848JB593A1 (704)
G
B
OWNER’S MANUAL
BRUSHCUTTERS
BC2604DL
BC2604DW
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BC2604DL / BC2604DW
SAFETY FIRST
Instructions contained in warnings within this manual marked
Contents
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.
1. Parts location .................................................. 4
2. Specifications ................................................. 4
3. Warning labels on the machine ...................... 5
4. Symbols on the machine ................................ 5
5. For safe operation........................................... 6
6. Set up ............................................................. 9
7. Fuel ............................................................... 10
8. Operation ...................................................... 11
9. Maintenance ................................................. 13
10. Storage ......................................................... 15
11. Troubleshooting guide .................................. 16
G
B
WARNINGS IN THE MANUAL
WARNING
This mark indicates instructions, which must be followed in or-
der to prevent accidents, which could lead to serious bodily in-
jury or death.
IMPORTANT
This mark indicates instructions, which must be followed, or it
leads to mechanical failure, breakdown, or damage.
NOTE
This mark indicates hints or directions useful in the use of the
product.
1. Parts location
5
3
3
5
BC2604DL
BC2604DW
(1) Primer pump
(2) Air cleaner cover
(3) Choke lever
(4) Fuel tank
1
1
4
13
13
4
11
(5) Starter knob
(6) Blade
(7) Gear case
2
2
11
14
14
12
9
15
12
(8) Debris guard
(9) Loop handle
(10) Drive shaft housing
(11) Sholder strap hanger
(12) Throttle lever
(13) Ignition switch
(14) Throttle cable
(15) Protector
16
10
10
(16) Handle
7
7
8
8
6
6
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BC2604DL / BC2604DW
2. Specification
BC2604DL / BC2604DW
Overall size (L 3 W 3 H) ............................ 1800 x 395 x 315 / 1800 x 610 x 520 mm
Dry weight .................................................................................................. 5.1 / 5.5 kg
Engine
Model ............................................................................................... Zenoah G26L
Displacement ........................................................................................... 25.4 cm3
Fuel............................................................................ Mixture (Gasoline 50 : Oil 1)
(when using ZENOAH genuine oil)
Carburetor .................................................................................... Diaphragm type
Ignition system ...........................................Transistor controlled flywheel magneto
Spark plug ........................................................................................ NGK BPMR7A
Fuel tank capacity............................................................................................... 0.75 L
Starter ...................................................................................................... Recoil starter
Clutch .................................................................................................. Centrifugal type
Reduction ratio .................................................................................................... 1.357
Cutting head rotating direction ............................. Counter-clockwise (Operator view)
Specifications are subject to change without notice.
3. Warning labels on the machine
15m (50ft)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(1) Read owner’s manual before operating this machine.
(2) Wear head, eye and ear protection.
(3) Wear foot protection.
(4) Wear gloves.
(5) Beware of thrown objects.
(6) Warning / Attention
(7) Keep all children, bystanders and helpers 15 meters away from the machine.
Never modify your machine.
If warning label peels off or becomes 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).
We won’t warrant the machine, if you use the
remodeled brushcutter or if you don’t observe
the proper usage written in the manual.
The port to refuel the “MIX GASOLINE”
Position: FUEL TANK CAP
4. Symbols on the
machine
The direction to close the choke
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.
Position: AIR CLEANER COVER
The direction to open the choke
Position: AIR CLEANER COVER
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BC2604DL / BC2604DW
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 diffi-
cult 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.
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 when-
ever any questions arise. Also
note, if you have any questions
which cannot be answered
herein, contact the dealer from
whom you purchased the prod-
uct.
3. Always be sure to include this
manual when selling, lending, or
otherwise transferring the own-
ership of this product.
4. Never allow children or anyone
unable to fully understand the
directions given in the manual
to use the machine.
G
B
WORKING PLAN
1. You should never use the prod-
uct when under the influence of
alcohol, when suffering from ex-
haustion or lack of sleep, when
suffering from drowsiness as a re-
sult of having taken cold medicine
or at any other time when a pos-
sibility exists that your judgment
might be impaired or that you
might not be able to operate the
product properly and in a safe
manner.
