MTD TB475SS, TB490BC User Manual
Operator’s Manual
PRINTED IN U.S.A.
PART NO. 769-01361 (10/04)
TB425CS,
TB475SS,
TB490BC
4-Cycle Gas Trimmers
IMPORTANT: READ SAFETY RULES AND INSTRUCTIONS CAREFULLY
2
INTRODUCTION
Copy the serial number
here:
THANK YOU
Thank you for buying this quality product. This modern
outdoor power tool will provide many hours of useful
service. You will find it to be a great labor-saving device.
This operator’s manual provides you with easy-tounderstand operating instructions. Read the whole
manual and follow all the instructions to keep your new
outdoor power tool in top operating condition.
PRODUCT REFERENCES, ILLUSTRATIONS
AND SPECIFICATIONS
All information, illustrations, and specifications in this
manual are based on the latest product information
available at the time of printing. We reserve the right to
make changes at any time without notice.
Copyright© 2004 MTD SOUTHWEST INC, All Rights
Reserved.
SERVICE INFORMATION
Service on this unit both within and after the warranty
period should be performed only by an authorized and
approved service dealer.
For service call 1-800-520-5520 to obtain a list of
authorized service dealers near you. For more details
about your unit, visit our website at www.troybilt.com.
DO NOT RETURN THE UNIT TO THE RETAILER.
PROOF OF PURCHASE WILL BE REQUIRED FOR
WARRANTY SERVICE.
Before beginning, locate the unit’s model plate. It lists
the model and serial numbers of your unit. Refer to the
sample plate below and copy the information for future
reference.
Make sure you carefully read and understand this manual
before starting or operating this equipment.
THIS PRODUCT IS COVERED BY ONE OR MORE U.S.
PATENTS. OTHER PATENTS PENDING.
TABLE OF CONTENTS
Service Information . . . . . . . . . . . . . . . . . . . . . . . . .2
Rules for Safe Operation . . . . . . . . . . . . . . . . . . . . .3
Know Your Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . .8
Oil and Fuel Information . . . . . . . . . . . . . . . . . . . . .11
Starting/Stopping Instructions . . . . . . . . . . . . . . . .13
Operating Instructions . . . . . . . . . . . . . . . . . . . . . .14
Maintenance and Repair Instructions . . . . . . . . . . .17
Cleaning and Storage . . . . . . . . . . . . . . . . . . . . . . .26
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . .27
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Warranty Information . . . . . . . . . . . . . . . . . . . . . . .30
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . E31-E35
Copy the model and parent
part number here:
SPARK ARRESTOR NOTE
NOTE: For users on U.S. Forest Land and in the
states of California, Maine, Oregon and Washington.
All U.S. Forest Land and the state of California (Public
Resources Codes 4442 and 4443), Oregon and
Washington require, by law that certain internal
combustion engines operated on forest brush and/or
grass-covered areas be equipped with a spark arrestor,
maintained in effective working order, or the engine be
constructed, equipped and maintained for the prevention
of fire. Check with your state or local authorities for
regulations pertaining to these requirements. Failure to
follow these requirements could subject you to liability or
a fine. This unit is factory equipped with a spark
arrestor. If it requires replacement, ask your LOCAL
SERVICE DEALER to install the Accessory Part
#180890 Spark Arrestor Kit.
CALIFORNIA PROPOSITION 65 WARNING
WARNING
THE ENGINE EXHAUST FROM THIS
PRODUCT CONTAINS CHEMICALS
KNOWN TO THE STATE OF CALIFORNIA
TO CAUSE CANCER, BIRTH DEFECTS
OR OTHER REPRODUCTIVE HARM.
MODEL :
S/N :
ITEM :
3
RULES FOR SAFE OPERATION
SYMBOL MEANING
The purpose of safety symbols is to attract your
attention to possible dangers. The safety symbols,
and their explanations, deserve your careful attention
and understanding. The safety warnings do not by
themselves eliminate any danger. The instructions or
warnings they give are not substitutes for proper
accident prevention measures.
NOTE: Advises you of information or instructions vital to
the operation or maintenance of the equipment.
SYMBOL MEANING
Failure to obey a
safety warning can
result in injury to yourself and others.
Always follow the safety precautions to
reduce the risk of fire, electric shock and
personal injury.
WARNING:
Failure to obey a
safety warning will
result in serious injury to yourself or to
others. Always follow the safety precautions
to reduce the risk of fire, electric shock and
personal injury.
DANGER:
Failure to obey a
safety warning may
result in property damage or personal injury
to yourself or to others. Always follow the
safety precautions to reduce the risk of fire,
electric shock and personal injury.
CAUTION:
Indicates
danger,
warning or caution. Attention is required in
order to avoid serious personal injury. May
be used in conjunction with other symbols
or pictographs.
SAFETY ALERT:
Read the Operator’s Manual(s) and follow all
warnings and safety instructions.
Failure to do so can result in serious injury to the
operator and/or bystanders.
FOR QUESTIONS, CALL 1-800-520-5520
READ ALL INSTRUCTIONS
BEFORE OPERATING
• Read the instructions carefully. Be familiar with the
controls and proper use of the unit.
• Do not operate this unit when tired, ill, or under the
influence of alcohol, drugs, or medication.
• Children and teens under the age of 15 must not use
the unit, except for teens guided by an adult.
• All guards and safety attachments must be installed
properly before operating the unit.
• Inspect the unit before use. Replace damaged parts.
Check for fuel leaks. Make sure all fasteners are in
place and secure. Replace parts that are cracked,
chipped, or damaged in any way. Do not operate the
unit with loose or damaged parts.
• Carefully inspect the area before starting the unit.
Remove all debris and hard or sharp objects such as
glass, wire, etc.
• Be aware of the risk of injury to the head, hands and
feet.
• Clear the area of children, bystanders, and pets. At a
minimum, keep all children, bystanders, and pets
outside a 50 feet (15 m.) radius; there still may be a
risk to bystanders from thrown objects. Bystanders
should be encouraged to wear eye protection. If you
are approached, stop the unit immediately.
• Use only 0.095 inch,
2.41 mm (for the TB425CS &
TB475SS), or 0.105 inch, 2.67 mm (for the TB490BC
brushcutter), diameter original equipment
manufacturer replacement line. Never use metalreinforced line, wire or rope. These can break off and
become dangerous projectiles.
• Squeeze the throttle control and check that it returns
automatically to the idle position. Make all adjustments
or repairs before using unit.
SAFETY WARNINGS FOR GAS UNITS
• Store fuel only in containers specifically designed and
approved for the storage of such materials.
• Avoid creating a source of ignition for spilled fuel. Do
not start the engine until fuel vapors dissipate.
When using the unit,
you must follow the
safety rules. Please read these instructions
before operating the unit in order to ensure
the safety of the operator and any bystanders.
Please keep these instructions for later use.
WARNING:
• IMPORTANT SAFETY INSTRUCTIONS •
Gasoline is highly
flammable, and its
vapors can explode if ignited. Take the
following precautions:
WARNING:
4
RULES FOR SAFE OPERATION
• Always stop the engine and allow it to cool before
filling the fuel tank. Never remove the fuel tank cap or
add fuel when the engine is hot. Never operate the unit
without the fuel cap securely in place. Loosen the fuel
tank cap slowly to relieve any pressure in the tank.
• Add fuel in a clean, well-ventilated outdoor area where
there are no sparks or flames. Remove the fuel cap
slowly, and only after the engine stops. Do not smoke
while fueling. Wipe up any spilled fuel from the unit
immediately.
• Avoid creating a source of ignition for spilled fuel. Do
not start the engine until fuel vapors dissipate.
• Move the unit at least 30 feet (9.1 m) from the fueling
source and site before starting the engine. Do not
smoke. Keep sparks and open flames away from the
area while adding fuel or operating the unit.
WHILE OPERATING
• Never start or run the unit inside a closed room or
building. Breathing exhaust fumes can be fatal.
Operate this unit only in a well-ventilated outdoor area.
• Wear safety glasses or goggles that meet ANSI Z87.1
standards and are marked as such. Wear ear/hearing
protection when operating this unit. Wear a face or
dust mask if the operation is dusty.
