848-J8P-93A0 (603) OWNER / OPERATOR MANUAL EXtreme™ EXZ2401S-BC EX2-BC EX-LRT EX-PS EX-HE WARNING WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. 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. ■ WARNINGS IN THE MANUAL WARNING This mark indicates instructions which must be followed in order to prevent accidents which could lead to serious bodily injury or death.
1. Parts location 14 1 2 3 13 4 7 6 9 12 5 8 11 10 EX2-BC 16 15 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.
2. Specifications Engine Type······················································································ Air-cooled 2-stroke gasoline Model········································································································ Zenoah GZ23N Displacement ······················································································· 1.5cu-in (23.6cm3) Max. output ····························································· 1.15Hp (0.
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). WARNING Never modify your machine.
4. Symbols on the machine 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. 3. Always be sure to include this manual when selling, lending, or otherwise transferring the ownership of this product. 4.
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. ■ WORKING PLAN 1.
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.
5. For safe operation WARNING Make sure the throttle is at idle position. Never place the throttle into the high speed position or half throttle position (throttle lock 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 (idle position).
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. ■ MAINTENANCE 1.
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 it to cool down. Take a careful look around to make sure that there are no sparks or open flames anywhere nearby before refueling. 4.
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. When difficult to engage, twist the engine slightly. 3. Fasten the clamp securely with two screws. SE1 SE2 IMPORTANT Tighten the screws gradually by turns.
6. Set up (EX2-BC only) EX2-BC SE1 EX2-BC SE2 EX2-BC SE3 14 ■ INSTALLING DEBRIS GUARD • Put the debris guard on the gear box, attach it with the 2 screws and hardware provided. (SE1) ■ INSTALLING CUTTING HEAD (SE2) 1. While locking the gear shaft, by inserting the supplied tool into the upper holder on the gear box, loosen and remove the hexagon nut(lefthanded) 2. Then screw in the cutting head to the gear shaft over the holders. Hand-tighten it securely. ■ BALANCE UNIT 1.
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 the screw firmly in. 4. Using a wrench, screw in the bolt provided to fix the trimming mechanism into place.
6. Set up (EX-PS only) EX-PS SE1 (1) (2) (3) (4) (5) ■ 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 screw is to be inserted with the hole on the main pipe, and screw the screw firmly in. 5. Using a wrench, screw in the bolt provided to fix the mechanism into place.
6. Set up (EX-PS only) EX-PS SE4 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 EX-PS SE5 4. Adjust the chain tension by turning the tensioner screw until the tie straps just touch the bottom side of the bar rail. (SE5) (1) Chain tension adjusting screw (a) Loosen (b) Tighten EX-PS SE6 5.
6. Set up (EX-HE only) EX-HE SE1 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 EX-HE SE2 EX-HE SE3 2.Install the blade guard to the gear case with the provided 3 screws, then clamp it to the shaft tube with 2 screws. (SE2) 3.
7. Fuel and chain oil 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. • The RedMax engines are lubricated by oil specially formulated for air-cooled 2-cycle gasoline engine use.
7. Fuel and chain oil 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 abnormal lean mixture. 5. Put a clear indication on the outside of the container to avoid mixing up with other containers. ■ FUELING THE UNIT 1. Untwist and remove the fuel cap.
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. OP1 ADJUSTING HANDLE POSITION • Loosen the handle bracket screws and reposition the handle to your best operating position. Re-tighten the screws.
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 OP6 (5) WARNING (6) (4) (7) OP7 The product is equipped with a centrifugal clutch mechanism, so the cutting attachment begins to rotate as soon as the engine is started by pulling the throttle.
8. Operation 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. (OP9) (1) cable adjuster OP9 .04 in (1~2mm) (1) ■ ADJUSTING IDLING SPEED (OP10) 1. When the engine tends stop frequently at idling mode, turn the adjusting screw clockwise. 2.
8. Operation (EX2-BC only) ■ 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. 2. Keep the debris guard in place at all times when the unit is operated. EX2-BC OP1 TRIMMING GRASS AND WEEDS • Always remember that the TIP of the line does cutting. You will achieve better results by not crowding the line into the cutting area.
8. Operation (Optional blade usage EX2-BC only) 9” 22-tooth: SST229 9” 24-tooth: SST249 CUTTER APPLICATION CHART 8” 8-tooth: SGB088 9” 8-tooth: SGB089 8” 4-tooth: SGB048 9” 4-tooth: SGB049 Nylon line head Under growth Heavy weeds Light weeds Grass ■ CHOOSE THE BLADE 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.
8. Operation (Optional blade usage EX2-BC only) EX2-BC OP4 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). WARNING EX2-BC OP5 EX2-BC OP6 • The product is equipped with a centrifugal clutch mechanism, so the cutting attachment begins to rotate as soon as the engine is started by putting the throttle into the start position.
8. Operation (Optional blade usage EX2-BC only) EX2-BC OP7 ■ 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) WARNING EX2-BC OP8 • The rotating parts fastened incorrectly may cause serious accident to the operator. • Make sure that the blade is not bent, warped, cracked, broken or damaged.
8. Operation (Optional blade usage EX2-BC only) 2. How you can reduce the chance of blade thrust: a. Recognize that blade thrust 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 EX2-BC only) EX2-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. IMPORTANT • It is recommended that filing should be done by professionals. • Especially regarding filing the saw blade, Leave it to the professionals.
8. Operation (EX-LRT only) 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. • Never hold the trimmer in a way in which the blades are pointed towards someone else.
8. Operation (EX-PS only) EX-PS OP1 ■ 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). Be sure to refill the oil tank every time when refueling the saw.