WORKING CONDITION
1. When using the product, you
should wear proper clothing and
protective equipment.
(1) Helmet
2. When planning your work sched-
ule, allow plenty of time to rest.
Limit the amount of time over
which the product is to be used
continuously to somewhere
around 30 ~ 40 minutes per ses-
sion, and take 10 ~ 20 minutes of
rest between work sessions. Also
try to keep the total amount of
work performed in a single day
under 2 hours or less.
(2) Ear protectors
(3) Protection goggles or face
protector
(4) Thick work gloves
(5) Non-slip-sole work boots
2. And you should carry with you.
(1) Attached tools
(2) Properly reserved fuel
(3) Spare blade
(4) Things to notify your working
area (rope, warning signs)
(5) Whistle (for collaboration or
emergency)
WARNING
1. If you don’t observe the working
time, or working manner (See
“USING THE PRODUCT”), Re-
petitive Stress Injury (RSI) could
occur.
(6) Hatchet or saw (for removal of
obstacles)
3. Do not wear loose clothing, jew-
elry, short trousers, sandals, or go
barefoot. Do not wear anything
which might be caught by a mov-
ing part of the unit. Secure hair
so it is above shoulder length.
If you feel discomfort, redness and
swelling of your fingers or any
other part of your body, see a doc-
tor before getting worse.
2. To avoid noise complaints, in gen-
eral, operate product between
8 a.m. and 5 p.m. on weekdays
and 9 a.m. to 5 p.m. on weekends.
WORKING CIRCUMSTANCE
1. Never start the engine inside a
closed room or building. Exhaust
gases contain dangerous carbon
monoxide.
NOTE
2. Never use the product,
a. when the ground is slippery
or when you can’t maintain a
steady posture.
Check and follow the local regula-
tions as to sound level and hours of
operations for the product.
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5. For safe operation
BEFORE STARTING
ensure that neither the cutting
part nor the throttle come into
contact with any obstacle when
the engine starts.
THE ENGINE
1. The area within a perimeter of
15 m 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 pe-
rimeter of the area. When work is
to be performed simultaneously
by two or more persons, care
should also be taken to constantly
look around or otherwise check
for the presence and locations of
other people working so as to
maintain a distance between
each person sufficient to ensure
safety.
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 at-
tachment stops rotating when the
throttle is moved fully back to its
original position. If it continues to
rotate even after the throttle has
been moved fully back, turn off
the engine and take the unit to
your authorized ZENOAH servic-
ing dealer for repair.
2. Check the condition of working
area to avoid any accident by hit-
ting hidden obstacles such as
stumps, stones, cans, or broken
glass.
USING THE PRODUCT
IMPORTANT
IMPORTANT
Remove any obstacle before begin-
ning work.
Cut only materials recommended by the
manufacturer. And use only for tasks
explained in the manual.
3. Inspect the entire unit for loose
fasteners and fuel leakage. Make
sure that the cutting attachment
is properly installed and securely
fastened.
1. Grip the handles firmly with both
hands using your whole hand. Place
your feet slightly apart (slightly further
apart than the width of your shoul-
ders) so that your weight is distrib-
uted evenly across both legs, and
always be sure to maintain a steady,
even posture while working.
4. Be sure the debris guard is firmly
attached in place.
5. Always use the shoulder strap.
Adjust the strap for comfort be-
fore starting the engine. The strap
should be adjusted so the left
hand can comfortably hold the
handlebar grip approximately
waist high.
2. Keep cutting attachment below waist
level.
3. Maintain the speed of the engine at
the level required to perform cutting
work, and never raise the speed of
the engine above the level necessary.
4. If the unit starts to shake or vibrate,
turn off the engine and check the
whole unit. Do not use it until the
trouble has been properly corrected.
5. Keep all parts of your body away from
rotating cutting attachment and hot
surfaces.
6. Never touch the muffler, spark plug,
or other metallic parts of the engine
while the engine is in operation or
immediately after shutting down the
engine. Doing so could result in seri-
ous burns or electrical shock.