• Wear heavy long pants, boots, gloves and a long
sleeve shirt. Do not wear loose clothing, jewelry, short
pants, sandals or go barefoot. Secure hair above
shoulder level.
• The cutting attachment shield must always be in place
while operating the unit as a trimmer. Do not operate
unit without both trimming lines extended, and the
proper line installed. Do not extend the trimming line
beyond the length of the shield.
• This unit has a clutch. The cutting attachment remains
stationary when the engine is idling. If it does not, have
the unit adjusted by an authorized service technician.
• Adjust the handle to your size in order to provide the
best grip.
• Be sure the cutting attachment is not in contact with
anything before starting the unit.
• Use the unit only in daylight or good artificial light.
• Avoid accidental starting. Be in the starting position
whenever pulling the starter rope. The operator and
unit must be in a stable position while starting. Refer
to Starting/Stopping Instructions.
• Use the right tool. Only use this tool for its intended
purpose.
• Do not overreach. Always keep proper footing and
balance.
• Always hold the unit with both hands when operating.
Keep a firm grip on both handles or grips.
• Keep hands, face, and feet at a distance from all
moving parts. Do not touch or try to stop the cutting
attachment when it rotates.
• Do not touch the engine, gear housing or muffler.
These parts get extremely hot from operation, even
after the unit is turned off.
• Do not operate the engine faster than the speed
needed to cut, trim or edge. Do not run the engine at
high speed when not cutting.
• Always stop the engine when cutting is delayed or
when walking from one cutting location to another.
• If you strike or become entangled with a foreign
object, stop the engine immediately and check for
damage. Do not operate before repairing damage. Do
not operate the unit with loose or damaged parts.
• Stop the unit, switch the engine to off, and disconnect
the spark plug for maintenance or repair.
• Use only original equipment manufacturer replacement
parts and accessories for this unit. These are available
from your authorized service dealer. Use of any
unauthorized parts or accessories could lead to
serious injury to the user, or damage to the unit, and
void your warranty.
• Keep unit clean of vegetation and other materials.
They may become lodged between the cutting
attachment and shield.
• To reduce fire hazard, replace a faulty muffler and
spark arrestor. Keep the engine and muffler free from
grass, leaves, excessive grease or carbon build up.
TB490BC ONLY:
WHILE OPERATING
WITH CUTTING BLADE
• Read and understand all safety warnings before
operating this unit.
• Always use the shoulder harness when using the
brush blade accessory.
• Keep the J-handle between the operator and cutting
attachment or blade at all times.
• NEVER cut when the cutting blade is 30 inches
(76 cm) or more above the ground level.
• Blade thrust may occur when the spinning blade
contacts an object that it does not immediately cut.
Blade thrust can be violent enough to propel the unit
and/or operator in any direction, possibly causing a loss
of control. Blade thrust can occur without warning if the
blade snags, stalls or binds. This is more likely to occur
in areas where it is difficult to see the material being cut.
• For operation with the brush blade, do not cut
anything thicker than 1/2 inch or a violent kickback
could occur.
5
RULES FOR SAFE OPERATION
• Do not attempt to touch or stop the blade when it is
rotating.
•A coasting blade can cause injury while it continues to
spin after the engine is stopped or the throttle trigger
is released. Maintain proper control until the blade has
completely stopped rotating.
• Do not run the unit at high speed when not cutting.
• If you strike or become entangled with a foreign
object, stop the engine immediately and check for
damage. Have any damage repaired before attempting
further operations. Do not operate unit with a bent,
cracked or dull blade. Discard blades that are bent,
warped, cracked or broken.
• Do not sharpen the cutting blade. Sharpening the blade
can cause the blade tip to break off while in use. This
can result in severe personal injury. Replace the blade.
• Do not use the cutting blade for edging or as an edger;
severe personal injury to yourself or others may incur.
Use the cutting blade only for the purpose described
in this manual.
• Stop the engine IMMEDIATELY if you feel excessive
vibration. Vibration is a sign of trouble. Inspect
thoroughly for loose nuts, bolts or damage before
continuing. Repair or replace affected parts as
necessary.
After Use
• Clean cutting blades with a household cleaner to
remove any gum buildup. Oil the blade with machine
oil to prevent rust.
• Lock up and store the cutting blade in an appropriate
area to protect the blade from unauthorized use or
damage.
OTHER SAFETY WARNINGS
• Never store a fueled unit inside a building where fumes
may reach an open flame or spark.
• Allow the engine to cool before storing or transporting.
Be sure to secure the unit while transporting.
• Store the unit in a dry area, locked up or up high to
prevent unauthorized use or damage, out of the reach
of children.
• Never douse or squirt the unit with water or any other
liquid. Keep handles dry, clean and free from debris.
Clean after each use, see Cleaning and Storage
instructions.
• Keep these instructions. Refer to them often and use
them to instruct other users. If you loan someone this
unit, also loan them these instructions.
SAVE THESE
INSTRUCTIONS
6
RULES FOR SAFE OPERATION
SYMBOL MEANING
• SAFETY ALERT SYMBOL
Indicates danger, warning, or
caution. May be used in conjunction
with other symbols or pictographs.
• WARNING - READ OPERATOR'S
MANUAL
Read the Operator’s Manual(s) and
follow all warnings and safety
instructions. Failure to do so can
result in serious injury to the
operator and/or bystanders.
• WEAR EYE AND HEARING
PROTECTION
WARNING: Thrown objects and
loud noise can cause severe eye
injury and hearing loss. Wear eye
protection meeting ANSI Z87.1-1989
standards and ear protection when
operating this unit.
Use a full face
shield when needed.
• KEEP BYSTANDERS AWAY
WARNING: Keep all bystanders,
especially children and pets, at least
50 feet (15 m.) from the operating area.
• UNLEADED FUEL
Always use clean, fresh unleaded fuel.
• THROWN OBJECTS AND
ROTATING CUTTER CAN CAUSE
SEVERE INJURY
WARNING:Do not
operate without the cutting
attachment shield in place.
Keep away from the rotating cutting
attachment.
SAFETY AND INTERNATIONAL SYMBOLS
This operator's manual describes safety and international symbols and pictographs that may appear on this product.
Read the operator's manual for complete safety, assembly, operating and maintenance and repair information.
SYMBOL MEANING
•ON/OFF STOP CONTROL
ON / START / RUN
•ON/OFF STOP CONTROL
OFF or STOP
• HOT SURFACE WARNING
Do not touch a hot muffler or
cylinder. You may get burned. These
parts get extremely hot from
operation. When turned off they
remain hot for a short time.
•
TB490BC ONLY:
BRUSHCUTTERS
• REPLACE
DULL BLADE
Do not sharpen the cutting blade.
Sharpening the blade can cause the
blade tip to break off while in use. This
can result in severe personal injury.
•
TB490BC ONLY:
TRIMMER/
BRUSHCUTTER SAFETY
WARNING:Thrown
objects and rotating cutter can cause
severe injury. Keep bystanders,
especially children and pets, at least
50 feet (15 m) away from the cutting
area. The cutting attachment shield
must be used when using the
trimmer cutting attachment.
• OIL
Refer to operator's manual for the
proper type of oil.
7
KNOW YOUR UNIT
APPLICATIONS
As a trimmer:
• Cutting grass and light weeds
• Edging
• Decorative trimming around trees, fences, etc.
As a brushcutter (TB490BC only):
• Cutting weeds and light brush of up to 1/2 inch in
diameter
Other optional accessories may be used with your unit.
Refer to Operating the EZ-Link System for a list of add-ons.
NOTE: The below illustration may differ slightly
from your unit. For example, the picture shows
a straight shaft. Your unit may have a curved
shaft. Also, the TB475SS has a D-handle,
although only a J-handle is pictured.
Primer
Bulb
Oil Fill Plug /
Dipstick
Air Filter
Cover
Engine
Feet
Spark Plug
Cutting Attachment
Shield
Fuel
Cap
Throttle
Control
Throttle Lock-Out
(TB490BC only)
J-Handle
(TB425CS & TB475SS only)
Cutting Attachment
Gear
Housing
Shaft Grip
On/Off Stop Control
Shaft
Housing
Starter Rope Grip
EZ-Link™
Blade Shield /
Shield Mount
(TB490BC only)
Brush Blade
(TB490BC only)
Line Cutting Blade
Spark Plug
Muffler
Muffler Guard
Spark Arrestor
Shoulder Strap Clip
8
ASSEMBLY INSTRUCTIONS
ADJUST THE D-HANDLE
The TB475SS uses a D-handle, which is pre-installed on
the unit. If you ever need to adjust it, make sure it is at
least 6 inches from the end of the shaft grip (Fig. 1).
