Zenoah HC510DV Owner's/Operator's Manual
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Zenoah HC510DV Owner's/Operator's Manual

Zenoah HC510DV Owner's/Operator's Manual

Zenoah cut-off saw owner's manual
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OWNER / OPERATOR MANUAL
Dust Collection Type
WARNING
Diamond wheel use only, Do not use
abrasive wheels with this product.
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 :
CUT-OFF SAW
HC510DV
200101 and up
WARNING
Before using our products, please
read this manual carefully to
understand the proper use of your
unit.
848-C8X-93A1 (60 )

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  • Page 1 State of California to cause cancer, birth defects or other reproductive harm. APPLICABLE SERIAL NUMBERS : CUT-OFF SAW HC510DV Before using our products, please read this manual carefully to understand the proper use of your unit.

  • 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 2. Specifications Model Name and Number ···································································CUT-OFF SAW, HC510DV Overall Size (with 14 in. Blade)(LxWxH) ························· 29.4(735)x9.4(235)x19.8(495) in. (mm) Dry Weight (excluding Blade) ··············································································· 29.0 lbs (13 kg) Engine Type ··············································· Single-Cylinder Air-Cooled 2-Cycle Gasoline Engine Displacement ······················································································ 3.1cu-in. (49.3cm Max.

  • Page 5: Warning Labels On The Machine

    3. Warning labels on 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). WARNING Never modify your machine.

  • Page 6: Symbols On The Machine

    4. Symbols on the machine IMPORTANT ENGINE INFORMATION THIS ENGINE CONFORMS TO U.S. EPA PH1 FOR SMALL OFF-ROAD ENGINES. ENGINE FAMILY : 3KZXS. 0494LM ; EM ENGINE DISPLACEMENT : 49.3cm REFER TO OWNER’S MANUMAL FOR MAINTE- NANCE SPECIFICATIONS AND ADJUSTMENTS. MANUFACTURED: RedMax Made in Japan...

  • Page 7: For Safe Operation

    5. For safe operation ■ BEFORE USING THE MACHINE a. Cut-off saws are high-speed cutting tools and very dangerous to operate; therefore it is very important that you read and fully understand the contents of the owner’s manual before using. b.
  • Page 8 5. For safe operation 8  exposes the operator to Whitefinger disease. This condition produces numerous burning sensations and interferes with the ability to feel and regulate temperature. Get medical advise at once if you experience these symptoms. h. Be sure to keep this manual handy so that you may refer to it later whenever any questions arise.
  • Page 9 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 10: Operation Safety Precautions

    5. For safe operation 10  the other one’s presence and how to sign the danger etc. d. Fix the cutting object if it is unfixed. e. Never operate the engine without wheel guard. f. Adjust the wheel guard to deflect sparks, dust, and material away from the operator and flammable materials.

  • Page 11: After Using The Saw

    5. For safe operation i. Do not cut above shoulder height. j. If someone calls out while working or if you wish to continue work in another spot, or if you want to check the unit, always be sure to turn off the engine before making your next move.

  • Page 12: Set Up

    6. Set up 12  WARNING Use adequate cutter blades suited to materials to be cut. Use of inadequate cutter blades may cause irregular wear of blades, poor cutting performances, or irregular overheating, etc. Continuance of those inadequate operations may damage the blades and cause serious accidents.
  • Page 13 6. Set up ■ MOUNTING OF CUTTER BLADE WARNING The flange bolt shall be securely fixed. (Fixing torque: 266~434 in-lbs (30~50 N·m)) Insufficient fixing of the bolt may cause brake away of the blade and is extremely dangerous. 1. Unscrew a flange bolt and remove flange washer (A).

  • Page 14: Fuel

    OIL or ISO EGC GRADE) • Do not use BIA or TCW (2-stroke water- cooling type) mixed oil. 14  ■ RECOMMENDED MIXING RATIO GASOLINE 50:OIL 1 (when using ZENOAH genuine oil) 50:1 MIXING CHART GASOLINE gal. 2-CYCLE OIL fl.oz 2.6 GASOLINE...