STARTING THE ENGINE
1. Keep bystanders and animals at
least 15 m (50 ft) away from the
operating point. If you are ap-
proached, immediately stop the
engine.
2. 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. When starting
the engine, place the product
onto the ground in a flat clear area
and hold it firmly in place so as to
GB-6
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BC2604DL / BC2604DW
5. For safe operation
• IF SOMEONE COMES
HANDLING FUEL
1. Guard against hazardous situa-
tions at all times. Warn adults to
keep pets and children away from
the area. Be careful if you are ap-
proached. Injury may result from
flying debris.
2. If someone calls out or otherwise
interrupts you while working, al-
ways be sure to turn off the en-
gine before turning around.
1. The engine of the ZENOAH prod-
uct is designed to run on a mixed
fuel, which contains highly flam-
mable gasoline. Never store cans
of fuel or 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.
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2. Never smoke while operating the
unit or refilling its fuel tank.
MAINTENANCE
1. In order to maintain your product
in proper working order, perform
the maintenance and checking
operations described in the
manual at regular intervals.
2. Always be sure to turn off the en-
gine before performing any main-
tenance or checking procedures.
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 any-
where nearby before refueling.
4. Wipe spilled fuel completely us-
ing a dry rag if any fuel spillage
occurs during refueling.
WARNING
5. After refueling, screw the fuel cap
back tightly onto the fuel tank and
then carry the unit to a spot 3 m
or more away from where it was
refueled before turning on the en-
gine.
The metallic parts reach high tem-
peratures immediately after stop-
ping the engine.
3. When replacing the cutting at-
tachment or any other part, or
when replacing the oil or any lu-
bricant, always be sure to use
only ZENOAH products or
products which have been cer-
tified by ZENOAH for use with
the ZENOAH product.
4. In the event that any part must be
replaced or any maintenance or
repair work not described in this
manual must be performed,
please contact a representative
from the store nearest ZENOAH
authorized servicing dealer for
assistance.
TRANSPORTATION
1. When hand-carrying the product,
cover over the cutting part if nec-
essary, lift up the product and
carry it paying attention to the
blade.
2. Never transport the product over
rough roads over long distances
by vehicle without removing all
fuel from the fuel tank. If doing so,
fuel might leak from the tank dur-
ing transport.
5. Do not use any accessory or at-
tachment other than those bear-
ing the ZENOAH mark and rec-
ommended for the unit.
6. Under no circumstances should
you ever take apart the product
or alter it in any way. Doing so
might result in the product be-
coming damaged during opera-
tion or the product becoming un-
able to operate properly.
GB-7
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6. Set up
INSTALLING HANDLE (BC2604DL)
• Mount the handle to the shaft tube and clamp it at a
location that is comfortable to you.
INSTALLING DEBRIS GUARD FOR LINE HEAD
• Attach the debris guard (RED) with the bolts provided.
INSTALLING LINE HEAD
1. While locking the gear shaft by inserting the supplied tool
into the upper holder on the gear box, loosen and remove
the bolt (left-handed).
2. Fit the line head assembly to the gear shaft by using bolt
(A). Hand tighten it securely.
INSTALLING HANDLE (BC2604DW)
1. Loosen the 4bolts on the upper cap and insert the
handles equally. Retighten the bolts.
2. Put the handle assembly into the bracket and put the
upper cap over it. Tighten the cap securely.
INSTALLING DEBRIS GUARD FOR METAL BLADE
• Attach the debris guard (BLACK) with the bolts pro-
vided.
CONNECTING THROTTLE WIRE (BC2604DW)
1. Remove the air cleaner cover.
2. Connect the end of the throttle wire to the joint on the
top of the carburetor.
NOTE
BLADE
• When installing the cleaner cover, make sure to put
the high-tension wire in it.
1. Put the angled bar into the side holes of the inner holder and
the gearcase.
2. Remove the blade bolt (Lefthanded) and the outer holder
from the gearshaft.
3. Put the blade onto the inner holder. Make the marked side
face the holder.
4. Put the outer holder onto the gearshaft making the recessed
side face the blade.
5. Fasten the blade by the blade bolt with the spring washer
and the bolt cover .
