848-JAC-93A0 (404)

OWNER / OPERATOR MANUAL

BRUSHCUTTERS

BC250

WARNING

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

WARNING

Before using our brushcutters, please read this manual carefully to understand the proper use of your unit.

APPLICABLE SERIAL NUMBERS :

DRIVE UNIT 40400101 and up ENGINE UNIT KU40001 and up

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.

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.

CONTENTS

1. Parts location …………………………………4

2. Specifications …………………………………4

3. Warning labels on the machine ……………5

4. Symbols on the machine ……………………6

5. For safe operation ……………………………7

6. Set up …………………………………………13

7. Fuel……………………………………………14

8. Operation ……………………………………16

9. Maintenance …………………………………19

10. Storage ………………………………………23

11. Troubleshooting guide ………………………24

12. Parts list ………………………………………25

1. Parts location

15

13

14

12 11

8

9

10

7

6

1

2

5

4

3

1. Loop handle

2. Ignition switch

3. Throttle cable

4. Throttle lever

5. Throttle set button

6. Drive shaft housing

7. Debris guard

8. Cutting line head

9. Gear case

10. Spark arrester

11. Starter knob

12. Fuel tank

13. Primer pump

14. Choke lever

15. Air cleaner cover

2. Specifications

■ BC250

Overall size(LxWxH)

·············································································· 72.0(1830)x9.0(228)x9.5(241) in(mm)

Dry weight

··················································· 11.1 lbs (5.04kg) (11.9 lbs (5.40kg) Including tap head)

Engine Type······················································································ Air-cooled 2-stroke gasoline

Model······································································································ Zenoah GT25N2

Displacement ······················································································· 1.6cu-in (25.4cm

3 )

Max. output ··································································· 1.2Hp (0.9kW)at 8500/min -1 (rpm)

Idle speed··························································································3000±400/min -1 (rpm)

Fuel ······················································································· Mixture(Gasoline 50 : Oil 1)

Carburetor ··················································································· Walbro Diaphragm type

Spark plug ··································································································NGK BPMR7A

Fuel tank capacity·······························································································22.3 fl.oz (0.62 )

Transmission··········································································· Centrifugal clutch, Rigid driveshaft

Reduction ratio ····················································································································· 1.462

Cutting head rotating direction ················································ Counter-clockwise(Operator view)

Durability period····················································································································50hrs.

Standard Accessories

4 in. 2-line Head ········································································································ 1 pc.

Goggle ······················································································································· 1 pc.

Tool Kit ······················································································································ 1 pc.

Specifications are subject to change without notice.

4 

3. Warning labels on the machine

(1) Read owner's manual before operating this machine.

(2) Wear head, eye and ear protection.

(3) Warning/Attention

(4) Keep all children, bystanders and helpers 15 meters away from the brushcutter

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 brushcutter.

We won't warrant the machine, if you use the remodeled brushcutter or you don't observe the proper usage written in the manual.

5 

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 take a mistake.

(a) The port to refuel the "MIX GASOLINE"

Position: FUEL TANK CAP

(b) The direction A to close the choke

The direction B to open the choke

Position: AIR CLEANER COVER

INFORMA TION IMPORTANTE CONCERNANT LE MO TEUR

CE MOTEUR EST CONFORME A LA REGLEMENTATION U.S. EPA 2004 POUR LES PETITS

MOTEURS HORS-ROUTE. DUREE DE CONFORMITE DES EMISSIONS : CATEGORIE A.

SE REFERER AU MODE D’EMPLOI POUR DE PLUS AMPLES INFORMATIONS.

FAMMILLE DE MO 4HCPS.025AD;EM

CYLINDREE : 3 DATE DE F TION : Avril 2004

6 

5. For safe operation

1. Read this manual carefully until you completely understand and follow all safety and operating instructions.

2. Keep this manual handy so that you may refer to it later whenever any questions arise. Also note, if you have any questions which cannot be answered herein, contact the dealer from whom you purchased the product.

3. Always be sure to include this manual when selling, lending, or otherwise transferring the ownership of this product.

4. Never allow children or anyone unable to fully understand the directions given in the manual to use the machine.

■ WORKING CONDITION

1. When using the product, you should wear proper clothing and protective equipment.

(1) Helmet

(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 and files

(2) Properly reserved fuel

(3) Spare blade

(4) Things to notify your working area (rope, warning signs)

(5) Whistle (for collaboration or emergency)

(6) Hatchet or saw (for removal of obstacles)

3. Do not wear loose clothing, jewelry, short trousers, sandals, or go barefoot. Do not wear anything which might be caught by a moving part of the unit. Secure hair so it is above shoulder length.

