Zenoah EXtreme EXZ2500S-BC, EX-BC, EX-LRT, EX-PS, EX-HE Owner's/Operator's Manual
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Zenoah EXtreme EXZ2500S-BC, EX-BC, EX-LRT, EX-PS, EX-HE Owner's/Operator's Manual

Zenoah EXtreme EXZ2500S-BC, EX-BC, EX-LRT, EX-PS, EX-HE Owner's/Operator's Manual

Zenoah brush cutter owner'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 50100000 and up
848-BP6-93A1 (501)

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Summary of Contents for Zenoah EXtreme EXZ2500S-BC, EX-BC, EX-LRT, EX-PS, EX-HE

  • 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 2: 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 3: Parts Location

    1. Parts location EX-BC EX-LRT EX-PS EX-HE 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 4: 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 5: 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 6: Symbols On The Machine

    4. Symbols on the machine IMPORTANT ENGINE INFORMATION THIS ENGINE CONFORMS TO 2005 U.S. EPA REGULATIONS FOR SMALL NONROAD ENGINES. COMPLIANCE PERIOD : CATEGORY A ENGINE FAMILY : 5KZXS.0254QR ; EM ENGINE DISPLACEMENT : REFER TO OWNER’S MANUAL FOR MAINTE- NANCE SPECIFICATIONS AND ADJUSTMENTS.

  • Page 7: For Safe Operation

    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.
  • Page 8 5. For safe operation 8  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.
  • Page 9 5. For safe operation ■ 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 10 5. For safe operation 10  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 11 5. For safe operation • 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.
  • Page 12 5. For safe operation 12  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.

  • Page 13: Set Up

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

    7. Fuel WARNING • Gasoline is very flammable. Avoid smoking or bringing any flame or sparks near fuel. Make sure to stop the engine and allow it cool before refueling the unit. Select outdoor bare ground for fueling and move at least 3m (10ft) away from the fueling point before starting the engine.
  • Page 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.

  • Page 21: Operation

    8. Operation (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 •...
  • Page 22 8. Operation 22  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 23 8. Operation .04 in (1~2mm) OP10 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 24 8. Operation (EX-BC only) EX-BC 24  ■ 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 25 8. Operation (Optional blade usage EX-BC only) CUTTER APPLICATION CHART Under growth Heavy weeds Light weeds Grass EX-BC EX-BC 9” 22-tooth: 8” 8-tooth: SST229 SGB088 9” 24-tooth: 9” 8-tooth: SST249 SGB089 ■ CHOOSE THE BLADE Choose a suitable recommended cutting attachment according to the object to be cut.
  • Page 26 8. Operation (Optional blade usage EX-BC only) EX-BC EX-BC EX-BC 26  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.9~11), 8.Operation (P.21~22).
  • Page 27 8. Operation (Optional blade usage EX-BC only) EX-BC EX-BC ■ 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.
  • Page 28 8. Operation (Optional blade usage EX-BC only) 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.
  • Page 29 8. Operation (Optional blade usage EX-BC only) EX-BC ■ 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 30 8. Operation (EX-LRT only) EX-LRT 30  WARNING 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 trimmer.
  • Page 31 8. Operation (EX-PS only) EX-PS EX-PS ■ 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 you'll get from a tank of fuel).
  • Page 32 8. Operation (EX-PS only) 32  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 33 8. Operation (EX-HE only) EX-HE WARNING • 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.

  • Page 34: Maintenance

    9. Maintenance Maintenance, replacement, or repair of the emission control device and systems may be performed by any non-road engine repair establishment or individual. ■ 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...
  • Page 35 9. Maintenance .025 in 0.655mm WARNING • Make 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 •...
  • Page 36 9. Maintenance 36  ■ 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 37 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. 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 failure on the part of the brushcutter.
  • Page 38 9. Maintenance EX-BC EX-BC EX-BC EX-BC EX-BC 38  (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.
  • Page 39 9. Maintenance EX-LRT EX-LRT (EX-LRT only) ■ BLADES (MA1) • When 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.
  • Page 40 9. Maintenance EX-PS EX-PS EX-PS 40  (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)
  • Page 41 9. Maintenance EX-PS EX-PS EX-PS (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 42 9. Maintenance EX-PS EX-PS EX-PS 42  (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.
  • Page 43 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.

  • Page 44: Storage

    10. Storage 11. Troubleshooting guide Case 1. Starting failure CHECK fuel tank fuel filter carburetor adjustment screw ➞ sparking (no spark) spark plug Case 2. Engine starts but does not keep running/Hard re-starting. CHECK fuel tank carburetor adjustment screw muffler,cylinder (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.

  • Page 45: 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.
  • Page 46 12. Parts list Fig.1 EXZ-PU (S/N 302845 and up) 46 ...
  • Page 47 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 •...
  • Page 48 12. Parts list Fig.2 EX-BC (S/N 302960 and up) 48 ...
  • Page 49 Fig.2 EX-BC (S/N 302960 and up) Key# Description GEARCASE ASSY • GEARCASE • BEARING • BEARING • RING • SEAL • SHAFT • GEAR • NUT, M10 • PINION • BEARING • BEARING • RING • RING • BOLT • BOLT •...
  • Page 50 12. Parts list Fig.3 ENGINE UNIT (50100000 and up) 50 ...
  • Page 51 Fig.3 ENGINE UNIT (50100000 and up) Key# Description CYLINDER GASKET, base BOLT, M5x22 INSULATOR GASKET, insulator GASKET, carburetor SCREW, M5x20 REEDVALVE (S) ASSY • VALVECASE (S) • REEDVALVE • STOPPER • SCREW, M3x8 PIRE AIR (S) REEDVALVE (F) ASSY • VALVECASE (F) •...
  • Page 52 12. Parts list Fig.4 EX-LRT (S/N 000531 and up) 52 ...
  • Page 53 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 54 12. Parts list Fig.5 EX-PS (S/N 000000 and up) 54 ...
  • Page 55 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 ASSY SCREW GASKET OIL PIPE ASSY •...
  • Page 56 12. Parts list Fig.6 EX-HE (S/N 000101 and up) 56 ...
  • Page 57 Fig.6 EX-HE (S/N 000101 and up) Key# Description GEARCASE ASSY • GEARCASE • O-RING • BEARING • SEAL • RING • SHAFT • GEAR • PINION • BEARING • BEARING • RING • RING • BOLT • WASHER • WASHER •...

  • Page 58: Limited Warranty

    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.
  • Page 59 ZENOAH AMERICA INC. au (770)-381-5147 Note importante: vous recevrez une carte d'enregistrement de garantie au moment de l'achat. Veuillez la remplir et l'adresser à RedMax / KOMATSU ZENOAH AMERICA sous sept (7) jours en prenant soin de conserver une copie pour vous.
  • Page 60 KOMATSU ZENOAH AMERICA INC. 4344 Shackleford Road Suite 500 Norcross, Georgia 30093 © Printed in Japan...

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