RedMax EXTREME EXZ2500S-BC Owner's/Operator's Manual
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RedMax EXTREME EXZ2500S-BC Owner's/Operator's Manual

RedMax EXTREME EXZ2500S-BC Owner's/Operator's Manual

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OWNER / OPERATOR MANUAL
EXZ2500S-BC
EX-LRT
WARNING
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects or other reproductive harm.
APPLICABLE SERIAL NUMBERS :
EXZ-PU
EX-BC
EX-LRT
EX-PS
EX-HE
EXtreme™
EX-BC
EX-PS
302845 and up
302960 and up
000531 and up
000000 and up
000101 and up
EX-HE
WARNING
Before using our products, please
read this manual carefully to
understand the proper use of your
unit.
ENGINE UNIT 352001 and up
T3087-93110 (303)

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  • Page 1 OWNER / OPERATOR MANUAL EXZ2500S-BC EX-LRT WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. APPLICABLE SERIAL NUMBERS : EXZ-PU 302845 and up EX-BC 302960 and up EX-LRT 000531 and up EX-PS...

  • Page 3: Table Of Contents

    SAFETY FIRST Instructions contained in warnings within this manual marked with a 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. ■...

  • Page 4: Parts Location

    1. Parts location EX-BC EX-LRT EX-PS EX-HE 4  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.

  • Page 5: Specifications

    2. Specifications Engine Type······················································································ Air-cooled 2-stroke gasoline Model········································································································ Zenoah GZ25N Displacement ······················································································· 1.6cu-in (25.4cm Max. output ··································································· 1.2Hp (0.9kW)at 7500/min Idle speed··························································································3000±200/min Fuel ······················································································· Mixture(Gasoline 50 : Oil 1) Carburetor ··················································································· Walbro Diaphragm type Spark plug·····································································································NGK CMR7A Fuel tank capacity·······························································································22.0 fl.oz (0.65 ) Durability period··················································································································300hrs.

  • Page 6: Warning Labels On The Machine

    3. Warning labels on the machine (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. IMPORTANT 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 labels and affix them in the required location(s).

  • Page 7: Symbols On The Machine

    4. Symbols on the machine IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS U.S. EPA PH2 AND 2001 CALIFORNIA EMISSION REGULATIONS FOR SI SORE’s COMPLIANCE PERIOD : CATEGORYA: ENGINE FAMILY : 1KZXS.0254QR ; EM ENGINE DISPLACEMENT : 25.4cc REFER TO OWNER’S MANUAL FOR MAINTE- NANCE SPECIFICATIONS AND ADJUSTMENTS.

  • Page 8: For Safe Operation

    5. For safe operation 8  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.
  • Page 9 5. For safe operation 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.
  • Page 10 5. For safe operation 10  ■ 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.
  • Page 11 5. For safe operation WARNING 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.
  • Page 12 ■ HANDLING FUEL 1. The engine of the RedMax product is designed to run on a mixed fuel which contains highly flammable gasoline. Never store cans of fuel or...
  • Page 13 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.

  • Page 14: Set Up

    6. Set up 14  ■ 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.
  • Page 15 6. Set up (EX-BC only) EX-BC EX-BC EX-BC ■ 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.
  • Page 16 6. Set up (EX-LRT only) EX-LRT 16  ■ 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 the screw firmly in.
  • Page 17 6. Set up (EX-PS only) EX-PS EX-PS EX-PS ■ 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.
  • Page 18 6. Set up (EX-PS only) EX-PS EX-PS EX-PS 18  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.
  • Page 19 6. Set up (EX-HE only) EX-HE EX-HE EX-HE EX-HE 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.

  • Page 20: Fuel

    3m(10ft) away from the fueling point before starting the engine. • The RedMax engines are lubricated by oil specially formulated for air-cooled 2-cycle gasoline engine use. If RedMax oil is not available, use an anti-oxidant added quality oil expressly labeled for air-cooled 2-cycle engine use.
  • Page 21 7. Fuel container to avoid mixing up with gasoline or other containers. 6. Indicate the contents on outside of container for easy identification. ■ FUELING THE UNIT 1. Untwist and remove the fuel cap. Rest the cap on a dustless place. 2.