2. While holding the three pieces together, install the four
(4) screws through the top clamp and into middle clamp.
NOTE: The holes in the top and middle clamp will line up
only when assembled correctly.
3. Place the clamps and the J-handle over the shaft
housing and onto the bottom clamp.
4. Hold each hex nut in the bottom clamp recess with a
finger. Start screws with a large Phillips screwdriver.
Do not tighten until you make the handle adjustment.
5. Slide the J-handle in or out until the arrow/white line on
the decal touches the clamp assembly (Fig. 3). You must
first loosen the screws if the handle is pre-installed.
Fig. 2
Fig. 3
6. While holding the unit in the operating position
(Fig. 27), position the J-handle to the location that
provides you the best grip.
7. Tighten the clamp screws evenly, until the J-handle
is secure.
INSTALL AND ADJUST THE J-HANDLE
1. Place the J-handle between the top and middle
clamp pieces (Fig. 2).
Decal
TB490BC ONLY: INSTALL THE HARNESS
1. Push the strap through the center of the buckle.
2. Pull the strap over the cross bar and down through
the slot in the buckle (Fig. 4).
3. Put the harness on over head and onto shoulder.
Snap it on to the support fitting (Fig. 5).
4. Adjust length to fit the operator’s size. Pull tab to
lengthen, pull strap to shorten (Fig 6).
Support Fitting
Fig. 4
Fig. 5
Fig. 6
TB490BC ONLY: REMOVE AND INSTALL
THE CUTTING ATTACHMENT SHIELD
Remove the cutting attachment shield when
using the unit as a brushcutter
Remove the cutting attachment shield from the shield
mount by removing the three (3) screws with a flat blade
screwdriver (Fig. 7). Store parts for future use.
The cutting
attachment shield
should NOT be installed when operating the
unit with a blade. Remove the cutting
attachment shield before removing or
installing the blade.
WARNING:
Always use the
shoulder harness
when using the cutting blade to avoid
serious personal injury.
WARNING:
(4) Screws
Top Clamp
J-Handle
Middle Clamp
Bottom Clamp
Nuts
Shaft
Housing
Bottom Clamp
Shaft Grip
Minimum 6 inches
(15.24 cm)
Fig. 1
9
ASSEMBLY INSTRUCTIONS
Install the cutting attachment shield when using
the unit as a grass trimmer
Install the cutting attachment shield on the shield mount
by inserting the three (3) screws into the shield mount.
Tighten securely with a flat blade screwdriver (Fig. 7).
TB490BC ONLY: REMOVE THE CUTTING
ATTACHMENT & INSTALL CUTTING BLADE
NOTE: To make cutting blade removal and installation easier,
place the unit on the ground or on a work bench
.
Remove the Cutting Attachment Shield
See Remove and Install the Cutting Attachment Shield.
Remove the Cutting Attachment
1.
Align the shaft bushing hole with the locking rod slot and
insert the locking rod into the shaft bushing hole (Fig. 8).
(3) Screws
Cutting
Attachment
Shield
Shield Mount
Gear Housing
Fig. 7
Cutting Attachment
Locking Rod
Slot
Locking Rod
Shaft Bushing Hole
Locking Rod Slot
Output Shaft
Bushing
Locking Rod
Output Shaft
2. Hold the locking rod in place by grasping it next to
the boom of the unit (Fig. 9).
3. While holding the locking rod, remove the cutting
attachment by turning it clockwise off of the output shaft
(Fig. 10). Store the cutting attachment for future use.
NOTE: The blade retainer under the cutting attachment
will be used when installing the cutting blade.
Fig. 8
Fig. 10
Fig. 9
Install the Cutting Blade
4. Place the cutting blade on the output shaft bushing
(Fig. 11).
Shield
Mount
Locking Rod
Cutting
Blade
Blade Retainer
Nut
Output Shaft
Bushing
Pilot Hole
Fig. 11
The gear housing
gets hot with use. It
can result in injury to the operator. The
housing remains hot for a short time even
after the unit is turned off. Do not touch the
gear housing until it has cooled.
WARNING:
To avoid serious
personal injury, the
cutting attachment shield MUST be in place
at all times while operating the unit as a
grass trimmer.
WARNING:
To avoid serious
personal injury,
always wear gloves while handling or
installing the blade.
WARNING:
10
ASSEMBLY INSTRUCTIONS
Fig. 15
Fig. 12
Pilot Step
TB490BC ON LY: REMOVE CUTTING BLADE
& INSTALL THE CUTTING ATTACHMENT
Remove the Cutting Blade
1. Align the shaft bushing hole with the locking rod slot
and insert the locking rod into the bushing hole (Fig. 8).
2. Hold the locking rod in place by grasping it next to
the boom of the unit (Fig. 14).
3. While holding the locking rod, loosen the nut on the
blade by turning it clockwise with a 5/8 inch closedend or socket wrench (Fig. 14).
Fig. 13
9. Remove the locking rod from the locking rod slot.
1/4-1/2 turn
Counterclockwise
6. Align the shaft bushing hole with the locking rod
slot and insert the locking rod into the bushing hole
(Fig. 8).
7. Put the blade retainer and nut on the output shaft.
Make sure that the blade is installed correctly.
8. Tighten nut counterclockwise against the blade while
holding the locking rod:
• If using a torque wrench and an 5/8 inch socket tighten
to: 325 - 335 in•lb, 27 - 28 ft.•lb, 37 - 38 N•m.
•Without a torque wrench, use a 5/8 inch closed-end or
socket wrench, turning the nut until the blade retainer
is snug against the shaft bushing. Make sure that the
blade is installed correctly, then rotate the nut an
additional 1/4 to 1/2 turn counterclockwise (Fig. 13).
Cutting Attachment
Locking Rod
Clockwise
6. Remove the locking rod.
7. Install the cutting attachment shield. Refer to Remove
and Install the Cutting Attachment Shield.
Blade Retainer
Output Shaft
Bushing
Fig. 14
5. Make sure that the cutting blade is centered on the
pilot step and sitting flat against the output shaft
bushing (Fig. 12).
4. Remove the nut, blade retainer and blade. Store the
nut and blade together for future use in a secure
place. Store out of children’s reach.
Install the Cutting Attachment
5.
Align the shaft bushing hole with the locking rod slot and
insert the locking rod into the shaft bushing hole (Fig. 8).
Place the blade retainer on the output shaft with the flat
surface against the output shaft bushing (Fig. 15). Screw
the cutting attachment counterclockwise onto the output
shaft. Tighten securely.
NOTE: The blade retainer must be installed on the output
shaft in the position shown for the cutting
attachment to work correctly.
If the cutting blade
is off-center, the
unit will vibrate and the blade may fly off,
causing possible serious personal injury.
WARNING:
To avoid serious
personal injury,
always wear gloves while handling or
installing the blade.
WARNING:
Do not sharpen the
cutting blade.
Sharpening the blade can cause the blade tip
to break off while in use. This can result in
severe personal injury. Replace the blade.
WARNING:
To avoid serious
personal injury or
damage to the unit, do not start or operate this
unit with the locking rod in the locking rod slot.
WARNING:
To avoid serious
personal injury, the
cutting attachment shield MUST be in place at
all times while operating the unit as a trimmer.
WARNING:
11
OIL AND FUEL INFORMATION
RECOMMENDED OIL TYPE
Using the proper type and weight of oil in
the crankcase is extremely important.
Check the oil before each use and change
the oil regularly. Failure to use the correct oil, or using
dirty oil, can cause premature engine wear and failure.
Use a high-quality SAE 30 weight oil of API (American
Petroleum Institute) service class SF, SG, SH.
ADDING OIL TO CRANKCASE: INITIAL USE
NOTE: This unit is shipped without oil. In order to avoid
damage to the unit, put oil in the crankcase
before you attempt to start the unit.
