Zenoah BKZ5000DL User Manual

BKZ4500DL / BKZ5000DL

848KH093A3 (704)

OWNER’S MANUAL

BRUSHCUTTERS

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BKZ4500DL
BKZ5000DL

GB-1

BKZ4500DL / BKZ5000DL

ZENOAH CO., LTD.

1st April 2007

Masahiko GOUDA

EXPLANATION OF SYMBOLS AND SAFETY WARNINGS

BKZ4500DL

WARNING!!!

RISK OF DAMAGING HEARING

Wear head, eye and ear protection.

BKZ5000DL

WARNING!!!

RISK OF DAMAGING HEARING

Wear head, eye and ear protection.

MODEL

EN27917

LpA

BKZ4500DL 45.2 cm399 dB(A) 117 dB(A) 118 dB(A) 0.8 m/s27.2 m/s
BKZ5000DL 50.6 cm3102 dB(A) 118 dB(A) 120 dB(A) 0.8 m/s27.5 m/s

SOUND LEVEL VIBRATION LEVEL

idling

ISO 7916

racing

ISO 10884

measured

LwA

guaranteed

2

2

GB-2

APPROVAL NUMBER OF CE EXHAUST EMISSION REGULATION

DIRECTIVE 97/68/EC AMENDED 2002/88/EC
BKZ4500DL : e13*97/68SH2G3*2002/88*0097*02
BKZ5000DL : e13*97/68SH3G3*2002/88*0099*03

BKZ4500DL / BKZ5000DL

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 .................................................. 3

2. Specifications ................................................. 4

3. Warning labels on the machine ...................... 4

4. Symbols on the machine ................................ 4

5. For safe operation ........................................... 5

6. Set up ............................................................. 8

7. Fuel ................................................................. 9

8. Operation ...................................................... 10

9. Maintenance ................................................. 13

10. Storage ......................................................... 15

11. Disposal ........................................................ 15

12. Troubleshooting guide .................................. 16

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1. Parts location

(1) Primer
(2) Air cleaner cover
(3) Choke lever
(4) Fuel tank
(5) Starter knob
(6) Blade
(7) Angle transmission
(8) Cutting Attachment guard

(9) Loop handle
(10) Shaft tube
(11) Flexible shaft
(12) Throttle trigger
(13) Stop switch
(14) Throttle cable
(15) Frame
(16) Back cushion

11

13

12

6

7

8

9

10

15

5

16

3

14

4

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BKZ4500DL / BKZ5000DL

2. Specification

Model BKZ4500DL BKZ5000DL

Overall size (LxWxH) mm 2805x395x590
Dry weight kg 12.0
Engine Model Zenoah GZ45N Zenoah GZ50N

Displacement cm
Fuel Mixture (Gasoline 50 : Oil 1) when using Zenoah genuine oil
Carburetor Diaphragm type
Ignition system Flywheel magneto (C.D.I.)

Spark plug NGK CMR7H
Fuel tank capacity L 1.0
Starter Recoil starter
Clutch Centrifugal type
Reduction ratio 1.4
Cutting head rotating direction Counter-clockwise (Operator view)

Specifications are subject to change without notice.

3

45.2 50.6

3. Warning labels on the machine

(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.

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).

4. Symbols on

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.

Position: FUEL TANK CAP

15

m

(50ft)

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”

GB-4

The direction to close the choke
Position: ENGINE COVER

The direction to open the choke
Position: ENGINE COVER

5. For safe operation

BKZ4500DL / BKZ5000DL

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
(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.

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
8 a.m. and 5 p.m. on weekdays
and 9 a.m. to 5 p.m. on weekends.

IMPORTANT

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

GB-5

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BKZ4500DL / BKZ5000DL

5. For safe operation

GB-6

BEFORE STARTING
THE ENGINE

1.

The area within a perimeter of
15 m (50 ft) 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 glass.

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 to attach the cutting at­tachment guard securely in
place, or you may get serious in­jury.

5. Always use the shoulder strap.
Adjust the strap for comfort be­fore starting the engine. The strap
should be adjusted so the left
hand can comfortably hold the
handlebar grip approximately
waist high.

STARTING THE ENGINE

1. Keep bystanders and animals at
least 15 m (50 ft) 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.

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 ZENOAH 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 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 serious burns or
electrical shock.

5. For safe operation

BKZ4500DL / BKZ5000DL

• 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 and disconnect the spark
plug wire 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 ZENOAH products or
products which have been cer­tified 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.

