Zenoah EXZ2500S-BC, EX-BC, EX-LRT, EX-PS, EX-HE manual

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. W ARNING EXZ-PU 302845 and up EX-[...]

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. ■ WARNINGS IN THE MANUAL This mark indicates i[...]

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. Knob bolt 9. Spark arrester 10. Starter knob 11. Fuel tank 12. Primer pump 13. Choke lever 14.[...]

 4  2. Specifications Engine Type ······················································································ Air-cooled 2-stroke gasoline Model ···················································[...]

(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. If warning label peel off or become soiled and impossible to read, you should contact the dealer from which you purchased the product to order new lab[...]

 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. (a) The port to refuel the "MIX GASOLINE" Position: FUEL TANK CAP (b) The direction to close the choke Position: AIR CLEANER COVER (c) The direction to open the choke Position:[...]

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. ■ WO[...]

 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. When work is to be performed simultaneously by two or more p[...]

 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 it continues to rotate even after the throttle has been moved fully back, turn off the engine and ta[...]

• 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. ■ MAINTENANCE 1. [...]

 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. 3. When refilling the tank, always turn off the engine and allow [...]

■ 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. When difficult to [...]

 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. (SE1) (1) debris guard (2) plate (3) screw ■ INSTALLING CUTTING HEAD (SE2) 1. While locking the gear shaft, by inserting the supplied tool into the upper holder on the gear box, loose[...]

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. 3. Line up the hole on the end of the trimming mechanism into which the screw is to be inserted with the hole on the main pipe, and screw th[...]

 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. 4. Line up the hole on the end of the gear case into which the [...]

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. (SE3)(SE4) (1) Hole (2) Moving direction (3) Chain tensioner nut 4. Adjust the chain tension by turning the tensioner screw until the tie straps just touch the bottom side of the [...]

 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. Screw in the lock screw and fasten the clamp bolt firmly. (SE1) (1) Clamp bolt (2) Lock screw[...]

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. • These engines are certified to operate on unleaded ga[...]

 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. 5. Put a clear indication on t[...]

(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. ADJUSTING HANDLE POSITION • Loosen the handle bracket screws and re- position the handle to your best [...]

 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. (OP7) (1) choke lever (2) close (3) open (4) ignition switch (5) start (6) stop (7) throttle set button The product is equipped with a centrifugal clutch mechanism, so the cutting attachment [...]

• 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. When the engine tends stop frequently at idling mo[...]

 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. 2. Keep the debris guard in place at all times when the unit is operated. TRIMM[...]

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. Operation (Optional blade usage EX-BC only) ■ CHOOSE THE BLADE Choose a suitable recommended cutting attachment according to the obje[...]

 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.21~22). • The product is equipped with a centrifugal clutch mechanism, so the cutting attachm[...]

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. (OP7) • The rotating parts fastened incorrectly may cause s[...]

 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. Be ex[...]

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. 2. Round the root of the edge, using round file. 3. Do not use water when using a grinder. • [...]

 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. For this reason, you should always be careful to follow the following instructions when using your [...]

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. (OP1) (1) Chain oil The oil reservoir has a capacity sufficient to provide about 40 minutes of cutting time (when set to deliver the minimum flow rate, or about as long as you'll get[...]

 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. (b) Counte[...]

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. • Before starting a j[...]

 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.23) if necessary clea[...]

•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. Check and clean the filter element in warm, soapy water as required. Dry completely be[...]

 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. ■ SPARK ARRESTER • The muffler is equipped with a spark arrester to[...]

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. • If waste gets stuck and causes blockage around the intake air cooling vent or between the cylinder fins, it may cause the engine to overheat, and that in turn may cause mechanical failure on[...]

 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. Avoid using a larger line as it may cut down the trimming performance. For safety reasons,[...]

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. 1. Loosen lock nut (A) as shown in the diagram. 2. Tighten [...]

 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. (MA1) (1) Oiling port ■ GUIDE BAR Remove sawdust in the bar groove and the oiling port. (MA2) (1) Groove (2) Oiling port (Type: Sprocket nose) Grease the nose sprocket from the feeding port on the[...]

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.(MA4) (1) Ruler (2) Gap (3) No gap (4) Chain tilts ■ SPROCKET[...]

 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. (1) Appropriate gauge checker (2) Make the shoulder round (3) Depth gauge standard Make sure every cutter has [...]

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. • When removing and installing the cutter holder(a), [...]

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 carburetor adjustment screw ➞ out of normal range ➞ adjust to normal range sparking (no spark) ➞ spark plug is fouled/wet ➞ clean/dry ➞ plug gap [...]

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. 3. When placing parts orders for repair and/or replacement, check if the model name and th[...]

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. T3002-12202 1 12 • COVER[...]

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• SHAFT T3002-13210 1 8• GEAR 6440-13220 1 9• NUT, M10 T3002-13260 1 10 • PINION T3002-13310 1 11 • BEARING T3300-13531 1 12 • BEARING T3403[...]

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, carburetor 4810-13130 1 7 SCREW, M5x20 0263-90520 1 8 REEDVALVE (S) ASSY 4810-16100 1 9• VALVECASE (S) 4810-16110 1 10 • REEDVALVE 4810-16120 1 11 ?[...]

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 6782-13200 1 7• CASING A ––––––––– 1 8• PLATE 6782-13220 1 9 GREESE FITTING 3199-13350 3 10 LABEL 6782-13250 1 11 SCREW M4x8 0263-1040[...]

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 3199-13350 1 7 SCREW, tensioner T3073-13310 1 8 NUT, tensioner T3073-13320 1 9 BOLT 01252-30630 1 10 SHIM T3073-13250 1 11 BOLT 3245-11350 1 12 CHAIN COVER [...]

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• SHAFT 3541-13212 1 8• GEAR 6367-13130 1 9• PINION 6367-13140 1 10 • BEARING 06000-00609 1 11 • BEARING 06001-00609 1 12 • RING 04065-02412 1 [...]

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. EMISSION-RELATED PARTS ARE: TH[...]

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 gratuitement pour l'acheteur initial et chaque acheteur successif toute(s) pièce(s) se révélant de constitution et/ou de montage défectueux [...]

KOMATSU ZENOAH AMERICA INC. 4344 Shackleford Road Suite 500 Norcross, Georgia 30093 ©P rinted in Japan[...]