■ WORKING CIRCUMSTANCE

1. Never start the engine inside a closed room or building. Exhaust gases contain dangerous carbon monoxide.

2. Never use the product, a. when the ground is slippery or when you can’t maintain a steady posture.

7 

8 

5. For safe operation b. At night, at times of heavy fog, or at any other times when your field of vision might be limited and it would be difficult to gain a clear view of the working area. c. During rain storms, during lightning storms, at times of strong or gale-force winds, or at any other times when weather conditions might make it unsafe to use the product.

■ WORKING PLAN

1. You should never use the product when under the influence of alcohol, when suffering from exhaustion or lack of sleep, when suffering from drowsiness as a result of having taken cold medicine or at any other time when a possibility exists that your judgment might be impaired or that you might not be able to operate the product properly and in a safe manner.

2. When planning your work schedule, 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 session, 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.

WARNING

1. If you don’t observe the working time, or working manner (See

■ USING THE

PRODUCT), Repetitive Stress Injury(RSI) could occur.

If you feel discomfort, redness and swelling of your fingers or any other part of your body, see a doctor before getting worse.

2. To avoid noise complaints, in general, operate product between 8a.m. and 5p.m. on weekdays and 9a.m. to 5p.m. weekends.

NOTE

Check and follow the local regulations as to sound level and hours of operations for the product.

5. For safe operation

■ BEFORE STARTING THE ENGINE

1. The area within a perimeter of 50 feet (15m) of the person using the product should be considered a hazardous area into which no one should enter. If necessary yellow warning rope, warning signs should be placed around the perimeter of the area. 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.

2. Check the condition of working area to avoid any accident by hitting hidden obstacles such as stumps, stones, cans, or broken grass.

IMPORTANT

Remove any obstacle before beginning work.

3. Inspect the entire unit for loose fasteners and fuel leakage. Make sure that the cutting attachment is properly installed and securely fastened.

4. Be sure the debris guard is firmly attached in place.

■ STARTING THE ENGINE

1. Keep bystanders and animals at least 50feet

(15m) away from the operating point. If you are approached, 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 ensure that neither the cutting part nor the throttle come into contact with any obstacle when the engine starts.

9 

10 

5. For safe operation

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 attachment 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 Red

Max servicing dealer for repair.

■ USING THE PRODUCT

IMPORTANT

Cut only materials recommended by the manufacturer. And use only for tasks explained in the manual.

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.

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 start 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 serious burns or electrical shock.

5. For safe operation

• IF SOMEONE COMES

1. Guard against hazardous situations at all times.

Warn adults to keep pets and children away from the area. Be careful if you are approached.

Injury may result from flying debris.

2. If someone calls out or otherwise interrupts you while working, always be sure to turn off the engine before turning around.

■ MAINTENANCE

1. 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 engine before performing any maintenance or checking procedures.

WARNING

The metallic parts reach high temperatures immediately after stopping the engine.

3. When replacing the cutting attachment or any other part, or when replacing the oil or any lubricant, always be sure to use only RedMax products or products which have been certified by RedMax for use with the RedMax

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 RedMax authorized servicing dealer for assistance.

5. Do not use any accessory or attachment other than those bearing the RedMax 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 becoming damaged during operation or the product becoming unable to operate properly.

■ HANDLING FUEL

1. The engine of the RedMax product is designed to run on a mixed fuel which contains highly flammable gasoline. Never store cans of fuel or

11 

12 

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. Wipe spilled fuel completely using 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 10feet (3m) or more away from where it was refueled before turning on the engine.

■ TRANSPORTATION

1. When hand-carrying the product, cover over the cutting part if necessary, 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 during transport.

6. Set up

SE1

SE2

(1)

■ INSTALLING HANDLE

• Mount the handle to the shaft tube and clamp it at a location that is comfortable to you. (SE1)

(1) About 19 inches (48cm)

■ INSTALLING DEBRIS GUARD

• Put the debris guard on the tube, attach it with the 2 screws and clamp provided. (SE2)

SE3

■ INSTALLING CUTTING HEAD (SE3)

1. While locking the gear shaft, by inserting the supplied tool into the upper holder on the gear box, loosen and remove the hexagon nut(lefthanded)

2. Fit the line head assembly to the gear shaft over the holders. Hand-tighten it securely.

Blades should not be used on this model trimmer.