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

HANDLING FUEL

1. The engine of the ZENOAH prod­uct is designed to run on a mixed
fuel, which contains 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, 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 3 m
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.

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BKZ4500DL / BKZ5000DL

6. Set up

INSTALLING HANDLE

• Mount the handle to the shaft tube and clamp it at a
location that the edge of CE label is matched with the
handle.

WARNING

• Stop tightening the screws when the gap A be­comes zero.

CE label

FLEXIBLE SHAFT

1. Remove the bolt located on the joint of the shaft tube.

2. Match the groove of the liner with the threaded hole
and fix with screw securely.

(1)Bolt
(2)Joint
(3)Groove

While rotating the flexible shaft located on the opposite

3.
end from the liner, insert the flexible shaft into the joint
until it is tightly connected. (Note that it is normal at this
time for the flexible shaft not to project from the liner.)

(1)Flexible shaft
(2)Liner
(3)Clutch housing

4. Put the engine side end of the flexible shaft into the
clutch housing, making the hole on the shaft upside.
Push it on until the stopper catches the hole.

INSTALLING CUTTING
ATTACHMENT GUARD

•Attach the cutting
attachment guard with the
bolts provided to the shaft.

INSTALLING BLADE

1. Put the angled bar(1) into
the side holes of the inner
holder and the angle
transmission.

2.

Remove the nut (Lefthanded)
and the outer holder(3) from
the gearshaft.

3. Put the blade onto the inner
holder(2). Make the marked
side face the holder.

4. Put the outer holder(3) onto
the gearshaft making the
recessed side face the
blade.

5. Fasten the blade by the nut
and the cover(4).

INSTALLING LINE HEAD

1. While locking the gear shaft by inserting the supplied
tool into the upper holder on the angle transmission,
loosen and remove the nut (left-handed).

2. Detach the cover(1), fit the line head assembly to the
gear shaft. Hand tighten it securely.

(1) Stopper
(2) Flexible liner
(3) Clutch housing

5. Pass the end of the wire on the side of the blade
through the sleeve of the connector case.

6. Insert the end of the wire on the side of the blade into
the end of the wire on the side of the engine, and put
the sleeve over the connected part (Fig. 6).

7.

Align the throttle wire and the sleeve with the hollow of
the connector case and insert them into the connector
case, and close the connector case. In order to close
the connector case, align half the surface of the con­nector case with the other half surface and press the
upper half surface strongly with your fingers.

(1) The end of the

wire on the side

of the engine
(2) Sleeve
(3) The end of the

wire on the side

(1)

of the blade
(4) Connector case

GB-8

INSTALLING CUTTING
ATTA C HMENT GUARD
FOR LINE HEAD

• When using line head, make
sure to attach the guard
skirt.

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.

7. Fuel

BKZ4500DL / BKZ5000DL

■ FUEL

• 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 3 m (10 ft) away from the
fueling point before starting the engine.

• 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 2­cycle engine use (JASO FC GRADE OIL or ISO EGC
GRADE).

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

■ RECOMMENDED MIXING RATIO

GASOLINE 50 : OIL 1
<when using ZENOAH genuine oil>

• 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 89RON (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

• 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
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.

1. Select bare ground for fueling.

2. Move at least 3 m (10 ft) 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 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.

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BKZ4500DL / BKZ5000DL

8. Operation

STARTING ENGINE

WARNING

• The cutting head will start rotating upon the en­gine starts.

1. Feed fuel into the fuel tank and tighten the cap se­curely.

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 several times until overflown fuel flows
out in the clear tube.

(1)

4. Move the choke lever to the closed position.

(1)

(2)

(3)

(1) choke lever
(2) close
(3) open

5. Set the stop switch to the “RUN” position.
Place the unit on a flat, firm place.
Keep the cutting head clear of everything around it.

(1)

WARNING

• 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 trigger 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 trigger come into contact with any ob­stacle when the engine starts.

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 downward to open the choke.
And restart engine.

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

NOTE

1. When restarting the engine immediately after stop­ping it, leave the choke open.

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.

(1) stop switch

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

GB-10

STOPPING ENGINE

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

2. Shift the stop switch to the STOP position.

(1)

(1) stop switch

IMPORTANT

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

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.

(2)

(1)

ADJUSTING IDLING SPEED

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.

(1)

(1) Cable adjuster
(2) 1~2mm (0.04in)

(1) Idle speed adjuster
(cross screw)

BKZ4500DL / BKZ5000DL

G
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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 fas­tened according to instruction and the blade turns
smoothly without abnormal noise.

NOTE

•Warm up the engine before adjusting the idling speed.