CONNECTING SWITCH WIRES (BC2604DW)
• Connect the switch wires between the engine and the
main unit. Pair the wires of the same color.
BALANCE UNIT
1. Put on strap and attach unit to strap.
2. Slide clampi up or down until unit balances with head
aparting from the ground when using it.
PROTECTOR (BC2604DW)
• Wrap the protector around the outer pipe as shown in
the figure, and fasten the hooks.
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7. Fuel
■ FUEL
3. Pour in all of the oil and agitate well.
4. Pour in the rest of gasoline and agitate again for at
least one minute. As some oils may be difficult to agi-
tate 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.
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 refuel-
ing the unit. Select outdoor bare ground for fuel-
ing and move at least 3 m (10 ft) away from the
fueling point before starting the engine.
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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.
■ FUELING THE UNIT
1. Untwist and remove the fuel cap. Rest the cap on a
dustless place.
2. Put fuel into the fuel tank to 80% of the full capacity.
3. Fasten the fuel cap securely and wipe up any fuel
spillage around the unit.
• The Zenoah engines are lubricated by oil specially
formulated for air-cooled 2-cycle gasoline engine use.
If Zenoah oil is not available, use an anti-oxidant
added quality oil expressly labeled for air-cooled 2-
cycle engine use (JASO FC GRADE OIL or ISO EGC
GRADE).
WARNING
1. Select bare ground for fueling.
2. Move at least 10 feet (3 meters) away from the fu-
eling point before starting the engine.
3. Stop the engine before refueling the unit. At that
time, be sure to sufficiently agitate the mixed gaso-
line in the container.
• Do not use BIA or TCW (2-stroke water-cooling type)
mixed oil.
■ FORYOUR ENGINE LIFE, AVOID:
1. FUEL WITH NO OIL (RAW GASOLINE) – It will cause
severe damage to the internal engine parts very
quickly.
2. GASOHOL – It can cause deterioration of rubber and/
or plastic parts and disruption of engine lubrication.
3. OIL FOR 4-CYCLE ENGINE USE – It can cause spark
plug fouling, exhaust port blocking, or piston ring stick-
ing.
■ RECOMMENDED MIXING RATIO
GASOLINE 50 : OIL 1
<when using ZENOAH genuine oil>
• Exhaust emission are controlled by the funda-
mental engine parameters and components (eq.,
carburation, ignition timing and port timing) with-
out addition of any major hardware or the intro-
duction of an inert material during combustion.
• These engines are certified to operate on unleaded
gasoline.
4. Mixed fuels which have been left unused for a pe-
riod of one month or more may clog the carburetor
and result in the engine failing to operate properly.
5. In the case of storing the product for a long period of
time, clean the fuel tank after rendering it empty. Next,
activate the engine and empty the carburetor of the
composite fuel.
• Make sure to use gasoline with a minimum octane
number of 89RON (USA/Canada: 87AL).
• If you use a gasoline of a lower octane value than
prescribed, there is a danger that the engine tem-
perature may rise and an engine problem such as
piston seizing may consequently occur.
6. In the case of scrapping the used mixed oil container,
scrap it only at an authorized repository site.
NOTE
• Unleaded gasoline is recommended to reduce the
contamination of the air for the sake of your health
and the environment.
As for details of quality assurance, read the description
in the section Limited Warranty carefully. Moreover, nor-
mal wear and change in product with no functional influ-
ence are not covered by the warranty. Also, be careful
that, if the usage in the instruction manual is not observed
as to the mixed gasoline, etc. described therein, it may
not be covered by the warranty.
• Poor quality gasolines or oils may damage sealing
rings, fuel lines or fuel tank of the engine.
■ HOW TO MIX FUEL
IMPORTANT
Pay attention to agitation.
1. Measure out the quantities of gasoline and oil to be
mixed.
2. Put some of the gasoline into a clean, approved fuel
container.
