HE Zenoah
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OWNER / OPERA T OR MANUAL EXtreme™ 848-BP6-93A1 (501) The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. W ARNING Before using our products, please read this manual carefully to understand the proper use of your unit.
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 carefully and follow them without fail.
1. Parts location EX-BC EX-PS EX-LRT EX-HE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 1. Loop handle 2. Shoulder strap hanger 3. Ignition switch 4. Throttle cable 5. Throttle lever 6. Throttle set button 7. Drive shaft housing 8.
4 2. Specifications Engine Type ················································································.
(1) Read owner's manual before operating this machine. (2) Wear head, eye and ear protection. (3) Warning/Attention (4) Keep all children, bystanders and helpers 15 meters away from the machine.
6 For safe operation and maintenance, symbols are carved in relief on the machine. According to these indications, please be careful not to make a mistake.
5. For safe operation 1. Read this manual carefully until you completely understand and follow all safety and operating instructions. 2. Keep this manual handy so that you may refer to it later whenever any questions arise. Also note, if you have any questions which cannot be answered herein, contact the dealer from whom you purchased the product.
b. At night, at times of heavy fog, or at any other times when your field of vision might be limited and it would be difficult to gain a clear view of the working area. c. During rain storms, during lightning storms, at times of strong or gale-force winds, or at any other times when weather conditions might make it unsafe to use the product.
9 ■ BEFORE STARTING THE ENGINE 1. The area within a perimeter of 50 feet (15m) of the person using the product should be considered a hazardous area into which no one should enter. If necessary yellow warning rope, warning signs should be placed around the perimeter of the area.
10 Never place the throttle into the high speed position when starting the engine. 3. After starting the engine, check to make sure that the cutting attachment stops rotating when the throttle is moved fully back to its original position.
• IF SOMEONE COMES 1. Guard against hazardous situations at all times. Warn adults to keep pets and children away from the area. Be careful if you are approached. Injury may result from flying debris. 2. If someone calls out or otherwise interrupts you while working, always be sure to turn off the engine before turning around.
12 5. For safe operation refill the tank of the unit in any place where there is a boiler, stove, wood fire, electrical sparks, welding sparks, or any other source of heat or fire which might ignite the fuel. 2. Never smoke while operating the unit or refilling its fuel tank.
■ MOUNTING ENGINE (SE1) 1. Push the driveshaft housing toward the clutch housing and rotate it by hand to check that the driveshaft is engaged with the gears. 2. Insert the driveshaft housing into the clutch housing until it bottoms, and align the positioning holes on the clutch housing and the shaft tube and install the screw.
14 6. Set up (EX-BC only) EX-BC SE2 ■ INSTALLING DEBRIS GUARD • Put the debris guard on the gear box, attach it with the 4 screws and hardware provided.
6. Set up (EX-LRT only) EX-LRT SE1 ■ ATTACHING THE TRIMMING MECHANISM (SE1) 1. Remove the screw screwed into the end of the trimming mechanism. 2. Insert the end of the trimming mechanism into the main pipe.
16 6. Set up (EX-PS only) (1) (2) (3) (4) (5) EX-PS SE1 EX-PS SE2 EX-PS SE3 ■ ATTACHING THE PRUNING MECHANISM (SE1) 1. Remove the cap on the end of the main pipe. 2. Remove the screw screwed into the end of the gear case. 3. Insert the end of the gear case into the main pipe.
6. Set up (EX-PS only) 3. Fit the chain tensioner nut into the lower hole of the guide bar, then install the chain cover, and fasten the mounting nut to finger tightness.
18 6. Set up (EX-HE only) EX-HE SE1 EX-HE SE2 EX-HE SE3 EX-HE SE4 1. Insert the driveshaft into the clutch drum, then attach the gearbox to the shaft tube as aligning the positioning holes. Wipe out grease on the tube and the inside of the gearbox.
7. Fuel ■ RECOMMENDED MIXING RATIO GASOLINE 50:OIL 1 • Exhaust emission are controlled by the fundamental engine parameters and components(eq., carburation, ignition timing and port timing) without addition of any major hardware or the introduction of an inert material during combustion.
20 7. Fuel again for at least one minute. As some oils may be difficult to agitate depending on oil ingredients, sufficient agitation 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 abnormally lean mixture.
(EX-HE only) ■ STARTING ENGINE The RedMax stick edger is designed for edging lawn in gardens, parks, roadsides and so on. Before starting the engine, take the operating position and adjust the handle position and the wheel height as necessary.
22 8. Operation lever is in to the “start” position. (OP6) 6. While holding the unit firmly, pull out the starter rope quickly until engine fires.
• Except for an emergency, avoid stopping the engine while pulling the throttle lever. ■ ADJUSTING THROTTLE CABLE • The normal play is 1 or 2mm when measured at the carburetor side end. Readjust with the cable adjuster as required. (OP9) (1) cable adjuster ■ ADJUSTING IDLING SPEED (OP10) 1.
