Zenoah Brush Cutter BC2603DL User Manual

848JA093A0 (311)  
G
B
O W N ER’S MAN UAL  
BRUSHCUTTERS  
BC2603DL  
BC2603DW  
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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
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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
BC2603DL  
BC2603DW  
(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
GB-3  
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2. Specification  
BC2603DL / BC2603DW  
Overall size (L W H) ............................ 1800 x 395 x 315 / 1800 x 610 x 520 mm  
Dry weight .................................................................................................. 5.3 / 6.7 kg  
Engine  
Model ............................................................................................... Zenoah G26L  
Displacement ........................................................................................... 25.4 cm3  
Fuel............................................................................ Mixture (Gasoline 50 : Oil 1)  
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.  
If warning label peels off or becomes soiled and  
3. Warning labels on  
the machine  
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).  
Read owner’s manual before operat-  
ing this machine.  
Never modify your machine.  
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.  
Wear head, eye and ear protection.  
Warning / Attention  
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.  
The port to refuel the “MIX GASOLINE”  
Position: FUEL TANK CAP  
Keep all children, bystanders and helpers 15  
meters away from the machine.  
The direction to close the choke  
Position: AIR CLEANER COVER  
The direction to open the choke  
Position: AIR CLEANER COVER  
GB-4  
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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
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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.  
GB-5  
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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 KOMATSU  
ZENOAH servicing dealer for re-  
pair.  
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 shoulders) so that  
your weight is distributed 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 vi-  
brate, turn off the engine and  
check the whole unit. Do not use  
it until the trouble has been prop-  
erly 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 op-  
eration or immediately after shut-  
ting down the engine. Doing so  
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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5. For safe operation  
could result in serious burns or elec-  
trical shock.  
HANDLING FUEL  
1. The engine of the KOMATSU  
ZENOAH product is designed to  
run on a mixed fuel, which con-  
tains highly flammable 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, weld-  
ing sparks, or any other source  
of heat or fire which might ignite  
the fuel.  
IF SOMEONE COMES  
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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.  
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 any-  
where nearby before refueling.  
4. Wipe spilled fuel completely us-  
ing a dry rag if any fuel spillage  
occurs during refueling.  
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.  
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.  
WARNING  
The metallic parts reach high tem-  
peratures immediately after stop-  
ping the engine.  
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.  
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 KOMATSU ZENOAH prod-  
ucts or products which have  
been certified by KOMATSU  
ZENOAH for use with the  
KOMATSU 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 KOMATSU  
ZENOAH authorized servicing  
dealer for assistance.  
5. Do not use any accessory or at-  
tachment other than those bear-  
ing the KOMATSU ZENOAH mark  
and recommended 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 (BC2603DL)  
• Mount the handle to the shaft tube and clamp it at a  
location that is comfortable to you.  
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 (BC2603DW)  
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 provided.  
CONNECTING THROTTLE WIRE (BC2603DW)  
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  
1. Put the angled bar into the side holes of the inner  
holder and the gearcase.  
• When installing the cleaner cover, make sure to put  
the high-tension wire in it.  
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 (BC2603DW)  
• 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 clamp up or down until unit balances with head  
aparting from the ground when using it.  
PROTECTOR (BC2603DW)  
• Wrap the protector around the outer pipe as shown in  
the figure, and fasten the hooks.  
INSTALLING DEBRIS GUARD FOR LINE HEAD  
Attach the debris guard (RED) with the bolts provided.  
GB-8  
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7. Fuel  
FUEL  
least one minute. As some oils may be difficult to  
agitate depending on oil ingredients, sufficient agi-  
tation 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 ab-  
normally 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.  
G
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5. Put a clear indication on the outside of the container  
to avoid mixing up with gasoline or other contain-  
ers.  
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 Komatsu Zenoah engines are lubricated by oil  
specially formulated for air-cooled 2-cycle gasoline  
engine use. If Komatsu 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 fuel-  
ing point before starting the engine.  
3. Stop the engine before refueling the unit. At that time,  
be sure to sufficiently agitate the mixed gasoline 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 sticking.  
4. Mixed fuels which have been left unused for a  
period of one month or more may clog the carbu-  
retor and result in the engine failing to operate prop-  
erly.  
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.  
6. In the case of scrapping the used mixed oil con-  
tainer, scrap it only at an authorized repository site.  