13 

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. If RedMax 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)

• Do not use BIA or TCW (2-stroke watercooling type) mixed oil.

■ RECOMMENDED MIXING RATIO

GASOLINE 50:OIL 1

50:1 MIXING CHART

GASOLINE gal.

1 2 3 4 5

2-CYCLE OIL fl.oz 2.6

5.2

7.8 10.4

13

GASOLINE liter 1 2 3 4 5

2-CYCLE OIL ml 20 40 60 80 100

• Exhaust emission are controlled by the fundamental engine parameters and components(eq., carburation, ignition timing and port timing) without addition of any major hardware or the introduction 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 89 RON

(USA/Canada: 87AL)

• If you use a gasoline of a lower octane value than prescribed, there is a danger that the engine temperature may rise and an engine problem such as piston seizing may consequently occur.

• 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

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.

3. Pour in all of the oil and agitate well.

4. Pour In the rest of gasoline and agitate

14 

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.

■ 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.

WARNING

1. Select bare ground for fueling.

2. Move at least 10feet (3meters) away from the fueling 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.

FOR YOUR 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 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.

6. In the case of scrapping the used mixed oil container, scrap it only at an authorized repository site.

NOTE

As lot 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.

15 

8. Operation

OP1

OP2

OP3

(2)

(1)

OP4

(3)

(4)

(1)

A

(2)

B

(3)

■ STARTING ENGINE

WARNING

The cutting head will start rotating upon the engine starts.

1. 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.

2. Push the primer pump several times until overflown fuel flows out in the return tube. (OP1)

3. Move the choke lever to the closed position.

(OP2)

(1) Choke lever (2) A: the closed position

(3) B: the open position

4. Set the ignition switch to the “start” position.

(OP3)

(1) Ignition switch (2) Stop

(3) Start (4) Throttle set button

5 While pulling the throttle lever, push the set button, and release the throttle lever, then throttle lever is in to the "start" position. (OP3)

6. While holding the unit firmly, pull out the starter rope quickly until engine fires. (OP4)

IMPORTANT

• 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 to the open position

(OP2). And pull out the starter rope quickly to restart engine. (OP4)

8. Allow the engine to warm up for several minutes before starting operation.

NOTE

1. When restarting the engine immediately after stopping it, leave the choke open (OP2) and push the primer pump several times (OP4).

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.

16 

8. Operation

OP5

(1)

OP6

■ STOPPING ENGINE (OP3)

1. Release the throttle lever and run the engine for a half minute.

2. Shift the ignition switch to the STOP position.

IMPORTANT

• Except for an emergency, avoid stopping the engine while pulling the throttle lever.

■ ADJUSTING IDLING SPEED (OP5)

1. When the engine tends 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.

(1) Idle adjusting screw

NOTE

• Warm up the engine before adjusting the idling speed.

■ CUTTING WORK (LINE HEAD USAGE)

WARNING

1. Always wear eye protection such as safety goggles. Never lean over the rotating cutting head. Rocks or other debris could be thrown into eyes and face and cause serious personal injury.

2. Keep the debris guard in place at all times when the unit is operated.

TRIMMING GRASS AND WEEDS

• Always remember that the TIP of the line does cutting. You will achieve better results by not crowding the line into the cutting area. Allow the unit to trim at its own pace.

1. Hold the unit so the head is off the ground and is tilted about 20 degrees toward the sweep direction. (OP6)

2. You can avoid thrown debris by sweeping from your left to the right.

17 

8. Operation

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.

4. Never swing the unit so hard as you are in danger of losing your balance or control of the unit.

5. Try to control the cutting motion with the hip rather than placing the full workload on the arm and hands.

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.

ADJUSTING THE LINE LENGTH

• Your brushcutters 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 advance about 1 inch(25.4 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.

18 

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.

■ MAINTENANCE CHART

I

N

E

E

N

G

S

H

A

F

T system/compornent fuel leaks, fuel spillage fuel tank, air filter, fuel filter idle adjusting screw spark plug procedure wipe out inspect/clean see

■ADJUSTING

IDLING SPEED (p.17) clean and readjust plug gap cylinder fins, intake air cooling vent clean muffler, spark arrester, cylinder exhaust port clean throttle lever, ignition switch cutting parts debris guard gear case screws/nuts/bolts check operation

✔ replace if

✔ something's wrong make sure to attach ✔ grease tighten/replace ✔ every every every

25 50 100 before hours hours hours note use after after after

✔

✔ ✔ replace, if necessary

✔ replace carburetor if necessary

✔

GAP: .025in(0.6~0.7mm) replace, if necessary

✔

✔

✔

✔ not adjusting screws

MA1

■ REFILLING TRIMMING LINE (MA1)

1. For replacement line, use a diameter of .095in

(2.4mm). The spool is capable for a line upto 20ft

(6m) on the 4” head. Avoid using a larger line as it may cut down the trimming performance.