PUTTING ON THE UNIT

1. Start the engine and warm it up.

2. As holding the front handle with your right hand, put
on the unit on your left shoulder.

3. After passing the front handle to your left hand, put
the right strap on your shoulder.

4. Adjust the shoulder strap length to your comfortable
position.

5. Connect the waist strap and the front middle strap.

6. Adjust the strap length to your comfortable position.

CUTTER APPLICATION CHART

• Replace by a suitable recommended cutting attach­ment according to the object to be cut.

• When replacing blade always be sure to use products
which have been certified by ZENOAH.

WARNING

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.

• 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.

WARNING

• Make sure to use shoulder strap and cutting at­tachment guard. If not, it is vary dangerous when
you slip or lose your balance.

• Be sure to use genuine parts made of Zenoah for
blades. In particular, never use special blades such
as shredder blades. If you use a special blade, the
unit may fail.

• Do not use the Zenoah blade 848-JLO-92A2 or the
blade whose thickness is more than 2mm.

• When sharpening, removing, or reattaching the
blade, be sure to wear thick, sturdy gloves and use
only proper tools and equipment to prevent injury.

GB-11

BKZ4500DL / BKZ5000DL

8. Operation

CUTTING METHOD

(a)Use the front left side cutting.
(b) Guide the blade from your right to left with it tilted

slightly to your left.

(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.

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
completely stop before checking the blade, and re­moving any object got caught in.

WARNING

CONTROLLING BLADE BOUNCE

•Kick back can cause serious personal injury. Care­fully study this section. It is important that you under­stand what causes kick back, how you can reduce
the chance of kick back and how you can remain in
control of the unit if kick back does occur.

1. What causes kick back:

• Kick back 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.

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.

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 cutting attachment guard in place at all

times when the unit is operated.

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.

1. Hold the unit so the head is off the ground and is tilted

about 20 degrees toward the sweep direction.

2. How you can reduce the chance of kick back:

a. Recognize that kick back can happen. By understand-

ing and knowing about bounce, you can help elimi­nate the element of surprise.

b. Cut fibrous weeds and grass only. Do not let the blade

contact materials it cannot cut such as hard, woody
vines and brush or rocks, fences, metal, etc

c. Be extra prepared for bounce if you must cut where

you cannot see the blade making contact such as in
areas of dense growth.

GB-12

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.

8. Operation

BKZ4500DL / BKZ5000DL

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

5. Tr y 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 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.

• Make the right and left lines the same length when
using the nylon line head.
(Be sure to install the genuine Zenoah cutting attach­ment guard when using the nylon line head.)

• If the lengths of the right and left lines are different,
the balance of the nylon line head will be disrupted,
resulting in increased vibration and product damage.

•

If you feel a vibration increase or drive shaft housing shak­ing while using the nylon line head, immediately stop opera­tion, check the following items, and correct any problems.

The lengths of the right and left lines are significantly
different.

-->Make them the same length.

The cover is removed.

-->Make sure to install it securely.

There is a crack or damage outside.

-->Replace the damaged part.

• If vibration or shaking persists even after repairing, or
if you cannot identify the cause of abnormality, con­tact your local authorized Zenoah dealer for repair.

• Never continue to operate the unit when vibration or
shaking of the drive shaft housing persists.

G
B

9. Maintenance

Every Every Every

System/components Procedure

fuel leaks, fuel spillage wipe out ✔
fuel tank, air filter, fuel filter inspect/clean ✔✔ replace, if necessary

idle speed adjuster ✔

spark plug ✔

ENGINE

cylinder fins, intake air cooling vent
muffler, spark arrester, cylinder exhaust port
throttle trigger, stop switch check operation ✔

cutting parts ✔

angle transmission grease ✔
screws/nuts/bolts tighten/replace ✔✔except adjusting screw

SHAFT

cutting attachment guard make sure to attach ✔
flexible shaft grease, seal ✔

BLADE

• Check the blade and the fasteners for looseness,
cracking, or bending.

• Check the cutting edges and reform with a flat file.

see adjusting replace carburetor
idling speed if necessary
clean and readjust GAP: 0.6 ~ 0.7 mm (.025 in)
plug gap replace, if necessary
clean ✔
clean ✔

replace if
something’s wrong

Before

use

25 50 100

hours hours hours

after after after

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.

• It is recommended that filing should be done by
professionals.

• Especially regarding filing the saw blade, Leave it to
the professionals.