Your unit is supplied with one 3.4 fluid oz. (100 ml.)
bottle of SAE 30 SF, SG, SH oil (Fig. 16).
NOTE: Save the bottle of oil. It can be used to measure
the correct amount during future oil changes.
See Changing the Oil.
1. Unscrew the top of the bottle of oil and remove the
paper seal covering the opening. Replace the top.
Next, cut the tip off the funnel spout (Fig. 16).
2. Place the unit on a flat level surface (Fig. 18).
3. Remove the oil plug / dipstick from the crankcase
(Fig. 17).
Fig. 16
Fig. 18
Oil Fill
NOTE: Never add oil to the fuel or fuel tank.
5. Wipe up any oil that may have spilled and reinstall
the oil fill plug / dipstick.
Check oil before each use and change as needed. Refer
to Changing the Oil.
Oil Fill Plug/Dipstick
Oil Fill Hole
Fig. 17
4. Pour the entire bottle of oil into the oil fill hole
(Fig. 18).
O-Ring
Funnel Spout
OVERFILLING OIL
CRANKCASE MAY
CAUSE SERIOUS PERSONAL INJURY.
Check and maintain the proper oil level in
the crank case; it is important and cannot
be overemphasized. Check the oil before
each use and change it as needed. See
Changing the Oil.
WARNING:
12
OIL AND FUEL INFORMATION
FUELING THE UNIT
1. Remove the fuel cap (Fig. 19).
Fig. 19
Fuel Cap
Fuel Tank
Gas Can Spout
2. Place the gas container’s spout into the fill hole on
the fuel tank (Fig. 19) and fill the tank.
NOTE: Do not overfill the tank.
3. Wipe up any gasoline that may have spilled.
4. Reinstall the fuel cap.
5. Move the unit at least 30 ft. (9.1 m) from the fueling
source and site before starting the engine.
NOTE: Dispose of the old gasoline in accordance to
Federal, State and Local regulations.
RECOMMENDED FUEL TYPE
Old fuel is the primary reason for improper unit
performance. Be sure to use fresh, clean, unleaded
gasoline.
NOTE: This is a four cycle engine. In order to avoid
damage to the unit, do not mix oil with
gasoline.
Definition of Blended Fuels
Today's fuels are often a blend of gasoline and
oxygenates such as ethanol, methanol or MTBE (ether).
Alcohol-blended fuel absorbs water. As little as 1%
water in the fuel can make fuel and oil separate or form
acids when stored. Use fresh fuel (less than 60 days
old), when using alcohol-blended fuel.
Using Blended Fuels
If you choose to use a blended fuel, or its use is
unavoidable, follow recommended precautions:
• Always use fresh unleaded gasoline
• Use the fuel additive STA-BIL
®
or an equivalent
• Drain tank and run the engine dry before storing unit
Using Fuel Additives
The use of fuel additives, such as STA-BIL®Gas
Stabilizer or an equivalent, will inhibit corrosion and
minimize the formation of gum deposits. Using a fuel
additive can keep fuel from forming harmful deposits in
the carburetor for up to six (6) months. Add 0.8 oz.
(23 ml.) of fuel additive per gallon of fuel according to the
instructions on the container. NEVER add fuel additives
directly to the unit's gas tank.
Unleaded
Gasoline
Add fuel in a clean,
well ventilated
outdoor area. Wipe up any spilled fuel
immediately. Avoid creating a source of
ignition for spilt fuel. Do not start the engine
until fuel vapors dissipate.
WARNING:
Gasoline is
extremely
flammable. Ignited Vapors may explode.
Always stop the engine and allow it to cool
before filling the fuel tank. Do not smoke
while filling the tank. Keep sparks and open
flames at a distance from the area.
WARNING:
Remove fuel cap
slowly to avoid injury
from fuel spray. Never operate the unit
without the fuel cap securely in place
.
WARNING:
13
STARTING/STOPPING INSTRUCTIONS
STARTING INSTRUCTIONS
STOPPING INSTRUCTIONS
1. Release your hand from the throttle control. Allow the
engine to cool down by idling.
2. Put the On/Off Stop Control in the OFF (O) position.
Start/On (I)
Stop/Off (O)
Throttle Lock-Out
(TB490BC only)
Throttle Control
Primer
Bulb
Starter Rope
Throttle Control
Cold Weather
Start Lever
(Fig. 23)
Cold
Weather
Start Lever
Run/ Open
Close/ Start
Fig. 20
Fig. 23
Fig. 22
Fig. 21
Operate this unit only in a
well- ventilated outdoor
area. Carbon monoxide exhaust fumes can be lethal in
a confined area.
WARNING:
Avoid accidental starting.
Make sure you are in the
starting position when pulling the starter rope
(Fig. 22).
To avoid serious injury, the operator and unit
must be in a stable position while starting.
Make sure that any Add-On item is installed correctly
and secure before starting the unit.
WARNING:
1. Check the oil level in the crankcase. Refer to
Checking the Oil Level.
2. Fill the fuel tank with fresh, clean unleaded gasoline.
Refer to Fueling the Unit.
NOTE: There is no need to turn the unit on. The On/Off
Stop Control is in the ON (I) position at all times
(Fig. 20).
IF COLD... For cold weather conditions (below 40°F),
flip the Cold Weather Start Lever (Fig. 23) down to the
start/closed position and continue to step 3. DO NOT
flip this lever down if the temperature is above 40°F.
3. Fully press and release the primer bulb 10 times,
slowly. Some amount of fuel should be visible in the
primer bulb and fuel lines (Fig. 21). If you can’t see
fuel in the bulb, press and release the bulb as many
times as it takes before you can see fuel in it.
4. With the unit in the starting position, do not squeeze
the throttle control (Fig. 22). Pull the starter rope out a
short distance, until you feel some resistance. This is
usually around 2-4 inches. Then pull the rope smoothly
and briskly. Repeat this 5 times. The engine should start
IF COLD... For cold weather conditions (below 40°F),
flip the Cold Weather Start Lever back up to the
run/open position.
5. Squeeze the throttle control (and squeeze the throttle
lock-out if your unit is a TB490BC) to warm up the
engine for 15 to 30 seconds. In cold weather, let the
engine warm up for 30 to 60 seconds.
IF... The engine does not start, go back to step 3.
IF... The engine stops while you are squeezing the
throttle, go back to step 4.
14
OPERATING INSTRUCTIONS
For edging (when using the line head cutting attachment
with EZ-Link™ models), lock the release button of the
cutting attachment into the 90° edging hole (Fig. 26).
OPERATING THE EZ-LINK™SYSTEM
The EZ-Link™ system enables the use of these optional
Add-Ons:
Cultivator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TBGC
Edger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TBLE
Hedge Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . TBAH
Straight Shaft Trimmer . . . . . . . . . . . . . . . . . . . . . . TBSS
Turbo Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TBTB
Pole Saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TBPS
Brushcutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TBBC*
*Do NOT use this attachment with an electric
powered unit.
Removing the Cutting Attachment or Add-On
1. Turn the knob counterclockwise to loosen (Fig. 24).
2. Press and hold the release button (Fig. 24).
3. While firmly holding the upper shaft housing, pull
the cutting attachment or add-on straight out of the
EZ-Link™ coupler (Fig. 25).
Installing the Cutting Attachment or Add-On
NOTE: Place the unit on the ground or on a work bench
to make add-on installation or removal easier.
1. Turn knob counterclockwise to loosen (Fig. 24).
Fig. 24
EZ-Link™ Coupler
Release Button
Guide Recess
Knob
Primary Hole
Upper Shaft Housing
EZ-Link™ Coupler
2. While firmly holding the add-on, push it straight into
the EZ-Link™ coupler (Fig. 25).
NOTE: Aligning the release button with the guide recess
will help installation (Fig. 24).
3. Turn the knob clockwise to tighten (Fig. 24).
Fig. 25
Fig. 26
Knob
Lower Shaft Housing
Release Button
90˚ Edging Hole
(Trimmer Only)
To avoid serious
personal injury and
damage to the unit, shut the unit off before
removing or installing add-ons.
WARNING:
Add-ons are to be
used in the primary
hole only. Using the wrong hole could lead to
personal injury or damage to the unit.