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8. Operation
STARTING ENGINE
WARNING
WARNING
The product is equipped with a centrifugal clutch mecha-
nism, so the cutting attachment begins to rotate as soon
as the engine is started by putting the throttle into the start
position. When starting the engine, place the product
onto the ground in a flat clear area and hold it firmly in
place so as to ensure that neither the cutting part nor the
throttle come into contact with any obstacle when the en-
gine starts.
The cutting head will start rotating upon the engine
starts.
1. Feed fuel into the fuel tank and tighten the cap se-
curely.
2. Rest the unit on a flat, firm place. Keep the cutting
head off the ground and clear of surrounding objects,
as it will start rotating upon starting of the engine.
3. Push the primer pump several times until overflown
fuel flows out in the clear tube.
(1) choke lever
(2) close
IMPORTANT
(3) open
(4) primer pump
•
Avoid pulling the rope to its end or returning it by releasing
the knob. Such actions can cause starter failures.
7. Move the choke lever downward to open the choke. And
restart engine.
4. Move the choke lever to the closed position.
8. Allow the engine to warm up for a several minutes before
starting operation.
5. Set the ignition switch to the “I” position. Set the throttle
lever to the start position (1 → 2 → 3).
Place the unit on a flat, firm place.
NOTE
Keep the cutting head clear of everything around it.
1. When restarting the engine immediately after stopping it,
leave the choke open.
2. Overchoking can make the engine hard to start due to ex-
cess fuel. When the engine failed to start after several at-
tempts, open the choke and repeat pulling the rope, or re-
move the spark plug and dry it.
T
AR
ST
O : Stop
I : Start
3. Ignition switch
STOPPING ENGINE
BC2604DL
BC2604DW
6. While holding the unit firmly, pull out the starter rope
quickly until engine fires.
T
R
TA
S
O : Stop
I : Start
3. Ignition switch
BC2604DL
BC2604DW
1. Release the throttle lever and run the engine for half
a minute.
2. Shift the ignition switch to the STOP position.
IMPORTANT
• Except for an emergency, avoid stopping the engine
while pulling the throttle lever.
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8. Operation
ADJUSTING THROTTLE CABLE
• The normal play is 1 or 2 mm when measured at the
carburetor side end. Readjust with the cable adjuster
as required.
G
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.04 in
(1)
(1 ~ 2 mm)
METAL BLADE USAGE
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 fas-
tened according to instruction and the blade turns
smoothly without abnormal noise.
(1) Cable adjuster
ADJUSTING IDLING SPEED
WARNING
• 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.
• If you find any error to the blade, discard it
and change new one which is certified by
ZENOAH.
(1) Idle adjusting screw
1. When the engine tends to stop frequently at idling
mode, turn the adjusting screw clockwise.
2. When the cutting head keeps rotating after releasing
the trigger, turn the adjusting screw counter-clockwise.
• 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.
NOTE
WARNING
• Warm up the engine before adjusting the idling speed.
• Make sure to use shoulder strap and debris
guard. If not, it is vary dangerous when you
slip or lose your balance.
CUTTER APPLICATION CHART
• Replace by a suitable recommended cutting attach-
ment according to the object to be cut.
• When replacing blade always be sure to use products
which have been certified by ZENOAH.
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.
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8. Operation
CUTTING METHOD
WARNING
(a)Use the front left side cutting.
(b) Guide the blade from your right to left with it tilted
slightly to your left.
CONTROLLING BLADE BOUNCE
• Kick out can cause serious personal injury. Carefully
study this section. It is important that you understand
what causes kick out, how you can reduce the chance
of kick out and how you can remain in control of the
unit if kick out does occur.
(c) When mowing a wide area, start working from your
left end to avoid interference of cut grass.
(d) The blade may be seized by weeds if the engine
speed is too low, or the blade cuts too deep into
weeds. Adjust the engine speed and cutting depth
according to the condition of object.
1. What causes kick out:
• Kick out can occur when the moving blade contacts
an object that it cannot cut. This contact causes the
blade to stop for an instant and then suddenly move
or ”bounce” away from the object that was hit. The
operator can lose control of the unit and the blade
can cause serious personal injury to the operator or
any person nearby if the blade contacts any part of
the body.