  • Page 15: Fueling The Unit

    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 16: Operation

    8. Operation 16  ■ STARTING ENGINE WARNING • Before starting the engine, check if there is any problem such as loose fitting of cutter blade or fuel leakages. • Place the machine on the ground and hold securely when starting. Do not start the engine while hanging it by one hand because the cutter blade may contact with the ground or other obstacles.
  • Page 17 8. Operation NOTE In case of restarting immediately after stopping the engine, pull the starter knob with the choke knob pushed in (choke open). 4. Push in a decomp valve on right side of the machine. (OP3) (1) Decomp valve NOTE In case a starter rope felt to be heavy, check if the decomp valve is pushed in.

  • Page 18: Stopping Engine

    8. Operation 18  In case of cold start of the engine, apply 1~2 minutes of warming up operation before use. ■ STOPPING ENGINE WARNING • In an emergency, immediately stop the engine. • Even after stopping the engine, the cutter blade continues to turn awhile by inertia.
  • Page 19 8. Operation ■ CUTTING OPERATION • For cutting, hold the machine in your body centre and lead the dust hose through both legs. Lightly bend the knees and keep a stable posture. • When applying the cutter blade to a work, start with low speed to form a guide notch, and then cut with full throttle.

  • Page 20: Maintenance

    9. Maintenance 20  Maintenance, replacement, or repair of the emission control device and systems may be performed by any non-road engine repair establishment or individual. WARNING • Be sure to stop the engine for check and maintenance. • Do not modify the machine nor disassemble the engine.
  • Page 21 9. Maintenance 0.6~0.7mm IMPORTANT • Clogging of air filter reduces engine performances. Inside of an engine will quickly wear by dusts if an air cleaner cover is not correctly fitted or if a filter is missed, deformed, or damaged. • Avoid dusts to penetrate into the engine when removing the air filter.
  • Page 22 9. Maintenance 22  IMPORTANT In case the fuel filter is clogged or the fuel pipe is bent, engine speed may not increase or may become unstable. ■ COOLING AIR PASSAGE WARNING • Do not touch the cylinder, muffler or spark plug by bare hands immediately after stopping the engine.

  • Page 23: Disassembling Procedure

    9. Maintenance This machine is equipped with a spring loaded semi-automatic tensioner. Therefore, by slackening cutting head fixing nuts and bolts, correct tension is always maintained. (MA6) Apply following procedures if readjustment is required: (1) Cutting head (2) Spring (3) Drive case 1.

  • Page 24: Assembling Procedure

    9. Maintenance MA10 MA11 MA12 MA13 24  3. Slacken a stay bolt on opposite side and remove together with a washer. (MA10) (1) Stay (2) Washer (3) Bolt 4. Slacken a semi-auto tensioner bolt using angle wrench. Push the cutting head toward the engine while swinging it up and down to slacken the belt tension.
  • Page 25 9. Maintenance MA14 2. Put the belt into a pulley groove on the main body. Then engage fan drive spline axle of the drive case with splines on the main body. 3. Assemble the drive case to the main body with 2 nuts and 4 screws.
  • Page 26 9. Maintenance MA15 26  4. Tighten the centre bolt of the idler pulley to fix the belt adjustment plate. 5. Fit the belt cover as original. ■ ENGINE ADJUSTMENT (MA15) WARNING It is dangerous if the cutter blade continues to turn even fingers are removed from the throttle lever.
  • Page 27 9. Maintenance 4. Make a test cut adjust the H needle for best cutting power, not for maximum speed. Standard Idle Speed: 2300~2700 rpm. (1) Idle adjust screw (T) (2) Low speed needle (L) (3) High speed needle (H) 27 ...
  • Page 28 9. Maintenance MA16 MA17 MA18 28  ■ STARTER ROPE EXCHANGE WARNING When exchanging the starter rope, pay attention so that built-in recoil spring does not jump out. Mistake in operation may end up with injury to the eye, etc. by jumped out spring. The starter rope wears and deteriorates with usage.
  • Page 29 9. Maintenance MA19 MA20 MA21 NOTE In case irregular wear is observed on a recoil boss or reel bore, exchange for new components. 5. Remove the rope from the reel. 6. Make a knot in end of new rope and lead it through a reel hole from outside.
  • Page 30 9. Maintenance 30  rope slowly be retracted to the reel. 12.Pull the rope 2~3 times to confirm if it is fully retracted. If it is not fully retracted, pull it out halfway and while holding the reel with left hand, hitch the rope to the reel notch and turn additional 2~3 turns clockwise.