CAUTION:
Lock the release
button in the primary
hole and securely tighten the knob before
operating this unit.
CAUTION:
Before you begin
using any
attachment, read and understand the manual
that came with the attachment. Follow all
safety information contained within.
WARNING:
15
OPERATING INSTRUCTIONS
HOLDING THE TRIMMER
Before operating the unit, stand in the operating position
(Fig. 27). Check for the following:
• The operator is wearing eye protection and proper
clothing
• With a slightly-bent right arm, the operator’s right hand
is holding the shaft grip
• The operator’s left arm is straight, the left hand holding
the handle
• The unit is at waist level
• The cutting attachment is parallel to the ground and
easily contacts the grass without the need to bend over
After starting the unit and standing in the operating position,
hook the shoulder strap to the unit (TB490BC only).
Fig. 27
ADJUSTING TRIMMING LINE LENGTH
The Bump Head™ cutting attachment allows you to
release trimming line without stopping the engine. To
release more line, lightly tap the cutting attachment on the
ground (Fig. 28) while operating the trimmer at high speed.
NOTE: Always keep the trimming line fully extended.
Line release becomes more difficult as the cutting
line becomes shorter.
Each time the head is bumped, about 1 inch (25.4 mm) of
trimming line is released. A blade in the cutting
attachment shield will cut the line to the proper length if
excess line is released.
For best results, tap the Bump Head™ on bare ground or
hard soil. If line release is attempted in tall grass, the
engine may stall. Always keep the trimming line fully
extended. Line release becomes more difficult as the
cutting line becomes shorter.
NOTE: Do not rest the Bump Head™ on the ground
while the unit is running.
Fig. 28
Some line breakage will occur from:
• Entanglement with foreign matter
• Normal line fatigue
• Attempting to cut thick, stalky weeds
• Forcing the line into objects such as walls or fence posts
TIPS FOR BEST TRIMMING RESULTS
• For best trimming results, operate unit at full throttle.
• Keep the cutting attachment parallel to the ground.
• Do not force the cutting attachment. Allow the tip of
the line to do the cutting, especially along walls.
Cutting with more than the tip will reduce cutting
efficiency and may overload the engine.
• Cut grass over 8 inches (200 mm) by working from top
to bottom in small increments to avoid premature line
wear or engine drag.
• For the TB490BC brushcutter, cut from left to right
whenever possible. Cutting to the right improves the
unit's cutting efficiency. Clippings are thrown away from
the operator. For the other units, cut from right to left.
• Slowly move the trimmer into and out of the cutting
area at the desired height. Move either in a forwardbackward or side-to-side motion. Cutting shorter
lengths produces the best results.
• Trim only when grass and weeds are dry.
• The life of your cutting line is dependent upon:
• Proper adherence of explained trimming techniques
• What vegetation is cut
• Where vegetation is cut
For example, the line will wear faster when trimming against
a foundation wall as opposed to trimming around a tree.
Do not remove or alter
the line cutting blade
assembly. Excessive line length will make the
clutch overheat. This may lead to serious
personal injury or damage to the unit.
CAUTION:
Always wear eye,
hearing, foot and
body protection to reduce the risk of injury
when operating this unit.
WARNING:
16
Fig. 29
Fig. 30
Fig. 31
DECORATIVE TRIMMING
Decorative trimming is accomplished by removing all
vegetation around trees, posts, fences and more.
Rotate the whole unit so that the cutting attachment is at
a 30° angle to the ground (Fig. 29).
TB490BC ONLY :USING THE CUTTING BLADE
Before operating the unit with the cutting blade, stand in
the operating position (Fig. 30). Refer to Holding the
Trimmer.
Cutting Blade Operating Tips
To establish a rhythmic cutting procedure:
• Plant feet firmly, comfortably apart.
• Bring the engine to full throttle before entering the
material to be cut. At full throttle the blade has
maximum cutting power and is less likely to bind, stall
or cause blade thrust (which can result in serious
personal injury to the operator or others).
• Cut while swinging the upper part of your body from
left to right.
• Always release the throttle trigger and allow the engine
to return to idle speed when not cutting.
• When you are finished, always unsnap the unit from
the harness before taking off the harness.
• Swing the unit in the opposite direction as the blade
spins, which increases the cutting action.
• After the return swing, move forward to the next area
to be cut plant your feet again.
• The cutting blade is designed with a second cutting
edge. You can use it by removing the blade, turning it
upside down, and reinstalling it.
To reduce the chance of material wrapping around the
blade, follow these steps:
• Cut at full throttle
• Swing the unit into material to be cut from your left to
your right (Fig. 31)
• Avoid the material just cut as you make the return swing
Always wear eye,
hearing, foot, body
protection and the shoulder strap to reduce the
risk of injury when operating this unit.
WARNING:
Do not use the
cutting blade for
edging or as an edger. Severe personal injury
to yourself or others can result.
WARNING:
The blade continues
to spin after the
engine is turned off. The coasting blade can
seriously cut you if accidentally touched.
WARNING:
Do not sharpen the
cutting blade.
Sharpening the blade can cause the blade tip
to break off while in use. This can result in
severe personal injury to yourself or others.
Replace the blade.
WARNING:
Bl
ade thrust may
occur when the
spinning blade contacts an object that it does
not immediately cut. Blade thrust can be violent
enough to cause the unit and/or operator to be
propelled in any direction, and possibly lose
control of the unit. Blade thrust can occur
without warning if the blade snags, stalls or
binds. This is more likely to occur in areas where
it is difficult to see the material being cut.
WARNING:
Do not clear away
any cut material with
the engine running or blade turning. To avoid
serious personal injury, turn off the engine.
Allow the blade to stop before removing
materials wrapped around the blade shaft.
WARNING:
OPERATING INSTRUCTIONS
17
MAINTENANCE AND REPAIR INSTRUCTIONS
To prevent serious
injury, never perform
maintenance or repairs with unit running.
Always service and repair a cool unit.
Disconnect the spark plug wire to ensure that
the unit cannot start.
WARNING:
MAINTENANCE SCHEDULE
Perform these required maintenance procedures at the
frequency stated in the table. These procedures should
also be a part of any seasonal tune-up.
NOTE: Some maintenance procedures may require
special tools or skills. If you are unsure about
these procedures take your unit to any non-road
engine repair establishment, individual or
authorized service dealer.
NOTE: Maintenance, replacement, or repair of the
emission control devices and system may be
performed by any non-road engine repair
establishment, individual or authorized service dealer.
FREQUENCY MAINTENANCE REQUIRED REFER TO
Before starting engine
Fill fuel tank with fresh fuel
Check oil
Page 12
Page 21
Every 10 hours Clean and re-oil air filter Page 22
First change at 10 hours
Every 25 hours thereafter
Every 25 hours
Change oil
Change oil
Clean spark arrestor
Page 22
Page 22
Page 26
10 hours on new engine
Every 25 hours
Every 25 hours
Check rocker arm to valve clearance and adjust
Check rocker arm to valve clearance and adjust
Check spark plug condition and gap
Page 24
Page 24
Page 26
LINE INSTALLATION
This section covers both SplitLine™ and standard single
line installation.
Always use 0.105 in. (2.67 mm) original equipment
manufacturer replacement line. Line other than the
specified may make the engine overheat or fail.
There are two methods to replace the trimming line:
• Wind the inner reel with new line
• Install a prewound inner reel
Winding the Existing Inner Reel
1. Hold the outer spool with one hand and unscrew the
Bump Knob clockwise (Fig. 32). Inspect the bolt inside
the bump knob to make sure it moves freely. Replace
the bump knob if damaged.
BUMP HEAD (
TB490BC ONLY)
Never use metal-
reinforced line, wire,
chain or rope. These can break off and
become dangerous projectiles.
WARNING:
Indexing Teeth
Fig. 33
Fig. 34
Inner Reel
Spring
Outer Spool
Bump Knob
Bolt
Fig. 32
2. Remove the inner reel from the outer spool (Fig. 32).
3. Remove spring from the inner reel (Fig. 32).
4. Use a clean cloth to clean the the inner reel, spring,
shaft and inner surface of the outer spool (Fig. 33).
5. Check the indexing teeth on the inner reel and outer
spool for wear (Fig. 34). If necessary, remove burrs or
replace the reel and spool.