WARNING

For safety reasons, do not use metalreinforced line.

2. Pinch the slotted area on the both sides of the spool housing to unhook the bottom cap.

3. Take out the spool and pull off the old line. Put one end of new line through the spool holes and pull it until the length is equal between each part of the line.

4. Wind up the line in the correct direction as indicated on the spool.

5. Hook each end of the line in the slot on the edge of the spool, and then put the ends through the eyelets on the housing. Make sure that the spring and the washers are in place.

6. While holding the spool against the housing, pull the line ends to release them from the slot.

7. Line up the slot on the bottom cap with the hook on the housing, press the cap against the housing until it clicks.

19 

9. Maintenance

MA2

(1)

MA3

MA4

.025 in

0.655mm

MA5

WARNING

• Make sure that the engine has stopped and is cool before performing any service to the machine. Contact with moving cutting head or hot muffler may result in a personal injury.

■ AIR FILTER

• The air filter, if clogged, will reduce the engine performance. Check and clean the filter element in warm, soapy water as required. Dry completely before installing. If the element is broken or shrunk, replace with a new one. (MA2)

(1) Air filter

■ FUEL FILTER

• When the engine runs short of fuel supply, check the fuel cap and the fuel filter for blockage.

(MA3)

(1) Fuel filter

■ SPARK PLUG

• Starting failure and mis-firing 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 replacement plug, use the correct type specified by RedMax. (MA4)

• When you take off the spark plug, twist (1) and pull off the cap (2). (MA5)

• REPLACEMENT PLUG IS A NGK BPMR7A.

IMPORTANT

• Note that using any spark plug other than those designated may result in the engine failing to operate properly or in the engine becoming overheated and damaged.

• 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.

TIGHTENING TORQUE:

87~104 in-lbs

(9.8~11.8 N.m.)

20 

9. Maintenance

MA6

MA7

(1)

■ MUFFLER

WARNING

• Inspect periodically, the muffler for loose fasteners, any damage or corrosion. If any sign of exhaust leakage is found, stop using the machine and have it repaired immediately.

• Note that failing to do so may result in the engine catching on fire.

■ SPARK ARRESTER

• The muffler is equipped with a spark arrester to prevent red hot carbon from flying out of the exhaust outlet. Periodically inspect and clean as necessary with a wire brush. In the State of

California it is required by law (Section 4442 of the California Public Resources Code) to equip a spark arrester when a gas powered tool is used in any forest covered, brush covered, or grass covered unimproved land. (MA6)

(1) Spark arrester

■ GEAR CASE (MA7)

• 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 depending on the job condition.

• Remove the side bolt in gearcase opposite of grease nipple before installing new grease to arrange for old grease to exit.

■ 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 muffler to become overheated, and that this in turn could cause the engine to catch on fire. Always make

21 

9. Maintenance

MA8

MA9

(2)

(1)

(1)

(2) sure that the muffler is clean and free of wood chips, leaves, and other waste before use.

• 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 (MA8) in order to be able to view the upper part of the cylinder.

IMPORTANT

• 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. (MA7)

(1) Cylinder

(2) Intake air cooling vent (back)

■ PROCEDURES TO BE PERFORMED AFTER

EVERY 100 HOURS OF USE

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 cylinder exhaust port at the same time.

(MA9)

(1) Screw driver

(2) Muffler

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.

22 

10. Storage

• Aged fuel is one of major causes of engine starting failure. Before storing the unit, empty the fuel tank and run the engine until it uses all the fuel left in the fuel line and the carburetor. Store the unit indoor taking necessary measures for rust prevention.

23 

11. Troubleshooting guide

Case 1. Starting failure

CHECK PROBABLE CAUSES ACTION fuel tank fuel filter

➞ incorrect fuel

➞ fuel filter is clogged

➞ drain it and with correct fuel

➞ clean carburetor adjustment screw ➞ out of normal range sparking (no spark)

➞ adjust to normal range

➞ spark plug is fouled/wet

➞ clean/dry spark plug

➞ plug gap is incorrect

➞ disconnected

➞ correct (GAP: 0.6~0.7mm)

➞ retighten

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 with correct fuel carburetor adjustment screw

➞ out of normal range ➞ adjust to normal range muffler,cylinder (exhaust port) ➞ carbon is built-up air cleaner

➞ clogged with dust cylinder fin, fan cover ➞ clogged with dust

➞ wipe away

➞ wash

➞ clean

When your unit seems to need further service, please consult with our RedMax service shop in your area.