RECOMMENDED MIXING RATIO  
GASOLINE 50 : OIL 1  
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.  
• 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.  
Note: As for details of quality assurance, read the description in  
the section Limited Warranty carefully. Moreover, normal wear and  
change in product with no functional influence 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.  
• Unleaded gasoline is recommended to reduce the  
contamination of the air for the sake of your health  
and the environment.  
• Poor quality gasolines or oils may damage sealing  
rings, fuel lines or fuel tank of the engine.  
HOW TO MIX FUEL  
• 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.  
3. Pour in all of the oil and agitate well.  
4. Pour in the rest of gasoline and agitate again for at  
GB-9  
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8. Operation  
STARTING ENGINE  
WARNING  
gine, 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 con-  
tact with any obstacle when the engine 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.  
IMPORTANT  
3. Push the primer pump several times until overflown  
fuel flows out in the clear tube.  
Avoid pulling the rope to its end or returning it by re-  
leasing the knob. Such actions can cause starter fail-  
ures.  
(1) choke lever  
(2) close  
(3) open  
7. Move the choke lever downward to open the choke.  
And restart engine.  
(4) primer pump  
8. Allow the engine to warm up for a several minutes  
before starting operation.  
NOTE  
4. Move the choke lever to the closed position.  
1. When restarting the engine immediately after stop-  
ping it, leave the choke open.  
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.  
Keep the cutting head clear of everything around it.  
2. Overchoking can make the engine hard to start due  
to excess fuel. When the engine failed to start after  
several attempts, open the choke and repeat pulling  
the rope, or remove the spark plug and dry it.  
Stop  
Start  
1
3. Ignition switch  
STOPPING ENGINE  
T
R
TA  
S
Stop  
Start  
2
Ignition switch  
T
R
TA  
S
BC2603DL  
BC2603DW  
6. While holding the unit firmly, pull out the starter rope  
quickly until engine fires.  
BC2603DL  
BC2603DW  
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.  
WARNING  
The product is equipped with a centrifugal clutch  
mechanism, so the cutting attachment begins to ro-  
tate as soon as the engine is started by putting the  
throttle into the start position.When starting the en-  
GB-10  
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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  
KOMATSU 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 KOMATSU 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.  
GB-12  
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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.  
G
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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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  
replace, if necessary  
replace carburetor  
idle adjusting screw  
spark plug  
idling speed (p. 22)  
clean and readjust  
if necessary  
GAP: .025 in (0.6 ~ 0.7 mm)  
plug gap  
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  
cutting parts  
something’s wrong  
grease  
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.  
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.  
• Check the cutting edges and reform with a flat file.  
(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  
KOMATSU 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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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.  
G
B
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.  
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.  
2. Tighten all screws, bolts, and fittings.  
Remove the bolt opposit to the grease nipple before  
installing new grease to arrange for old grease to exit.  
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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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 KOMATSU 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  
KOMATSU 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 FAIRURE OF A  
WARRANTED PARTS 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 LUBULICATION, USE OF ANY PARTS OR ACCES-  
SARIES OTHER THAN THOSE SPECIFIED BY THE COM-  
PANY, OR OTHER CAUSES BEYOND THE CONPANY’S  
CONTROL.  
THE PURCHASER SHALL BEAR COSTS OF TRANS-  
PORTING THE UNIT TO AND FROM THE KOMATSU  
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 KOMATSU  
ZENOAH DEALER.  
THIS WARRANTY DOES NOT COVER THOSE PARTS RE-  
PLACED BY NORMAL WEAR OR HARMLESS CHANGES  
IN THEIR APPEARANCE.  
THE PURCHASER OR OWNER IS RESPONSIBLE FOR THE  
PERFORMANCE OF THE REQUIRED MAINTENANCE AS  
DEFINED BY THE MANUFACTURER IN THE OWNER/OP-  
ERATOR MANUAL.  
THERE ARE NO OTHER EXPRESS WARRANTIES.  
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 REPLACEMNET POINT FOR  
THE PART.  
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.  
IF YOU NEED TO OBTAIN MORE INFORMATION, PLEASE  
C A L L YO U R N EA REST SERVI C E C EN TER,  
OR CHECK PLEASE KOMATSU ZENOAH WEB SITE  
ANY REPLACEMENT PART THAT IS EQUIVALENT IN PER-  
FORMANCE AND DULABILITY MAY BE USED IN NON-  
GB-16  
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