848-C8X-93A1 (60 ) OWNER / OPERATOR MANUAL CUT-OFF SAW HC510DV Dust Collection Type WARNING Diamond wheel use only, Do not use abrasive wheels with this product. 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 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Rear handle Safety lock Choke knob Air Cleaner cover Front handle Pulley cover Stand Decomp valve Drive case Throttle lever Cutter blade Blade cover Muffler Starter knobs Engine stop switch Fuel tank cap Flange bolt 2. Specifications Model Name and Number ···································································CUT-OFF SAW, HC510DV Overall Size (with 14 in. Blade)(LxWxH) ························· 29.4(735)x9.4(235)x19.
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. We won't warrant the machine, if you use the remodeled machine or you don't observe the proper usage written in the manual.
4. Symbols on the machine WARNING For safe operation and maintenance, symbols are indicated on the machine. According to these indications, please be careful not to take a mistake. (a) (a) The port to refuel the "MIX GASOLINE" Position: FUEL TANK CAP (b) (b) Choke will close when pulling the choke knob Position: CHOKE KNOB (c) (c) It indicates the start (I) and stop (O) direction Position: SWITCH IMPORTANT ENGINE INFORMATION THIS ENGINE CONFORMS TO U.S. EPA PH1 FOR SMALL OFF-ROAD ENGINES.
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. This unit has been designed for use in cutting concrete products, stone and cast-iron pipe at outside construction site. Never use this product for any other purpose since doing so could result in unforeseen accidents and injuries occurring. c.
5. For safe operation 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. i. Always be sure to include this manual when selling, lending, or otherwise transferring the ownership of this product. ■ WORKING GEAR AND CLOTHING a.
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.
5. For safe operation 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. g. Inspect the entire unit for loose fasteners and fuel leakage. Make sure that the blade is properly installed and securely fastened. h.
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. k. Never touch the spark plug or plug cord while the engine is in operation. Doing so may result in being subjected to an electrical shock. l.
6. Set up 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. ■ CHANGE OF DUST STOPPER IMPORTANT SE1 • To apply 12 inch blades, the dust stopper L (on the engine starter side) shall be exchanged with an attached 12 inch version before fitting blades.
6. Set up ■ MOUNTING OF CUTTER BLADE WARNING SE2 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). 2. Mount a cutter blade on flange washer (B) aligning its centre hole correctly with a projection of the washer. Holding the blade with flange washer (A), screw in the flange bolt.
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. • The RedMax engines are lubricated by oil specially formulated for air-cooled 2-cycle gasoline engine use.
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 the outside of the container to avoid mixing up with gasoline or other containers. 6. Indicate the contents on outside of container for easy identification.
8. Operation ■ 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. • As the engine starts with throttle lever locked in a starting position, the cutter blade starts to turn at the same time.
8. Operation NOTE In case of restarting immediately after stopping the engine, pull the starter knob with the choke knob pushed in (choke open). OP3 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. OP4 5. Place the machine on stable ground and confirm that there is no obstacle around the cutter blade. As in the left Fig.
8. Operation In case of cold start of the engine, apply 1~2 minutes of warming up operation before use. ■ STOPPING ENGINE WARNING OP5 • In an emergency, immediately stop the engine. • Even after stopping the engine, the cutter blade continues to turn awhile by inertia. Do not touch the blade until it is fully stopped. • Do not touch a muffler or the spark plug by bare hands immediately after stopping the engine. There is a danger of burn for its high temperature. 1.
8. Operation OP6 ■ 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. IMPORTANT Do not forcedly press the cutter blade during cutting. It may end up with quick wear of blade or troubles on a drive mechanism.
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. WARNING • Be sure to stop the engine for check and maintenance. • Do not modify the machine nor disassemble the engine. • Use RedMax genuine or specified spare parts and oils. ■ AIR CLEANER The air cleaner is adhered with much dusts produced by a cutting operation. At the end of day’s operation, be sure to check and clean it as follows: 1.
9. Maintenance 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. Cover an air inlet with a cloth after removing the filter. • To keep the engine performance, change the air filter at every 20 hours of operation. ■ SPARK PLUG WARNING MA2 0.6~0.
9. Maintenance 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 MA4 • Do not touch the cylinder, muffler or spark plug by bare hands immediately after stopping the engine. There is a danger of burn for its high temperature. • On the starting inspection, check the muffler and clean if there are adhered wood chips or dry leaves. Those may cause overheating of the muffler.
9. Maintenance MA6 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 MA7 1. Slacken 3 pieces of flange nuts which are holding the cutting head. (MA7) (1) Slacken MA8 2. Slacken a bracket bolt on the starter side. (MA8) (1) Slacken 3.
9. Maintenance MA10 3. Slacken a stay bolt on opposite side and remove together with a washer. (MA10) (1) Stay (2) Washer (3) Bolt MA11 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. (MA11) (1) Push toward the engine (2) Bolt (3) Slacken MA12 5. Remove the belt out from groove of pulley on the cutting head. 6. Remove a belt cover on the drive case. 7.
9. Maintenance 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. 4. Put the belt into the cutting head pulley. 5. Apply tension on the belt by screwing in the belt tensioner bolt to the end of the case. 6. Tighten 3 nuts and fix stay bolt on the opposite side as original. 7. Fit the belt cover and the pulley cover as original. 8.
9. Maintenance 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. In case it is not solved by readjusting an idle adjust screw with following procedure, there are possibility of throttle lever failure or clutch failure. Ask sales dealer for check and repair.
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.
9. Maintenance ■ 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. In case the rope becomes shaggy or partially worn, suggest exchanging it soon to avoid rope cut on operation site. To exchange rope, ask sales dealer or obtain RedMax genuine part and go through following procedure: MA16 1.
9. Maintenance NOTE In case irregular wear is observed on a recoil boss or reel bore, exchange for new components. MA19 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. Pull the rope hard to engage the knot into a reel pit and put end of the knot into a reel notch. (MA19) (1) Notch IMPORTANT In case the rope knot is too large or the rope end is protruded from the reel, the rope retraction may become difficult. MA20 MA21 7.
9. Maintenance 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. IMPORTANT Excessive turns of reel cause overload on the coil spring and may break it in short time.
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). • During storage, make fuel tank cap loose. If it is tighten too much, cap packing may deform by temporal change. 1. Remove the dust hose and the dust bag from the body. 2.
11. Troubleshooting guide Case 1. Starting failure CHECK fuel tank fuel filter carburetor adjustment screw sparking (no spark) spark plug ➞ ➞ ➞ ➞ ➞ ➞ PROBABLE CAUSES incorrect fuel fuel filter is clogged out of normal range spark plug is fouled/wet plug gap is incorrect disconnected ➞ ➞ ➞ ➞ ➞ ➞ ACTION drain it and with correct fuel clean adjust to normal range clean/dry correct (GAP: 0.6~0.7mm) retighten Case 2. Engine starts but does not keep running/Hard re-starting.
12. Parts list CUT-OFF SAW HC510DV 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 the serial number are applicable to those specified in the parts list, then use parts number described in the parts list. 4.
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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 2005 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, RedMax / KOMATSU ZENOAH AMERICA, INC., 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 : RedMax / 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.