24 

12. Parts list

BRUSHCUTTERS

BC250

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. The contents described in the parts list may change due to improvement.

5. The parts for the machine shall be supplied seven (7) years after the machine is discontinued. [It is possible that some specific parts may be subject to change of their delivery term and list price within the limit of seven (7) years after the machine is discontinued. It is also possible that some parts may be available even after the limit of seven (7) years.]

March 2004

APPLICABLE SERIAL NUMBERS :

DRIVE UNIT 40400101 and up ENGINE UNIT KU40001 and up

25 

12. Parts list

Fig.1 DRIVE UNIT BC250 (S/N 40400101 and up)

26 

Fig.1 DRIVE UNIT BC250 (S/N 40400101 and up)

Key# Part Number Description

1 848-JAC-58A0 PIPE

2 848-JA3-58B0 BUSH

3 848-JAC-58C0 LINER

4 848-JA3-58D0 • SEAL

5 848-JA3-58E0 SHAFT

6 848-JAC-6100 GEARCASE ASSY

7 848-B20-62A0 • GEARCASE

10

11

8

9

06004-06000 • BEARING

06000-00626 • BEARING

04065-02612 • RING

T3195-13210 • SHAFT

12 T3300-93250 • GEAR

13 848-JA3-61D0 • PINION

14

15

06001-00609

3210-13330

• BEARING

• RING

20

21

22

23

16

17

18

19

04065-02412 • RING

3199-13350 • FITTING

01641-20608 • WASHER

0225-00410 • BOLT

4820-13180 • BOLT TORX

T3300-91340 • HOLDER(A)

4820-12350 BOLT TORX

3577-32141 GRIP

24

25

T3302-12202 LEVER COMP.

6110-14412 • LEVER

26 6110-14410-01 • • STAY

27 6110-14410-02 • • COVER

28 T3002-12202-03 • • LEVER

29 6110-14410-04 • • SCREW

30 6110-14410-05 • • NUT

31 6110-14410-06 • • SHAFT

32 6110-14410-07 • • SPRING

33 6110-14410-08 • • SPRING

34 T3030-14410-09 • • BUTTON

35 6110-14410-10 • • E-RING

36

37

38

39

T3002-12220

T3002-12230

6420-14511

1855-82100

• CORD(A)

• CORD(B)

TUBE

CABLE COMP.

40 848-JAC-90R0 LABEL, name

Q'ty

2

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

Key# Part Number Description

50

51

52

53

47

48

49

T3195-24103 • GUARD COMP.

T3002-24121 • • BLADE

T4960-51431 • • SCREW TORX

3320-15310 • • NUT

3520-24120 • CLAMP

3540-24130 • BOLT

T3002-91190 GOGGLE

58

59

60

61

62

54 848-8U4-0050 WRENCH(T20)

55 848-8U5-0050 WRENCH(T25)

56

57

PT104 PIus

T3189-15112

TAP HEAD COMP.

• CASE

T3189-15191

T3189-15132

T3189-15142

T3189-15160

T3189-15180

• EYELET

• COVER

• CORD HOLDER

• SPRING

• CORD

42 848-JAC-3200 HANDLE ASSY

43 848-JAC-32A0 • HANDLE

44

45

46

0263-90530

0280-10504

T3195-24003

• SCREW

• NUT

GUARD ASSY

3

3

1

1

1

Q'ty

1

1

2

1

1

1

1

1

1

2

1

1

1

1

1

1

27 

12. Parts list

Fig.2 ENGINE UNIT BC250 (S/N KU40001 and up)

28 

Fig.2 ENGINE UNIT BC250 (S/N KU40001 and up)