WARNING
• If the grass or other object gets caught in the blade,
or if the unit starts to shake or vibrate, turn off the
engine and check the whole unit. Change the blade if
it has been damaged.
• Turn off the engine and make sure the blade has com-
pletely stop before checking the blade, and remov-
ing any object got caught in.
2. How you can reduce the chance of kick out:
a. Recognize that kick out can happen. By understand-
ing and knowing about bounce, you can help elimi-
nate 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. Be extra prepared for bounce if you must cut where
you cannot see the blade making contact such as in
areas of dense growth.
d. Keep the blade sharp. A dull blade increase the
chance of bounce.
e. Avoid feeding the blade too rapidly. The blade can
bounce away from material being cut if the blade is
fed faster than its cutting capability.
f. Cut only from your right to your left.
g. Keep your path of advance clear of material that has
been cut and other debris.
3. How you can maintain the best control:
a. Keep a good, firm grip on the unit with both hands. A
firm grip can help neutralize bounce. Keep your right
and left hands completely around the respective
handles.
b. Keep both feet spread apart in a comfortable stance
and yet braced for the possibility that the unit could
bounce. Do not overreach. Keep firm footing and
balance.
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8. Operation
CUTTING WORK (LINE HEAD USAGE)
WARNING
2. You can avoid thrown debris by sweeping from your
left to the right.
3. Use a slow, deliberate action to cut heavy growth.
The rate of cutting motion will depend on the material
being cut. Heavy growth will require slower action than
will light growth.
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.
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B
4. Never swing the unit so hard as you are in danger of
losing your balance or control of the unit.
2. Keep the debris guard in place at all times when
the unit is operated.
5. Try to control the cutting motion with the hip rather
than placing the full workload on the arm and hands.
TRIMMING GRASS AND WEEDS
• Always remember that the TIP of the line does cut-
ting. You will achieve better results by not crowding
the line into the cutting area. Allow the unit to trim at
its own pace.
6. Take precautions to avoid wire, grass and dead, dry,
long-stem weeds from wrapping around the head
shaft. Such materials can stall the head and cause
the clutch to slip, resulting in damage to the clutch
system if repeated frequently.
1. Hold the unit so the head is off the ground and is tilted
about 20 degrees toward the sweep direction.
ADJUSTING THE LINE LENGTH
• Your brush cutter is equipped with a semi- auto type
nylon line head that allows the operator to advance
the line without stopping the engine. When the line
becomes short, lightly tap the head on the ground
while running the engine at full throttle.
• Each time the head is bumped, the line advances
about 25 mm. For better effect, tap the head on bear
ground or hard soil. Avoid bumping in thick, tall grass
as the engine may stall by overload.
GB-13
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BC2604DL / BC2604DW
9. Maintenance
Every Every Every
25 50 100
hours hours hours
after after after
Before
use
System/components
Procedure
Note
fuel leaks, fuel spillage
fuel tank, air filter, fuel filter
wipe out
■
■
inspect/clean
see adjusting
idling speed
clean and readjust
plug gap
■
replace, if necessary
replace carburetor
if necessary
idle adjusting screw
spark plug
■
GAP: .025 in (0.6 ~ 0.7 mm)
replace, if necessary
■
cylinder fins, intake air cooling vent clean
muffler, spark arrester, cylinder exhaust port clean
■
■
throttle lever, ignition switch
check operation
replace if
something’s wrong
grease
■
■
cutting parts
gear case
■
screws/nuts/bolts
debris guard
tighten/replace
make sure to attach
■
■
■
not adjusting screws
BLADE
AIR FILTER
• Check the blade and the fasteners for looseness,
cracking, or bending.
• Check the cutting edges and reform with a flat file.
• The air filter, if clogged, will reduce the engine perfor-
mance. Check and clean the filter element in warm,
soapy water as required. Dry completely before in-
stalling. If the element is broken or shrunk, replace
with a new one.
(A) Saw blade
(B) 8-teeth blade
(C) 3-teeth blade
(1) Air filter
FUEL FILTER
• When the engine runs short of fuel supply, check the
fuel cap and the fuel filter for blockage.
Point :
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.