  • Page 31: Storage

    10. Storage WARNING When discharging fuel, be careful not to spill fuel and completely wipe off if spilled. Also, securely close a cap of storage tank. IMPORTANT • In case the machine is left for long time, inside of the carburetor may be clogged and cause engine failure (starting failure or poor output power).

  • Page 32: Troubleshooting Guide

    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 33: 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 34 12. Parts list Fig.1 CUTTER UNIT HC510DV (S/N 200101 and up) 34 ...
  • Page 35 Fig.1 CUTTER UNIT HC510DV (S/N 200101 and up) Key# Part Number Description 2894-61100 CASE COMP 01252-60510 • BOLT 06004-06001 • BEARING 2670-21220 • SEAL 2894-64110 SHAFT, inlet 2894-64120 PULLEY 2894-64210 2894-64250 SPACER 2894-64300 SHAFT COMP 01643-30823 WASHER 3350-43231 2894-64410 COVER, fan...
  • Page 36 12. Parts list Fig.2 POWER UNIT (1) HC510DV (S/N 200101 and up) 36 ...
  • Page 37 Fig.2 POWER UNIT (1) HC510DV (S/N 200101 and up) Key# Part Number Description 2884-12110 CYLINDER 2884-14100 VALVE ASS'Y 3388-23110 GROMMET 2880-14111 PIPE 2880-14120 SPRING 2880-14150 GUIDE 2670-14311 BRACKET 2670-14320 SCREW M5x14 2880-14350 SPACER 2880-14361 GASKET 2670-14211 GASKET, cylinder 2850-14220 BOLT M5x20...
  • Page 38 12. Parts list Fig.3 POWER UNIT (2) HC510DV (S/N 200101 and up) 38 ...
  • Page 39 Fig.3 POWER UNIT (2) HC510DV (S/N 200101 and up) Key# Part Number Description 2884-31110 COVER, cylinder 2670-14320 SCREW M5x14 2884-82603 PLATE COMP 2884-82630 • SEAL 2884-82640 • SEAL, plate 2670-14320 SCREW M5x14 2884-83100 CLEANER COMP 2884-83121 • ELEMENT 2884-83301 PLATE ASS'Y 2884-83320 •...
  • Page 40 12. Parts list Fig.4 CARBURETOR HC510DV (S/N 200101 and up) Key# Part Number Description 848-C8X-8101 CARBURETOR ASS’Y (WT-648A) 3306-81380 • SCREEN 2810-81120 • COVER 3310-81130 • SCREW T2050-06020 • GASKET KIT 3310-81230 • LEVER 3310-81240 • SCREW 2841-81270 • SPRING 3310-81250 •...
  • Page 41 • WRENCH T25 2670-96320 • WRENCH T20 2894-96000 SPACIAL TOOL SET (OP) 2890-96100 • PULLER ASS'Y (OP) 2616-96210 • WRENCH (OP) 2670-96220 • STOPPER (OP) HC510DV (S/N 200101 and up) Q'ty Key# Part Number 3350-96230 3350-96620 2670-96660 3350-96240 2670-96410 2810-96710 2894-96810...

  • Page 42: California Emission Control Warranty Statement Your Warranty Rights And Obligations

    KOMATSU ZENOAH recommends that you retain all receipts covering maintenance on your small off-road engine, but KOMATSU ZENOAH can not deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

  • Page 43: Limited Warranty

    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 ZENOAH AMERICA WITHIN SEVEN (7) DAYS. BE SURE TO KEEP A COPY FOR YOUR RECORDS.
  • Page 44 KOMATSU 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.

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