  • Page 22: Operation

    8. Operation 22  (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.
  • Page 23 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 WARNING The product is equipped with a centrifugal...
  • Page 24 8. Operation .04 in (1~2mm) OP10 24  IMPORTANT • 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.
  • Page 25 8. Operation (EX-BC only) EX-BC ■ CUTTING WORK (LINE HEAD USAGE) WARNING 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.
  • Page 26 Choose a suitable recommended cutting attachment according to the object to be cut. • When replacing blade always be sure to use products which have been certified by RedMax. WARNING • When sharpening, removing, or reattaching the blade, be sure to wear thick, sturdy gloves and use only proper tools and equipment to prevent injury.
  • Page 27 8. Operation (Optional blade usage EX-BC only) EX-BC EX-BC EX-BC IMPORTANT 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.10~12), 8.Operation (P.22~23). WARNING •...
  • Page 28 • If you find any error to the blade, discard it and change new one which is certified by RedMax. ■ By using the shoulder strap, hang the unit on your right side. Adjust the strap length so that the cutting head may become parallel to the ground.(OP8)
  • Page 29 8. Operation (Optional blade usage EX-BC only) 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...
  • Page 30 8. Operation (Optional blade usage EX-BC only) EX-BC 30  ■ 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.
  • Page 31 • Never hold the trimmer in a way in which the blades are pointed towards someone else. • Never allow the blades to come into proximity with your body while the engine of the trimmer is in operation.
  • Page 32 8. Operation (EX-PS only) EX-PS EX-PS 32  ■ 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 NOTE 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...
  • Page 33 8. Operation (EX-PS only) IMPORTANT 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.
  • Page 34 3. When starting to edge, run the engine at full throttle, and slowly have the blade cut into the edge groove. NOTE • Do not use the EX-HE to make a new groove into the ground. Such usage will not be covered by RedMax Warranty.

  • Page 35: Maintenance

    9. Maintenance ■ MAINTENANCE CHART system/compornent fuel leaks, fuel spillage fuel tank, air filter, fuel filter idle adjusting screw spark plug cylinder fins, intake air cooling vent clean muffler, spark arrester, cylinder exhaust port clean throttle lever, ignition switch cutting parts gear case screws/nuts/bolts debris guard...
  • Page 36 Clean the spark plug and check that the plug gap is in the correct range. For a replacement plug, use the correct type specified by RedMax. (MA3) • REPLACEMENT PLUG IS A NGK CMR7A. IMPORTANT •...
  • Page 37 9. Maintenance ■ MUFFLER WARNING • 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.
  • Page 38 9. Maintenance 38  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. IMPORTANT • 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...
  • Page 39 9. Maintenance EX-BC EX-BC EX-BC EX-BC EX-BC (EX-BC only) ■ 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.
  • Page 40 If the blades become so worn down that it is no longer possible to eliminate the gap between them, you should contact the authorized RedMax servicing dealer from which you purchased your RedMax® trimmer to have the blades resharpened or replaced. ■ GEAR CASE reduction multipurpose, lithium-based grease in the gearcase.
  • Page 41 9. Maintenance EX-PS EX-PS EX-PS (EX-PS only) ■ 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...
  • Page 42 9. Maintenance EX-PS EX-PS EX-PS 42  (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.
  • Page 43 9. Maintenance EX-PS EX-PS EX-PS (EX-PS only) After every cutter has been set, check the depth gauge and file it to the proper level as illustrated. (MA7) WARNING 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...
  • Page 44 9. Maintenance 44  (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.

  • Page 45: Storage

    10. Storage • Aged fuel is one of major causes of engine starting failure. Before storing the unit, empty the fuel tank and run the engine until it uses all the fuel left in the fuel line and the carburetor. Store the unit indoor taking necessary measures for rust prevention.

  • Page 46: Troubleshooting Guide

    (exhaust port) ➞ carbon is built-up air cleaner cylinder fin, fan cover When your unit seems to need further service, please consult with our RedMax service shop in your area. 46  PROBABLE CAUSES ➞ incorrect fuel ➞...