Key# Part Number

28

29

30

31

24

25

26

27

20

21

22

23

16

17

18

19

12

13

14

15

10

11

8

9

6

7

4

5

1

2

3

44

45

46

40

41

42

43

36

37

38

39

32

33

34

35

Description

6634401 SCREW

3075406 FRONT HOUSING

6635301 SCREW CLUTCH

6969601 WASHER CURVED

3075603 CLUTCH ASSY

6969501 WASHER PLAIN

6968901 NUT

6457403 ROTOR

4309501 CRANKCASE&SHAFT ASSY

6968501 • BEARING

5987501 • SEAL

9071301 GASKET CASE

6968401 • RING

5687401 • SEAL

6634801 • SCREW

3075003 • CRANKCASE ASSY

3090101 CRANKSHAFT ASSY

6457303 PISTON

6969001 RING

6969101 CLIP RING

6968701 WASHER

6997001 NEEDLE BEARING

6230101 WRIST PIN

6968801 KEY

4300401 PULLEY ASSY

6634701 BOLT MAFFLER

3074802 MUFFLER & arrester

6300206 MUFFLER GASKET

6457003 CYLINDER

9071102 GASKET INSULATOR

6634502 SCREW TORX

5994702 INSULATOR

9071103 GASKET CABURETOR

6634402 SCREW TORX

3074502 CARBURETOR

6970001 CLIP HOSE

6969901 CLIP HOSE

5688002 PLASTIC RUBBER TUBING

3078001 PRIMER ASSY

3097402 CHOKE LEVER&PLATE ASSY

6634501 • SCREW TORX

5994601 • CHOKE PLATE

4315001 • CARBURETOR PLATE

5945801 • CHOKE LEVER

6634601 BOLT CARBURETOR

5687301 ELEMENT

Key# Part Number Description

74

75

76

77

70

71

72

73

66

67

68

69

62

63

64

65

58

59

60

61

54

55

56

57

50

51

52

53

47

48

49

3099904

5946101 KNOB

9506501 DECAL

9506009 DECAL(To Start)

9506011 DECAL(caution)

8714402 SPARK PLUG

6634201 CAP SCREW

6635102 SCREW TORX

6300221 PLATE FIN

9070901 GASKET CYLINDER

5947001 REAR HOUSING

6656301 SCREW TORX

3075304 RECOIL ASSY

6635101 SCREW TORX

9506401 DECAL STARTER

9506010

9509001

3075804

3075705

3075904

5687901

5688001

5687801

5835901

6976501

3075803

6635401

6634901

2917803

2914301

2914302

COVER ASSY

DECAL(E Start)

DECAL(EMISSION)

TANK&CAP ASSY

• TANK ASSY

• • FILTER

• • PlPE RETURN

• • PlPE FUEL

• • TANK GROMMET

• • TANK

• • CLIP

• CAP ASSY

BOLT TORX

BOLT TORX

COIL&BOOT ASSY

LEAD ASSY(BLACK)

LEAD ASSY(RED)

78

79

5946201 SPACER

6996901 WASHER

80 848-EU0-53D0 CUSHION

81 01252-30630 BOLT

82 1565-12140 NUT

83 2630-31950 SCREW

84 1484-86280 WASHER

85 5883-32160 SCREW

Q'ty

1

1

1

1

2

1

1

1

1

1

2

2

1

2

1

1

1

3

1

1

2

1

1

1

2

1

2

1

4

1

2

1

2

1

1

1

1

1

1

1

1

1

2

1

1

1

Q'ty

1

1

2

1

1

3

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

2

4

1

3

1

2

1

2

1

1

2

1

1

1

1

1

29 

CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board and KOMATSU ZENOAH are pleased to explain the

emission control system warranty on your 1995 and later small off-road engine. In California, new small off-road engines must be designed, built and equipped to meet the state’s stringent anti-smog standards. KOMATSU ZENOAH must warrant the emission control system on your small off-road engine for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your small off-road engine.

Your emission control system may include parts such as the carburetor and the ignition system.

Where a warrantable condition exists, KOMATSU ZENOAH will repair your small off-road engine at no cost to you including diagnosis, parts and labor.

Manufacturer’s warranty coverage:

The 1995 and later small off-road engines are warranted for two years. If any emissionrelated part on your engine is defective, the part will be repaired or replaced by

KOMATSU ZENOAH.

Owner’s warranty responsibilities:

– As the small off-road engine owner, you are responsible for the performance of the

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

– As the small off-road engine owner, you should be aware, however, that KOMATSU

ZENOAH may deny you warranty coverage if your small off-road engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modification.

– You are responsible for presenting your small off-road engine to a KOMATSU ZENOAH distribution center as soon as a problem exists. The warranty repairs should be completed in e reasonable amount of time, not to exceed 30 days.

If you have any questions regarding your warranty rights and responsibilities, you should contact KOMATSU ZENOAH AMERICA INC. at (770)-381-5147 or you can write to

KOMATSU ZENOAH AMERICA INC.