24 8. Operation (EX-BC only) EX-BC OP1 ■ CUTTING WORK (LINE HEAD USAGE) 1. Always wear eye protection such as safety goggles. Never lean over the rotating cutting head. Rocks or other debris could be thrown into eyes and face and cause serious personal injury.
Under growth Heavy weeds Light weeds Grass Nylon line head CUTTER APPLICATION CHART 9” 22-tooth: SST229 9” 24-tooth: SST249 8” 8-tooth: SGB088 9” 8-tooth: SGB089 8” 4-tooth: SGB048 9” 4-tooth: SGB049 8.
26 8. Operation (Optional blade usage EX-BC only) Change the loop handle to the J-handle for safe operation. (OP4) (1) Bracket: 3583-14101 (2) J-handle: 6367-14200 ■ STARTING THE ENGINE Please refer 5.For safe operation (P.9~11), 8.Operation (P.
8. Operation (Optional blade usage EX-BC only) ■ OPERATION 1. Check the bolt to fasten the blade and be sure the bolt has no fault, and no abrasion. 2. Be sure that the blade and the holder have been fastened according to instruction and the blade turns smoothly without abnormal noise.
28 2. How you can reduce the chance of kick out: a. Recognize that kick out can happen. By understanding and knowing about bounce, you can help eliminate the element of surprise. b. Cut fibrous weeds and grass only. Do not let the blade contact materials it cannot cut such as hard, woody vines and brush or rocks, fences, metal, etc c.
8. Operation (Optional blade usage EX-BC only) EX-BC OP9 ■ MAINTENANCE BLADE • Check the blade and the fasteners for looseness, cracking, or bending. • Check the cutting edges and reform with a flat file. Point (OP9) : 1. Keep the end corner sharp.
30 8. Operation (EX-LRT only) This product is equipped with extremely sharp blades, and when used improperly these blades can be extremely dangerous, and improper handling can cause accidents which may in turn lead to serious injury or death.
EX-PS OP1 EX-PS OP2 ■ CHECKING OIL SUPPLY After starting the engine, run the chain at medium speed and see if chain oil is scattered off as shown in the figure.
32 8. Operation (EX-PS only) The oil flow adjusting screw must be pressed in slightly in order to turn. Failure to do so could damage the pump and screw. 3. With a screwdriver, push in on the oil flow rate adjusting screw and turn in the desired direction (there are three incremental settings): (a) Clockwise-decrease lubrication.
EX-HE OP1 8. Operation (EX-HE only) • Always wear eye protection such as safety goggles. Never lean over the rotating cutting head. Rocks or other debris could be thrown into eyes and face and cause serious personal injury. • Keep the blade guard and the mad guard attached in place at all times when the unit is operated.
34 9. Maintenance every every every 25 50 100 system/compornent procedure before hours hours hours note use after after after fuel leaks, fuel spillage wipe out ✔ fuel tank, air filter, fuel filter inspect/clean ✔✔ replace, if necessary see ■ ADJUSTING replace carburetor idle adjusting screw ✔ IDLING SPEED (p.
•M ake sure that the engine has stopped and is cool before performing any service to the machine. Contact with moving cutting head or hot muffler may result in a personal injury. ■ AIR FILTER • The air filter, if clogged, will reduce the engine performance.
36 ■ MUFFLER • Inspect periodically, the muffler for loose fasteners, any damage or corrosion. If any sign of exhaust leakage is found, stop using the machine and have it repaired immediately. • Note that failing to do so may result in the engine catching on fire.
9. Maintenance brushcutter. Note that it is necessary to remove the engine cover shown in (MA5) in order to be able to view the upper part of the cylinder.
38 9. Maintenance (EX-BC only) EX-BC MA1 EX-BC MA2 EX-BC MA3 EX-BC MA4 ■ REFILLING TRIMMING LINE 1. For replacement line, use a diameter of .095 in(2.4mm). The spool is capable for a line upto 27ft(8m)on the 4” head, and 46ft(14m)on the 6” head.
9. Maintenance (EX-LRT only) ■ BLADES (MA1) •W hen refilling the tank or resting, it is often a good idea to use the time to oil the cutting blades. • If a gap exists between the upper and lower blades, follow the procedure below to adjust them so that they fit more closely together.
40 9. Maintenance (EX-PS only) (1) EX-PS MA1 EX-PS MA2 EX-PS MA3 ■ OILING PORT Dismount the guide bar and check the oiling port for clogging.
9. Maintenance (EX-PS only) The bar rail should always be a 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.
42 9. Maintenance (EX-PS only) After every cutter has been set, check the depth gauge and file it to the proper level as illustrated. (MA7) Be sure to round off the front edge to reduce the chance of kickback or tie-strap breakage.
9. Maintenance (EX-HE only) ■ GEAR CASE • The reduction gears are lubricated by multipurpose, lithium-based grease in the gear case. At every 20 hours of use, supply the gear case with new grease. • Remove the cutter holders before installing new grease to arrange for old grease to exit.