18
MAINTENANCE AND REPAIR INSTRUCTIONS
Fig. 36
Fig. 37
Fig. 38
Fig. 39
Fig. 40
Fig. 35
NOTE: SplitLine™ can only be used with the inner reel
with the slotted holes. Single line can be used on
either type of inner reel. Use Figure 35 to identify
the inner reel you have.
NOTE: Always use the correct line length when installing
trimming line on the unit. The line may not release
properly if the line is too long.
Single Line Installation
Go To Step 8 for SplitLine™ Installation
6. Take approximately 18 feet (6 m) of new trimming
line, loop it into two equal lengths. Insert each end of
the line through one of the two holes in the inner reel
(Fig. 36). Pull the line through the inner reel so that
the loop is as small as possible.
7. Wind the lines in tight even layers, onto the reel
(Fig. 37). Wind the line in the direction indicated on
the inner reel. Place your index finger between the
two lines to stop the lines from overlapping. Do not
overlap the ends of the line. Proceed to step 11.
Spring
SplitLine™ Installation
8. Take approximately 9 feet (3 m) of new trimming line.
Insert one end of the line through one of the two
holes in the inner reel (Fig. 38). Pull the line through
the inner reel until only about 4 inches is left out.
9. Insert the end of the line into the open hole in the
inner reel and pull the line tight to make the loop as
small as possible (Fig. 38).
10. Before winding, split the line back about 6 inches.
11. Wind the line in tight even layers in the direction
indicated on the inner reel.
NOTE: Failure to wind the line in the direction indicated will
cause the cutting attachment to operate incorrectly.
Loop
Slotted
Holes
For Use with SplitLine™
or Single Line
For Use with Single
Line ONLY
Loop
Holding Slots
NOTE: The spring must be assembled on the inner reel
before reassembling the cutting attachment.
14. Hold the inner reel in place and install the bump knob
by turning counterclockwise. Tighten securely.
12. Insert the ends of the line into the two holding slots
(Fig. 39).
13. Insert the ends of the line through the eyelets in the
outer spool and place inner reel with spring inside the
outer spool (Fig. 40). Push the inner reel and outer
spool together. While holding the inner reel and outer
spool, grasp the ends and pull firmly to release the
line from the holding slots in the reel.
19
MAINTENANCE AND REPAIR INSTRUCTIONS
LINE INSTALLATION
Always use original equipment manufacturer 0.095 inch
(2.41 mm) replacement line. Lines other than those
specified may make the engine overheat or fail.
There are two methods to replace the SpeedSpool
®
trimming line:
• Wind the inner reel with new line
• Install a pre-wound inner reel
Winding the Inner Reel With New Line
NOTE: It Is unnecessary to remove the bump knob to
install a new trimming line.
1. Cut two pieces of 0.095 inch (2.41 mm) trimming
line, 10 feet (3 m) long.
2. Hold the outer spool and turn the inner reel
counterclockwise to line up the arrows on the outer
spool and inner reel (Fig. 41).
Top View Of The SpeedSpool
®
Outer Spool
Inner Reel
Fig. 41
Bump Knob
Arrows
SPEEDSPOOL®(TB425CS & TB475SS)
Never use metal-
reinforced line, wire,
chain or rope. These can break off and
become dangerous projectiles.
WARNING:
Always use the
correct line length
when installing trimming line on the unit.
The line may not release properly if the line
is too long.
WARNING:
Line Locking Hole
Trimming Line
Line Loading Hole
Eyelet
5. Insert the line into the locking hole (Fig. 43). Do not
push the line more than a 1/2 inch (12.7 mm) into the
line locking hole. The line will form a small loop
(Fig. 43) when it is inserted correctly.
3. Pull old line out of the line loading and line locking
holes (Fig. 42 and 43).
4. Insert a piece of trimming line straight into one of the
two eyelets in the outer spool. Push it up through the
line loading hole in the inner reel (Fig. 42). Do not
bend the line when inserting it into the eyelet.
Fig. 42
Fig. 43
INSTALLING A PREWOUND REEL
1. Hold the outer spool with one hand and unscrew the
bump knob clockwise (Fig. 32). Inspect the bolt inside
the bump knob to make sure it moves freely. Replace
the bump knob if damaged.
2. Remove the old inner reel from the outer spool
(Fig. 32).
3. Remove the spring from the old inner reel
(Fig. 32).
4. Place the spring in the new inner reel.
NOTE:The spring must be assembled on the inner reel
before reassembling the cutting attachment.
5. Insert the ends of the line through the eyelets in the
outer spool (Fig. 40).
6. Place the new inner reel inside the outer spool. Push the
inner reel and outer spool together. While holding the
inner reel and outer spool, grasp the ends and pull firmly
to release the line from the holding slots in the spool.
7. Hold the inner reel in place and install the bump knob
by turning counterclockwise. Tighten securely.
20
MAINTENANCE AND REPAIR INSTRUCTIONS
6. Pull the line from the outer spool until the line is tight
against the inner reel (Fig. 44).
Fig. 44
INSTALLING A PRE-WOUND REEL
1. Turn the bump knob counterclockwise and remove
the bump knob, spring and foam seal (Fig. 47).
9. If winding the line becomes difficult or if the line
jams, pull the ends of the line from the spool
(Fig. 46). Continue winding the inner reel
counterclockwise until approximately 6 inches of line
is left.
Fig. 45
Fig. 46
7. Repeat procedures 4-6 with the second piece of line.
8. Hold the outer spool. Wind the inner reel
counterclockwise until approximately four (4) inches
(102 mm) of line remain (Fig. 45).
NOTE: Do not wind the inner reel before installing the
second piece of line.
Bump Knob
Foam Seal
Spring
Inner Reel
Fig. 47
4. Hold the inner reel in place and install the bump
knob, spring and foam seal (Fig. 47). Press down
and turn the bump knob clockwise. Grasp the ends
and pull firmly to release the line from the holding
slots in the inner reel.
Releasing the Inner Reel
If the SpeedSpool®does not release line correctly, pull
the ends of the line firmly from the spool (Fig. 46). If this
does not the release line, follow the Cleaning the
SpeedSpool®instructions.
2. Pull the old inner reel with existing line from the outer
spool.
3. Insert the ends of the prewound inner reel line into
the outer spool eyelets (Fig. 48). Push the new inner
reel, arrow side up, into the outer spool.
Fig. 48
CLEANING THE SPEEDSPOOL
®
Cleaning the SpeedSpool®may be necessary if:
•A jammed or excessive line must be removed
• The SpeedSpool®becomes difficult to wind or does
not operate correctly when bumping the head on the
ground
1. Hold the outer spool, and unscrew the bump knob
counterclockwise (Fig. 49).
2. Pull out the bump knob, spring and foam seal (Fig. 47).
21
4. Remove any existing line from the inner reel before
cleaning. Remove any debris or grass from the knob,
spring, inner reel and foam seal. Wash the inner reel
with warm soapy water (Fig. 50).
Shaft
Plunger
NOTE: The inner reel must be totally dry before
reinstalling it into the outer spool. Do not lubricate
the inner reel or outer spool assembly.
6. Place the inner reel into the outer spool.
7. Place the bump knob, spring and foam seal into the
inner reel (Fig. 47).
8. Press the bump knob down and tighten clockwise.
9. Install new line as described in Line Installation for
the SpeedSpool
®
.
5. Clean the shaft and the inner surface of the outer
spool. To clean the shaft underneath the plunger,
press down on the plunger (Fig. 51). Remove any dirt
or debris from the shaft.
Fig. 51
Inner Reel
Fig. 50
MAINTENANCE AND REPAIR INSTRUCTIONS
CHECKING THE OIL LEVEL
The importance of checking and maintaining the proper
oil level in the crankcase cannot be overemphasized.
Check oil before each use:
1. Stop the engine and allow oil to drain into the crankcase.
2. Place the unit on a flat, level surface to get a proper
oil level reading.
3. Keep dirt, grass clippings and other debris out of the
engine. Clean the area around the oil fill plug/dipstick
before removing it.
4. Remove the oil fill plug/dipstick and wipe off oil.
Reinsert it all the way back in.