4344 Shackleford Road Suite 500

Norcross, Georgia 30093

RedMax

LIMITED WARRANTY

EMISSION-RELATED PARTS, FOR TWO (2) YEARS FROM THE DATE OF ORIGINAL DELIVERY OF THE UNIT,

KOMATSU ZENOAH AMERICA INC. (THE COMPANY),

THROUGH ANY RedMax DEALER, WILL REPAIR OR REPLACE, FREE OF CHARGE, FOR THE ORIGINAL AND EACH

SUBSEQUENT PURCHASER, ANY PART OR PARTS FOUND TO BE DEFECTIVE IN MATERIAL AND/OR

WORKMANSHIP. EMISSION-RELATED PARTS ARE:

THE CARBURETOR ASSY, COIL ASSY, ROTOR, SPARKPLUG,

AIR FILTER, FUEL FILTER, INTAKE MANIFOLD, AND THE GASKETS

ALL OTHER PARTS EXCEPT ABOVE PARTS, FOR TWO (2) YEARS OF HOME USE, NINETY (90) DAYS FOR COMMERCIAL

USE FROM THE DATE OF ORIGINAL PURCHASE, THE COMPANY, THROUGH RedMax DEALER, WILL REPAIR OR

REPLACE, FREE OF CHARGE, FOR THE ORIGINAL PURCHASER, ANY PART OF PARTS FOUND TO BE DEFECTIVE IN

MATERIAL AND/OR WORKMANSHIP. THIS IS THE EXCLUSIVE REMEDY.

THE PURCHASER SHALL BEAR COSTS OF TRANSPORTING THE UNIT TO AND FROM THE RedMax DEALER.

THE PURCHASER SHALL NOT BE CHARGED FOR DIAGNOSTIC LABOR WHICH LEADS TO THE DETERMINATION

THAT A WARRANTED PART IS DEFECTIVE, IF THE DIAGNOSTIC WORK IS PERFORMED AT THE RedMax DEALER.

THE PURCHASER OR OWNER IS RESPONSIBLE FOR THE PERFORMANCE OF THE REQUIRED MAINTENANCE AS

DEFINED BY THE MANUFACTURER IN THE OWNER/OPERATOR MANUAL.

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

NECESSARY" SHALL BE WARRANTED FOR THE WARRANTY PERIOD.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.

ANY REPLACEMENT PART THAT IS EQUIVALENT IN PERFORMANCE AND DULABILITY MAY BE USED IN NON-

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 PARTS STILL UNDER WARRANTY.

THE WARRANTY DOES NOT APPLY TO THOSE UNITS WHICH HAVE BEEN DAMAGED BY NEGLIGENCE OF

INSTRUCTION LISTED IN THE OWNER/OPERATOR MANUAL FOR PROPER USE AND MAINTENANCE OF THE UNITS,

ACCIDENTAL MISHANDLING, ALTERATION, ABUSE, IMPROPER LUBULICATION, USE OF ANY PARTS OR ACCESSARIES

OTHER THAN THOSE SPECIFIED BY THE COMPANY, OR OTHER CAUSES BEYOND THE CONPANY'S CONTROL.

THIS WARRANTY DOES NOT COVER THOSE PARTS REPLACED BY NORMAL WEAR OR HARMLESS CHANGES IN

THEIR APPEARANCE.

THERE ARE NO OTHER EXPRESS WARRANTIES.

IMPLIED WARRANTIES INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE

ARE LIMITED TO TWO (2) YEARS HOME OF USE, NINETY (90) DAYS FOR COMMERCIAL USE FROM THE ORIGINAL

DELIVERY DATE.

LIABILITIES FOR INCIDENTAL OR CONSEQUENTIAL DAMAGE UNDER ANY AND ALL WARRANTIES

ARE EXCLUDED.

SOME STATES DO NOT ALLOW LIMITATION ON HOW LONG AN IMPLIED WARRANTY LASTS OR EXCLUSION OR

LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMINATION OR EXCLUSION MAY

NOT APPLY TO YOU.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY

FROM STATE TO STATE.

IF YOU NEED TO OBTAIN INFORMATION ABOUT THE NEAREST SERVICE CENTER, PLEASE CALL KOMATSU

ZENOAH AMERICA INC. AT (770)-381-5147.

IMPORTANT: YOU WILL RECEIVE A WARRANTY REGISTRATION CARD AT TIME OF PURCHASE.PLEASE FILL

OUT THE CARD AND SEND IT TO RedMax / KOMATSU ZENOA AMERICA WITHIN SEVEN (7) DAYS.BE SURE TO KEEP

A COPY FOR YOUR RECORDS.