(1) Fuel filter
SPARK PLUG
IMPORTANT
• Starting failure and misfiring are often caused by a
fouled spark plug. Clean the spark plug and check
that the plug gap is in the correct range. For a re-
placement plug, use the correct type specified by
ZENOAH.
• It is recommended that filing should be done by
professionals.
• Especially regarding filing the saw blade, Leave it to
the professionals.
WARNING
• Make sure that the engine has stopped and is cool
before performing any service to the machine. Con-
tact with moving cutting head or hot muffler may
result in a personal injury.
0.6~0.7 mm
• REPLACEMENT PLUG IS A CHAMPION RZ7C.
GB-14
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BC2604DL / BC2604DW
9. Maintenance
IMPORTANT
• Check the intake air cooling vent and the area
around the cylinder cooling fins after every 25
hours of use for blockage, and remove any waste
which has attached itself to the brushcutter. Note
that it is necessary to remove the engine cover
shown in in order to be able to view the upper part
of the cylinder.
• Note that using any spark plug other than those des-
ignated may result in the engine failing to operate prop-
erly or in the engine becoming overheated and dam-
aged.
• To install the spark plug, first turn the plug until it is
finger tight, then tighten it a quarter turn more with a
socket wrench.
G
B
IMPORTANT
87 ~ 104 in-lbs
TIGHTENING TORQUE:
• 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.
(9.8 ~ 11.8 N.m.)
MUFFLER
WARNING
• Inspect periodically, the muffler for loose fasteners,
any damage or corrosion. If any sign of exhaust leak-
age is found, stop using the machine and have it re-
paired immediately.
(1) Cylinder
(2) Intake air cooling vent
• Note that failing to do so may result in the engine
catching on fire.
PROCEDURES TO BE PERFORMED AFTER
EVERY 100 HOURS OF USE
GEAR CASE
1. Remove the muffler, insert a screwdriver into the vent,
and wipe away any carbon buildup. Wipe away any
carbon buildup on the muffler exhaust vent and cylin-
der exhaust port at the same time.
• The reduction gears are lubricated by multipurpose,
lithium-based grease in the gear case. Supply new
grease every 25 hours of use or more often depend-
ing on the job condition.
• Remove the bolt opposit to the grease nipple before
installing new grease to arrange for old grease to exit.
2. Tighten all screws, bolts, and fittings.
3. Check to see if any oil or grease has worked its way
in between the clutch lining and drum, and if it has,
wipe it away using oil-free, lead-free gasoline.
INTAKE AIR COOLING VENT
WARNING
• Never touch the cylinder, muffler, or spark plugs
with your bare hands immediately after stopping
the engine. The engine can become very hot when
in operation, and doing so could result in severe
burns.
• When checking the machine to make sure that it
is okay before using it, check the area around the
muffler and remove any wood chips or leaves
which have attached themselves to the
brushcutter. Failing to do so could cause the muf-
fler to become overheated and that in turn could
cause the engine to catch on fire. Always make
sure that the muffler is clean and free of wood
chips, leaves, and other waste before use.
10. Storage
Aged fuel is one of major causes of engine starting fail-
ure. 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.
GB-15
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BC2604DL / BC2604DW
11. Troubleshooting guide
Case 1. Starting failure
CHECK
fuel tank
fuel filter
PROBABLE CAUSES
→ incorrect fuel
→ fuel filter is clogged
ACTION
→ drain it and use correct fuel
→ clean
carburetor adjustment screw → out of normal range
→ adjust to normal range
→ clean/dry
→ correct (GAP: 0.6 ~ 0.7 mm)
→ retighten
sparking (no spark)
spark plug
→ spark plug is fouled/wet
→ plug gap is incorrect
→ disconnected
Case 2. Engine starts but does not keep running/hard re-starting
CHECK
PROBABLE CAUSES
ACTION
fuel tank
→ incorrect fuel or staled fuel → drain it and use correct fuel
carburetor adjustment screw → out of normal range
muffler, cylinder (exhaust port) → carbon is built-up
→ adjust to normal range
→ wipe away
→ wash
air cleaner
→ clogged with dust
→ clogged with dust
cylinder fin, fan cover
→ clean
When your unit seems to need further service, please consult with our ZENOAH service shop in your area.