5. Remove the oil fill plug/dipstick and check the oil level.
Oil should be up to the top of the dipstick (Fig. 52).
6. If the level is low, add a small amount of oil to the oil
fill hole and recheck (Fig. 53). Repeat this procedure
until the oil level reaches the top of the dipstick.
NOTE: Do not overfill the unit.
Top of Dipstick
O-Ring
Oil Fill Plug/Dipstick
Fig. 52
Fig. 53
NOTE: Make sure the O-ring is in place on the oil fill
plug/dipstick when checking and changing the
oil (Fig. 53).
Oil Fill Plug/Dipstick
Oil Fill Hole
O-Ring
Full
Add 1.4-1.5 Oz.
(41-44 ml)
To prevent extensive
engine wear and
damage to the unit, always maintain the
proper oil level in the crankcase. Never
operate the unit with the oil level below the
bottom of the dipstick.
CAUTION:
Fig. 49
3. Pull the inner reel with existing line from the outer
spool (Fig. 48).
22
MAINTENANCE AND REPAIR INSTRUCTIONS
CHANGING THE OIL
For a new engine, change the oil after the first 10 hours of
operation. Change the oil while the engine is still warm. The
oil will flow freely and carry away more impurities.
1. Unplug spark plug boot to prevent accidental starting.
2. Remove the oil fill plug/dipstick.
3. Pour the oil out of the oil fill hole and into a container
by tipping the unit to a vertical position (Fig. 54).
Allow ample time for complete drainage.
Fig. 54
6. Replace the oil fill plug/dipstick.
7. Reconnect the spark plug boot.
4. Wipe up any oil residue on the unit and clean up any
oil that may have spilled. Dispose of the oil
according to Federal, State and local regulations.
5. Refill the crankcase with 3.4 fluid ounce (100 ml) of
SAE 30 SF, SG, SH oil.
NOTE: Use the bottle and spout saved from initial use to
measure the correct amount of oil. The top of the
label on the bottle measures approximately 3.4
ounces (100 ml) (Fig. 55). Check the level with the
dipstick. If the level is low, add a small amount of
oil and recheck. Do not overfill (Fig. 55).
Fill Level
Fig. 55
Wear gloves to
prevent injury when
handling the unit.
CAUTION:
AIR FILTER MAINTENANCE
Cleaning the Air Filter
Clean and re-oil the air filter every 10 hours of operation.
It is an important item to maintain. Failure to maintain
your air filter properly can result in poor performance or
can cause permanent damage to your engine.
1. Open the air filter cover. Push the tab on the right
side of the cover inward. Then pull the air filter cover
out and to the left (Fig. 56).
NOTE: It may be necessary to remove the fuel cap to
completely remove the air filter cover.
2. Remove the air filter (Fig. 56).
Air Filter
Air Filter Cover
Tab
Fig. 56
To avoid serious
personal injury,
always turn the unit off and allow it to cool
before you clean or service it.
WARNING:
23
3. Wash the filter in detergent and water (Fig. 57). Rinse
the filter thoroughly and allow it to dry.
4. Apply enough clean SAE 30 motor oil to lightly coat
the filter (Fig. 58).
Fig. 57
5. Squeeze the filter to spread and remove excess oil
(Fig. 59).
Fig. 60
Back Plate Slot
Slots
6. Replace the filter (Fig. 60).
NOTE: If the unit is operated without the air filter, you
will VOID the warranty.
7. Reinstall the air filter cover. Position the hooks on
the left side of the air filter cover into the slots at the
left side of the back plate (Fig. 60).
NOTE: It may be necessary to remove the fuel cap to
reinstall the air filter cover.
8. Swing the cover to the right until the tab on the air
filter cover snaps into place in the slot on the back
plate (Fig. 60).
9. Replace the fuel cap if it was removed.
Back Plate
CARBURETOR ADJUSTMENT
The idle speed of the engine is adjustable. An idle
adjustment screw is reached though a hole in the top of
the engine cover (Fig. 61).
NOTE: Careless adjustments can seriously damage your
unit. An authorized service dealer should make
carburetor adjustments.
Check Fuel
Old fuel is usually the reason for improper unit
performance. Drain and refill the tank with fresh fuel prior
to making any adjustments. Refer to Oil and Fuel
Information.
Fig. 59
Fig. 58
MAINTENANCE AND REPAIR INSTRUCTIONS
24
Idle Adjustment Screw
Clean Air Filter
The condition of the air filter is important to the operation
of the unit. A dirty air filter will restrict air flow. This is
often mistaken for an out of adjustment carburetor.
Check the condition of the air filter before adjusting the
idle speed screw. Refer to Air Filter Maintenance.
Adjust Idle Speed Screw
If, after checking the fuel and cleaning the air filter, the
engine still will not idle, adjust the idle speed screw as
follows:
1. Start the engine and let it run at a high idle for a minute
to warm up. Refer to Starting/Stopping Instructions.
2. Release the throttle trigger and let the engine idle. If the
engine stops, insert a small phillips or flat blade screwdriver
into the hole in the air filter/muffler cover (Fig. 61). Turn
the idle speed screw in, clockwise, 1/8 of a turn at a
time (as needed) until the engine idles smoothly.
NOTE: The cutting attachment should not rotate when
the engine idles.
3. If the cutting attachment rotates when the engine idles,
turn the idle speed screw counterclockwise 1/8 of a
turn at a time (as needed), to reduce idle speed.
Checking the fuel, cleaning the air filter, and adjusting
the idle speed should solve most engine problems. If not
and all of the following are true:
• the engine will not idle
• the engine hesitates or stalls on acceleration
• there is a loss of engine power
Have the carburetor adjusted by an authorized service dealer.
Fig. 61
Remove
Screws
Fig. 62
Engine Cover
2. Remove the two (2) screws on top of the engine cover
with a Flat-head or T-25 Torx screwdriver (Fig. 63).
Fig. 63
Engine Cover
Muffler
ROCKER ARM CLEARANCE
This requires disassembly of the engine. If you feel
unsure or unqualified to perform this, take the unit to an
authorized service center.
NOTE: Inspect the valve to rocker arm clearance with a
feeler gauge after the first 10 hours of operation
and then every 25 hours of operation thereafter.
• The engine must be cold when checking or adjusting
the valve clearance.
• This task should be performed inside, in a clean,
dust free area.
1. Remove the muffler cover by pressing down on it,
separating it from the engine cover. Using a flat
blade screwdriver, disengage the middle and front
tabs and slots first. The cover will hinge off from the
rear tab (Fig. 62).
Top View Of The Engine
Front Slot
Front Tab
Middle Tab
Middle Slot
Rear Slot
and Tab
MAINTENANCE AND REPAIR INSTRUCTIONS
The cutting
attachment may spin
during idle speed adjustments. Wear
protective clothing and observe all safety
instructions to prevent serious personal injury.
WARNING:
To prevent serious
personal injury,
make sure the cutting attachment has
stopped rotating before you turn it off and
set it down.
WARNING:
25
MAINTENANCE AND REPAIR INSTRUCTIONS
4. Disconnect the spark plug wire.
5. Clean dirt from around the spark plug. Remove the
spark plug from the cylinder head by turning a 5/8 in.
socket counterclockwise.
6. Remove the engine cover (Fig. 63).
7. Clean dirt from around the rocker arm cover.
Remove the screw holding the rocker arm cover with
a large flat blade screwdriver or Torx T-25 bit
(Fig. 65). Remove the rocker arm cover and gasket.
3. Remove the screw behind the engine cover (Fig. 64).
Rocker Arm Cover
Screw
Fig. 64
Fig. 65
Spark Plug Hole
8. Pull the starter rope slowly to bring the piston to the top
of its travel, (known as top dead center). Check that:
• The piston is at the top of its travel while looking in
the spark plug hole (Fig. 65)
• Both rocker arms move freely, and both valves are
closed
If these statements are not true, repeat this step.
9. Slide the feeler gauge between the rocker arm and
the valve return spring. Measure the clearance
between the valve stem and rocker arm (Fig. 66).
Measure both the intake and exhaust valves.
Adjusting Nuts
Feeler Gauge
Rocker Arms
Fig. 66
Fig. 67
The recommended clearance for the intake is .003 – .006
in. (.076 – 0.152 mm). The recommended clearance for
the exhaust is .013 – .016 in. (.330 – 0.406 mm).