KOMATSU ZENOAH AMERICA INC.

4344 Shackleford Road Suite 500

Norcross, Georgia 30093

RedMax

Garantie limitée

Pièces en rapport avec les émissions de gaz d'échappement : KOMATSU ZENOAH AMERICA INC., par l'intermédiaire de n'importe quel revendeur RedMax, réparera gratuitement ou remplacera gratuitement pour l'acheteur initial et chaque acheteur successif toute(s) pièce(s) se révélant de constitution et/ou de montage défectueux pendant deux (2) ans à compter de la date initiale de livraison d’une unité. Les pièces en rapport avec les

émissions de gaz d'échappement sont: l'assemblage carburateur, l'assemblage bobine, le rotor, la bougie, le filtre à air, le filtre à carburant, la tubulure d'admission et les joints

Toutes les pièces autres que celles mentionnées ci-dessus, deux (2) ans d'utilisation domestique, quatre-vingtdix (90) jours d'utilisation commerciale, à compter de la date d'achat initial. La société, par l'intermédiaire d'un distributeur RedMax, réparera ou remplacera toute(s) pièce(s), sans frais et au bénéfice de l'acheteur original, en prenant en charge les frais de pièces et/ou de main d'oeuvre. Telles sont les limites de la garantie.

Le coût du transport de l'unité jusqu'au revendeur RedMax et depuis celui-ci sera à la charge de l'acheteur.

L'acheteur ne supportera pas le coût de main d'oeuvre du diagnostic qui amène à la conclusion qu'une pièce garantie est défectueuse, si ce diagnostic est effectué chez le revendeur RedMax.

L’acheteur ou propriétaire a pour responsabilité d’effectuer l’entretien obligatoire tel que défini par le fabricant dans le manuel du propriétaire/de l'utilisateur.

Toute pièce garantie dont le remplacement n'est pas prévu dans le cadre de l’entretien obligatoire, ou pour laquelle est seulement prévue une inspection périodique pour "remplacement ou réparation si nécessaire" sera garantie pour la période de garantie. Toute pièce garantie arrivée à l’échéance de son premier remplacement prévu sera garantie jusqu’à celui-ci.

Toute pièce de rechange équivalente en performance ou en durabilité peut être utilisée pour l’entretien hors-garantie ou les réparations hors-garantie, et ce sans réduire l’obligation de garantie incombant à la société.

La société sera tenue responsable des dommages aux autres composants du moteur causés par la défaillance de pièce(s) garantie(s) en période de garantie.

La garantie ne s'applique pas aux unités endommagées par suite de: négligence dans la mise en oeuvre des instructions spécifiées dans le manuel du propriétaire/de l'utilisateur en vue d’une utilisation et d’un entretien correct, fausse manœuvre accidentelle, modification, utilisation abusive, lubrification incorrecte, utilisation de pièces ou d’accessoires autres que ceux spécifiés par la société, ou autres causes hors du contrôle de la société.

Cette garantie ne couvre pas les pièces remplacées en raison de leur usure normale ou de changements d’apparence sans effets.

Il n'existe aucune autre garantie explicite.

Les garanties implicites, y compris la valeur marchande et la valeur d'usage pour une utilisation particulière, sont

limitées deux (2) ans d'utilisation domestique, quatre-vingt-dix (90) jours d'utilisation commerciale, à compter de la date originale de livraison.

Les responsabilités pour les dommage conséquents ou incidents sont exclues de toutes les garanties.

Certaines provinces n'autorisant pas les limitations à la durée des garanties implicites, ou les exclusions ou limitations relatives aux dommages incidents ou conséquents, la limitation indiquée ci-dessus peut ne pas vous être applicable.

Cette garantie vous donne des droits juridiques spécifiques, et vous pouvez également jouir d’autres droits variant d'une province à l'autre.

Si vous désirez obtenir des informations sur le centre de service le plus proche, veuillez appeler KOMATSU

ZENOAH AMERICA INC. au (770)-381-5147

Note importante: vous recevrez une carte d'enregistrement de garantie au moment de l'achat. Veuillez la remplir et l'adresser à RedMax / KOMATSU ZENOAH AMERICA sous sept (7) jours en prenant soin de conserver une copie pour vous.

KOMATSU ZENOAH AMERICA INC.

4344 Shackleford Road Suite 500

Norcross, Georgia 30093

Printed in U.S.A.