Limited warranty
Should any failure occur on the product under normal oper-
ating conditions within the applicable warranty period, the
failed part will be replaced or repaired free of charge by a
ZENOAH authorized dealer.
WARRANTY MAINTENANCE OR REPAIRS, AND SHALL
NOT REDUCE THE WARRANTY OBLIGATION OF THE
COMPANY.
THE COMPANY IS LIABLE FOR DAMAGES TO OTHER
ENGINE COMPONENTS CAUSED BY THE FAILURE OF A
WARRANTED PART STILL UNDER WARRANTY.
WARRANTY PERIOD: 1 year (6 months if used profession-
ally, and 30 days if used for rental purpose) from the date of
initial purchase.
THE WARRANTY DOES NOT APPLY TO THOSE UNITS
WHICH HAVE BEEN DAMAGED BY NEGLIGENCE OF IN-
STRUCTION LISTED IN THE OWNER/OPERATOR MANUAL
FOR PROPER USE AND MAINTENANCE OF THE UNITS
ACCIDENT MISHANDLING, ALTERATION, ABUSE, IM-
PROPER LUBRICATION, USE OF ANY PARTS OR ACCES-
SORIES OTHER THAN THOSE SPECIFIED BY THE COM-
PANY, OR OTHER CAUSES BEYOND THE COMPANY’S
CONTROL.
THE PURCHASER SHALL BEAR COSTS OF TRANS-
PORTING THE UNIT TO AND FROM THE ZENOAH DEALER.
THE PURCHASER SHALL NOT BE CHARGED FOR DIAG-
NOSTIC LABOR WHICH LEADS TO THE DETERMINATION
THAT A WARRANTED PART IS DEFECTIVE, IF THE DIAG-
NOSTIC WORK IS PERFORMED AT THE ZENOAH DEALER.
THE PURCHASER OR OWNER IS RESPONSIBLE FOR THE
PERFORMANCE OF THE REQUIRED MAINTENANCE AS
DEFINED BY THE MANUFACTURER IN THE OWNER/OP-
ERATOR MANUAL.
THIS WARRANTY DOES NOT COVER THOSE PARTS RE-
PLACED BY NORMAL WEAR OR HARMLESS CHANGES
IN THEIR APPEARANCE.
ANY WARRANTED PART WHICH IS NOT SCHEDULED FOR
REPLACEMENT AS REQUIRED MAINTENANCE, OR
WHICH IS SCHEDULED ONLY FOR REGULAR INSPECTION
TO THE EFFECT OF REPAIR OR “REPLACE AS NECES-
SARY” SHALL BE WARRANTED FOR THE WARRANTY PE-
RIOD. ANY WARRANTED PART WHICH IS SCHEDULED
FOR REPLACEMENT AS REQUIRED MAINTENANCE
SHALL BE WARRANTED FOR THE PERIOD OF TIME UP
TO THE FIRST SCHEDULED REPLACEMENT POINT FOR
THE PART.
THERE ARE NO OTHER EXPRESS WARRANTIES.
IMPLIED WARRANTIES INCLUDING THOSE OF MER-
CHANTABILITY AND FITNESS FOR A PARTICULAR PUR-
POSE ARE LIMITED TO TWO (2) YEARS OF HOME USE
[ONE (1) YEAR FOR ANY OTHER USE] FROM THE ORIGI-
NAL DELIVERY DATE.
LIABILITIES FOR INCIDENTAL OR CONSEQUENTIAL
DAMAGE UNDER ANY AND ALL WARRANTIES ARE
EXCLUDED.
ANY REPLACEMENT PART THAT IS EQUIVALENT IN PER-
FORMANCE AND DURABILITY MAY BE USED IN NON-
IF YOU NEED TO OBTAIN MORE INFORMATION, PLEASE
C A L L Y O U R N E A R E S T S E RV I C E C E N T E R ,
O R C H E C K P L E A S E Z E N O A H W E B S I T E
GB-16
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