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. (b) Counter clockwise-increase lubrication. (c) Middle WARNING • Always wear work gloves made of leather or some other sturdy material when using the polesaw.
8. Operation (EX-HE only) WARNING EX-HE OP1 • 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 job, check the area and remove all obstacles and objects that could be thrown by the blade.
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. ENGINE ■ MAINTENANCE CHART every every every 25 50 100 before hours hours hours note use after after after system/compornent procedure fuel leaks, fuel spillage wipe out ✔ fuel tank, air filter, fuel filter inspect/clean ✔ idle adjusting screw spark plug see ■ADJUSTING IDLING SPEED (p.
9. Maintenance 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. MA1 (1) MA2 ■ 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 before installing. If the element is broken or shrunk, replace with a new one.
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. MA4 (1) ■ SPARK ARRESTER • The muffler is equipped with a spark arrester to prevent red hot carbon from flying out of the exhaust outlet. Periodically inspect and clean as necessary with a wire brush.
9. Maintenance MA5 (1) 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 (2) • 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.
9. Maintenance (EX2-BC only) EX2-BC MA1 ■ REFILLING TRIMMING LINE (MA1) 1. For replacement line, use a diameter of .095in (2.4mm). The spool is capable for a line upto 20ft (6m) on the 4” head. Avoid using a larger line as it may cut down the trimming performance. WARNING For safety reasons, metalreinforced line. do not use 2. Pinch the slotted area on the both sides of the spool housing to unhook the bottom cap. 3. Take out the spool and pull off the old line.
9. Maintenance (EX-LRT only) EX-LRT MA1 ■ 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. 1. Loosen lock nut (A) as shown in the diagram. 2. Tighten screw (B) fully, and then turn onethird to one-half of a rotation backward. 3. While holding onto the screw to keep it in position, tighten the lock nut. 4.
9. Maintenance (EX-PS only) EX-PS MA1 (1) ■ OILING PORT Dismount the guide bar and check the oiling port for clogging. (MA1) (1) Oiling port EX-PS MA2 ■ GUIDE BAR Remove sawdust in the bar groove and the oiling port. (MA2) (1) Groove (2) Oiling port EX-PS MA3 (Type: Sprocket nose) Grease the nose sprocket from the feeding port on the tip of the bar.
9. Maintenance (EX-PS only) EX-PS MA4 EX-PS MA5 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 Check for extensive wear, and replace it when the teeth are worn over 0.3mm.
9. Maintenance (EX-PS only) EX-PS MA7 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 EX-PS MA8 Make sure every cutter has the same length and edge angles as illustrated.
9. Maintenance (EX-HE only) MA1 ■ 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. NOTE • When removing and installing the cutter holder(a), use care not to allow any dirt and dust entering in to the gear case.
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. 11. Troubleshooting guide Case 1.
12. Parts list EXtreme™ EXZ2401S-BC EXZ-PU EX2-BC ENGINE EX-LRT (ATT) EX-PS (ATT) EX-HE (ATT) 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.
12. Parts list Fig.
Fig.1 EXZ-PU (S/N 60300000 and up) Key# 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 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 Description Part Number PIPE COMP., ø24x750 848-J8P-5820 SHAFT, 786x7 T3075-12210 SPACER 6036-12250 JOINT, PIPE-ASS’Y T3087-12400 • JOINT T3087-12410 • STOPPER T3087-12600 • KNOBBOLT 6036-12420 • WASHER 01643-30823 • BOLT 01252-30510 • BOLT 3540-13260 GRIP 848-J80-32H2 LEVER COMP.
12. Parts list Fig.
Fig.
12. Parts list Fig.
Fig.3 ENGINE UNIT (60100000 and up) Key# Q'ty Key# CYLINDER COMP. • COVER, TR-S • COVER, TR-F • GASKET, TR • BOLT 848-F08-1210 848-F08-12C0 848-F08-12D0 848-F08-12E0 4820-16310 1 1 1 2 4 6 7 8 9 10 11 GASKET, base BOLT TORX INSULATOR GASKET, insu GASKET, carb BOLT TORX T1551-12211 4820-12130 848-F08-14A0 848-F08-14B0 848-F08-14C0 T4950-52001 1 4 1 1 1 4 61 62 63 64 65 66 67 68 69 70 71 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 CRANKCASE COMP.
12. Parts list Fig.
Fig.4 EX-LRT (S/N 000531 and up) Key# Description Part Number Q'ty Key# 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 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 LEVER, clamp WASHER M6 WASHER 6x15x2.
12. Parts list Fig.
Fig.5 EX-PS (S/N 000000 and up) Key# Description Part Number Q'ty Key# 47 48 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 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 GEAR CASE (L)COMP. 848-A52-6211 • BEARING 06004-06001 GEAR CASE (R)COMP.
12. Parts list Fig.
Fig.6 EX-HE (S/N 000101 and up) Key# Description 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 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 GEARCASE ASSY • GEARCASE • O-RING • BEARING • SEAL • RING • SHAFT • GEAR • PINION • BEARING • BEARING • RING • RING • BOLT • WASHER • WASHER • BOLT • BOLT • COVER • BEARING • BOLT • HOLDER (A) • HOLDER (B) • FITTING • WASHER HANDLE COMP. BRACKET ASSY • BRACKET • CAP-L • CAP-U • BOLT • BOLT GUARD ASSY • GUARD COMP.
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.
RedMax 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.
RedMax Garantie limitée 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 pendant deux (2) ans à compter de la date initiale de livraison d’une unité.