  • Page 47: Parts List

    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.
  • Page 48 12. Parts list Fig.1 EXZ-PU (S/N 302845 and up) 48 ...
  • Page 49 Fig.1 EXZ-PU (S/N 302845 and up) Key# Description 1 PIPE-COMP, ø24x750 2 SHAFT, 786x7 3 SPACER 4 JOINT, PIPE-ASS’Y 5 • JOINT 6 • KNOBBOLT 7 • WASHER 8 • BOLT 9 • BOLT 10 GRIP 11 LEVER-COMP 12 • COVER COMP 13 •...
  • Page 50 12. Parts list Fig.2 EX-BC (S/N 302960 and up) 50 ...
  • Page 51 • • SCREW • • NUT • PLATE • BOLT TAP. HEAD 4" • CASE • CORD HOLDER • COVER • SPRING • TRIMMER LINE • PLATE, large • PLATE, small HOLDER (B) PIPE-COMP, ø24x750 SHAFT, 755x7 SHAFT-JOINT SPACER PLATE-NAME...
  • Page 52 12. Parts list Fig.3 ENGINE UNIT (352001 and up) 52 ...
  • Page 53 Fig.3 ENGINE UNIT (352001 and up) Key# Description CYLINDER GASKET, base BOLT, M5x22 INSULATOR GASKET, insulator GASKET, carburetor SCREW, M5x20 REEDVALVE (S)-A • VALVECASE (S) • REEDVALVE • STOPPER • SCREW, M3x8 PIRE AIR (S) REEDVALVE (F)-A • VALVECASE (F) •...
  • Page 54 12. Parts list Fig.4 EX-LRT (S/N 000531 and up) 54 ...
  • Page 55 Fig.4 EX-LRT (S/N 000531 and up) Key# Description LEVER, clamp WASHER M6 WASHER 6x15x2.0 ANGLE ADJUSTER BOLT M6x12 CASING A SET • CASING A • PLATE GREESE FITTING LABEL SCREW M4x8 COVER SNAP RING BEBEL GEAR SNAP RING BEARING CRANK SHAFT SNAP RING BLADE BEARING 608Z...
  • Page 56 12. Parts list Fig.5 EX-PS (S/N 000000 and up) 56 ...
  • Page 57 Fig.5 EX-PS (S/N 000000 and up) Key# Description GEAR CASE (L)COMP T3073-13100 • BEARING GEAR CASE (R)COMP T3073-13200 • BEARING BOLT FITTING SCREW, tensioner NUT, tensioner BOLT SHIM BOLT CHAIN COVER WORM GEAR OIL PUMP ASS’Y SCREW GASKET OIL PIPE ASS’Y •...
  • Page 58 12. Parts list Fig.6 EX-HE (S/N 000101 and up) 58 ...
  • Page 59 Fig.6 EX-HE (S/N 000101 and up) Key# Description GEARCASE-ASS’Y • GEARCASE • O-RING • BEARING • SEAL • RING • SHAFT • GEAR • PINION • BEARING • BEARING • RING • RING • BOLT • WASHER • WASHER • BOLT •...
  • Page 60 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and KOMATSU ZENOAH are pleased to explain the emission control system warranty on your 1995 and later small off-road engine. In California, new small off-road engines must be designed, built and equipped to meet the state’s stringent anti-smog standards.
  • Page 61 ZENOAH AMERICA INC. AT (770)-381-5147. IMPORTANT: YOU WILL RECEIVE A WARRANTY REGISTRATION CARD AT TIME OF PURCHASE.PLEASE FILL OUT THE CARD AND SEND IT TO RedMax / KOMATSU ZENOA AMERICA WITHIN SEVEN (7) DAYS.BE SURE TO KEEP A COPY FOR YOUR RECORDS.
  • Page 62 à compter de la date de livraison initiale d’une unité. Telles sont les limites de la garantie. Le coût du transport de l'unité jusqu'au revendeur RedMax et depuis celui-ci sera à la charge de l'acheteur. L'acheteur ne supportera pas le coût de main d'oeuvre du diagnostic qui amène à la conclusion qu'une pièce garantie est défectueuse, si ce diagnostic est effectué...
  • Page 64 KOMATSU ZENOAH AMERICA INC. 4344 Shackleford Road Suite 500 Norcross, Georgia 30093 © Printed in Japan...

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