Note

GB-13

BKZ4500DL / BKZ5000DL

(1)

9. Maintenance

REFILLING TRIMMING LINE

1. For replacement line, use a diameter of 2.4mm(.095in).
The spool is capable for a line upto 6m(20ft) on the
10cm(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.
Line up the slot on the bottom cap with the hook on the

7.
housing, press the cap against the housing until it clicks.

AIR FILTER

•The air filter, if clogged, will reduce the engine per­formance. Check and clean the paper element by air
blow as required. If the element becomes dirty, re­place with a new one.

(1) Paper element

FUEL FILTER

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

(1)

(1) Fuel filter

SPARK PLUG

• 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 re­placement plug, use the correct type specified by
ZENOAH.

WARNING

Make sure that the engine has stopped and is cool before per-

•

forming any service to the machine. Contact with moving cut­ting head or hot muffler may result in a personal injury.

GB-14

0.6~0.7 mm

• REPLACEMENT PLUG IS A NGK CMR7H.

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:

9.8 ~ 11.8 N.m.
(1 ~ 1.2 kgm)

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.

(1)

(2)

(2)

9. Maintenance

BKZ4500DL / BKZ5000DL

ANGLE TRANSMISSION

• The reduction gears are lubricated by multipurpose,
lithium-based grease in the angle transmission. Sup­ply new grease every 25 hours of use or more often
depending on the job condition.

• Remove the bolt of the grease nipple and the bolt
opposite side of the grease nipple. Install new grease
into the grease nipple to arrange for old grease to
exit from the opposite side.

(1)

FLEXIBLE SHAFT

1. Pull out the flexible liner while pulling the stopper up­ward.

2. Pull out the inner shaft from the clutch housing side
hole, apply Zenoah Guine Power Grease (Z3180-

91250) or lithium-based heat-resistant grease (#2) to
the shaft, and insert the shaft back into the liner.

(1) Grease

(1) Stopper
(2) Flexible liner
(3) Clutch housing

(4) Inner shaft

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.

• 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 upper cover and
the lower cover shown in 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.

(1) Cylinder
(2) Intake air
cooling vent

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.

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.

G
B

3. Replace the inside seal at the grip side of the flexible
shaft. (848-KH0-59K0)

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-

10. Storage

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

11. Disposal

When disposing your machine, fuel or oil for the machine,
be sure to allow your local regulations.

GB-15

BKZ4500DL / BKZ5000DL

12. Troubleshooting guide

Case 1. Starting failure

CHECK PROBABLE CAUSES ACTION

fuel tank → incorrect fuel → drain it and use correct fuel
fuel filter → fuel filter is clogged → clean
carburetor adjustment screw → out of normal range → adjust to normal range
sparking (no spark) → spark plug is fouled/wet → clean/dry

→ plug gap is incorrect → correct (GAP: 0.6 ~ 0.7 mm)

spark plug → disconnected → 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 use correct fuel
carburetor adjustment screw → out of normal range → adjust to normal range
muffler, cylinder (exhaust port) → carbon is built-up → wipe away
air cleaner → clogged with dust → wash
cylinder fin, fan cover → clogged with dust → 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 oper­ating conditions within the applicable warranty period, the
failed part will be replaced or repaired free of charge by a
ZENOAH authorized dealer.

WARRANTY PERIOD: 1 year (6 months if used profession­ally, and 30 days if used for rental purpose) from the date of
initial purchase.

THE PURCHASER SHALL BEAR COSTS OF TRANS­PORTING THE UNIT TO AND FROM THE ZENOAH 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 ZENOAH 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 REPLACEMENT 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 PART 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
ACCIDENT MISHANDLING, ALTERATION, ABUSE, IM­PROPER LUBRICATION, USE OF ANY PARTS OR ACCES­SORIES OTHER THAN THOSE SPECIFIED BY THE COM­PANY, OR OTHER CAUSES BEYOND THE COMPANY’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 MER-

CHANTABILITY AND FITNESS FOR A PARTICULAR PUR­POSE ARE LIMITED TO TWO (2) YEARS OF HOME USE
[ONE (1) YEAR FOR ANY OTHER USE] FROM THE ORIGI­NAL DELIVERY DATE.

LIABILITIES FOR INCIDENTAL OR CONSEQUENTIAL
DAMAGE UNDER ANY AND ALL WARRANTIES ARE
EXCLUDED.

IF YOU NEED TO OBTAIN MORE INFORMATION, PLEASE
CALL YOUR NEAREST SERVICE CENTER,
OR CHECK PLEASE ZENOAH WEB SITE
http://www.zenoah.net

GB-16