11 . T roubleshooting guide Case 1. Starting failure CHECK PROBABLE CAUSES ACTION fuel tank ➞ incorrect fuel ➞ drain it and with correct fuel fuel filter ➞ fuel filter is clogged ➞ clean carbu.
12. Parts list NOTE : 1. Use KOMATSU ZENOAH genuine parts as specified in the parts list for repair and/or replacement. 2. KOMATSU ZENOAH does not warrant the machines, which have been damaged by the use of any parts other than those specified by the company.
12. Parts list 46 Fig.1 EXZ-PU (S/N 302845 and up).
Key# Description Part Number Q'ty 1 PIPE COMP., ø24x750 T3075-12100 1 2 SHAFT, 786x7 T3075-12210 1 3 SPACER 6036-12250 1 4 JOINT, PIPE-ASS’Y T3087-12400 1 5• JOINT T3087-12410 1 6• KNOBBOLT 6036-12420 1 7• WASHER 01643-30823 1 8• BOLT 01252-30510 1 9• BOLT 3540-13260 1 10 GRIP 3577-32141 1 11 LEVER COMP.
12. Parts list 48 Fig.2 EX-BC (S/N 302960 and up).
Key# Description Part Number Q'ty 1 GEARCASE ASSY T3002-13001 1 2• GEARCASE 6489-13110 1 3• BEARING T3300-13521 1 4• BEARING T3403-13510 1 5• RING 04065-02612 1 6• SEAL 3565-13130 1 7.
Fig.3 ENGINE UNIT (50100000 and up) 50 12. Parts list.
51 Key# Description Part Number Q'ty 1 CYLINDER 4810-12111 1 2 GASKET, base 4810-12210 1 3B OLT, M5x22 1850-12130 2 4 INSULATOR 4810-13162 1 5 GASKET, insulator 4810-13120 1 6G ASKET, car.
12. Parts list 52 Fig.4 EX-LRT (S/N 000531 and up).
Key# Description Part Number Q'ty 1 LEVER, clamp 6598-13110 1 2 WASHER M6 0290-20615 1 3 WASHER 6x15x2.0 6782-13650 1 4 ANGLE ADJUSTER 6782-13141 1 5 BOLT M6x12 0225-10612 2 6 CASING A SET 6782-1.
12. Parts list 54 Fig.5 EX-PS (S/N 000000 and up).
Key# Description Part Number Q'ty 1 GEAR CASE (L)COMP. T3073-13100 1 2• BEARING 06004-06001 1 3 GEAR CASE (R)COMP. T3073-13200 1 4• BEARING 06002-00627 1 5 BOLT 01252-30512 5 6 FITTING 3199-1.
12. Parts list 56 Fig.6 EX-HE (S/N 000101 and up).
Key# Description Part Number Q'ty 1 GEARCASE ASSY 6367-13000 1 2• GEARCASE 6367-13110 1 3• O-RING 6367-13150 1 4• BEARING 06000-06201 1 5• SEAL 3180-13141 1 6• RING 04065-03212 1 7• S.
EMISSION-RELATED PARTS, FOR TWO (2) YEARS FROM THE DATE OF ORIGINAL DELIVERY OF THE UNIT, KOMATSU ZENOAH AMERICA INC. (THE COMPANY), THROUGH ANY RedMax DEALER, WILL REPAIR OR REPLACE, FREE OF CHARGE, FOR THE ORIGINAL AND EACH SUBSEQUENT PURCHASER, ANY PART OR PARTS FOUND TO BE DEFECTIVE IN MATERIAL AND/OR WORKMANSHIP.
Pièces en rapport avec les émissions de gaz d'échappement : KOMATSU ZENOAH AMERICA INC., par l'intermédiaire de n'importe quel revendeur RedMax, réparera gratuitement ou remplacera.
KOMATSU ZENOAH AMERICA INC. 4344 Shackleford Road Suite 500 Norcross, Georgia 30093 ©P rinted in Japan.
An important point after buying a device Zenoah EXZ2500S-BC, EX-BC, EX-LRT, EX-PS, EX-HE (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Zenoah EXZ2500S-BC, EX-BC, EX-LRT, EX-PS, EX-HE yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Zenoah EXZ2500S-BC, EX-BC, EX-LRT, EX-PS, EX-HE - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Zenoah EXZ2500S-BC, EX-BC, EX-LRT, EX-PS, EX-HE you will learn all the available features of the product, as well as information on its operation. The information that you get Zenoah EXZ2500S-BC, EX-BC, EX-LRT, EX-PS, EX-HE will certainly help you make a decision on the purchase.
If you already are a holder of Zenoah EXZ2500S-BC, EX-BC, EX-LRT, EX-PS, EX-HE, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Zenoah EXZ2500S-BC, EX-BC, EX-LRT, EX-PS, EX-HE.
However, one of the most important roles played by the user manual is to help in solving problems with Zenoah EXZ2500S-BC, EX-BC, EX-LRT, EX-PS, EX-HE. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Zenoah EXZ2500S-BC, EX-BC, EX-LRT, EX-PS, EX-HE along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