Use a standard automotive feeler gauge at .005 and .015 in.
(0.127 and 0.381 mm). The feeler gauge should slide
between the rocker arm and valve stem with a slight amount
of resistance, without binding. Figure 66 shows how to
measure the intake clearance, while Figure 67 shows the
exhaust clearance.
Feeler Gauge
Exhaust
Adjusting Nut
Exhaust
Rocker Arm
Exhaust
Clearance:
.013–.016 in.
(.330–0.406 mm)
Exhaust Valve Stem
10. If the clearance is not within specification:
a. Turn the adjusting nut using a 5/16 inch (8 mm)
wrench or nut driver (Fig. 67).
• To increase clearance, turn the adjusting nut
counterclockwise.
• To decrease clearance, turn the adjusting nut
clockwise.
b. Recheck both clearances, and adjust as necessary.
11. Reinstall the rocker arm cover using a new gasket.
Torque the screw to 20–30 in
•
lb (2.2–3.4 N•m).
12. Reinstall the engine cover. Check alignment of the
cover before tightening the screws. Tighten screws.
13. Reinstall the muffler cover. Slip the rear tab on the
muffler cover into the engine cover rear slot. Then
slide the remaining slots into the tabs until they snap
into place (Fig. 62).
14. Check the spark plug and reinstall. See Replacing
the Spark Plug.
15. Replace the spark plug wire.
INTAKE
EXHAUST
Intake Valve
Stem
Intake Clearance:
.003–.006 in.
(.076–0.152 mm)
26
CLEANING
Use a small brush to clean off the outside of the unit. Do
not use strong detergents. Household cleaners that
contain aromatic oils such as pine and lemon, and
solvents such as kerosene, can damage plastic housing
or handle. Wipe off any moisture with a soft cloth.
STORAGE
• Never store the unit with fuel in the tank where fumes
may reach an open flame or spark.
• Allow the engine to cool before storing.
• Lock up the unit to prevent unauthorized use or damage.
• Store the unit in a dry, well-ventilated area.
• Store the unit out of the reach of children.
NOTE: Remove the spark plug and drain all of the oil
from the cylinder before attempting to start the
trimmer after storage.
4. Change the oil, referring to Changing the Oil.
Dispose of the old oil in accordance to Federal, State
and Local regulations.
5. Thoroughly clean the unit and inspect for any loose
or damaged parts. Repair or replace damaged parts
and tighten loose screws, nuts or bolts. The unit is
ready for storage.
TRANSPORTING
• Allow the engine to cool before transporting.
• Secure the unit while transporting.
• Drain the gas tank before transporting.
• Tighten gas cap before transporting.
LONG TERM STORAGE
1. Drain all gasoline from the gas tank into a container.
Do not use gas that has been stored for more than 60
days. Dispose of the old gasoline in accordance to
Federal, State, and Local regulations.
2. Start the engine and allow it to run until it stalls. This
ensures that all gasoline has been drained from the
carburetor.
3. Allow the engine to cool. Remove the spark plug and
put 1 oz. (30 ml) of high quality motor oil into the
cylinder. Pull the starter rope slowly to distribute the
oil. Reinstall the spark plug.
To avoid serious
personal injury,
always turn your unit off and allow it to cool
before you clean or service it.
WARNING:
MAINTENANCE AND REPAIR INSTRUCTIONS
0.025 in.
(0.655 mm.)
REPLACING THE SPARK PLUG
Use a replacement part number 180890 spark plug. The
correct air gap is 0.025 in. (0.655 mm.). Remove the plug
after every 25 hours of operation and check its
condition.
1. Stop the engine and allow it to cool. Grasp the plug
wire firmly and pull the cap from the spark plug.
2. Clean dirt from around the spark plug. Remove the
spark plug from the cylinder head by turning a 5/8 in.
socket counterclockwise.
3. Replace cracked, fouled or dirty spark plug. Set the air
gap at 0.025 in. (0.655 mm.) using a feeler gauge (Fig. 68).
Fig. 68
4. Install a correctly-gapped spark plug in the cylinder
head. Turn the 5/8 in. socket clockwise until snug.
If using a torque wrench torque to:
110-120 in.•lb. (12.3-13.5 N•m)
Do not over tighten.
Fig. 69
Muffler
Spark Arrestor Screen
Spark Arrestor Cover
Screw
Tab
Slot
SPARK ARRESTOR MAINTENANCE
1. Remove the muffler cover. See Rocker Arm Clearance.
2. With a flat blade screwdriver or Torx T-20 bit,
remove the screw attaching the spark arrestor cover
to the muffler (Fig. 69).
3. Pull the tab on the spark arrestor cover out of the
muffler. Remove the spark arrestor cover.
4. Remove the spark arrestor screen from the spark
arrestor cover.
5. Clean the spark arrestor screen with a wire brush or
replace it.
6. Reinstall the spark arrestor screen, spark arrestor
cover and screw.
Do not sand blast,
scrape or clean
electrodes. Grit in the engine could damage
the cylinder.
WARNING:
27
TROUBLESHOOTING
If further assistance is required, contact your authorized service dealer.
CAUSE ACTION
Cutting attachment bound with grass Stop the engine and clean cutting attachment
Cutting attachment out of line Refill with new line
Inner reel bound up Replace the inner reel
Cutting head dirty Clean inner reel and outer spool
Line welded Disassemble, remove the welded section and rewind
Line twisted when refilled Disassemble and rewind the line
Not enough line is exposed Push the bump knob and pull out line until 4 inches
(102 mm) of line is outside of the cutting attachment
CAUSE ACTION
Old fuel Drain gas tank and add fresh fuel
Improper carburetor adjustment Take to an authorized service dealer for adjustment
Fouled spark plug Replace or clean the spark plug
Plugged spark arrestor Clean or replace spark arrestor
CAUSE ACTION
Empty fuel tank Fill fuel tank with new fuel
Primer bulb wasn't pressed enough Press primer bulb fully and slowly 10 times
Old fuel Drain gas tank and add fresh fuel
Fouled spark plug Replace or clean the spark plug
Plugged spark arrestor Clean or replace spark arrestor
ENGINE WILL NOT START
ENGINE WILL NOT IDLE
ENGINE WILL NOT ACCELERATE
ENGINE LACKS POWER OR STALLS WHEN CUTTING
CAUSE ACTION
Air filter is plugged Replace or clean the air filter
Old fuel Drain gas tank and add fresh fuel
Improper carburetor adjustment Adjust carburetor
CAUSE ACTION
Old fuel Drain gas tank and add fresh fuel
Improper carburetor adjustment Take to an authorized service dealer for adjustment
Cutting attachment bound with grass Stop the engine and clean the cutting attachment
Dirty air filter Clean or replace the air filter
Plugged spark arrestor Clean or replace spark arrestor
CUTTING ATTACHMENT WILL NOT ADVANCE LINE
CAUSE ACTION
Oil, cleaner or lubricant in cutting head Clean and thoroughly dry the cutting head
CUTTING LINE ADVANCES UNCONTROLLABLY
When it is above 40°F outside & the Cold Weather Start
Lever is in the CLOSED / START position
When it is below 40°F outside & the Cold Weather Start
Lever is in the RUN / OPEN position
Flip the Cold Weather Start Lever to RUN / OPEN
Flip the Cold Weather Start Lever to CLOSED / START
and follow the Starting Instructions
28
SPECIFICATIONS
ENGINE*
DRIVE SHAFT AND CUTTING ATTACHMENT*
*All specifications are based on the latest product information available at the time of printing. We reserve the right to
make changes at any time without notice.
Drive Shaft Housing............................................................................................................................ Steel Tube (EZ-Link™)
Throttle Control.......................................................................................................................................... Finger-Tip Trigger
Approximate Unit Weight (No fuel, with handle, shield and cutting attachment) ........................................... 13.5 lbs (6 kg)
Cutting Mechanism: TB425CS & TB475SS: ...................................................................... Dual String Cutting Head
TB490BC: ................................................. 4-Tooth Cutting Blade, Dual String Cutting Head
Line Spool.............................................................................................................................................. Bump Line Releaser
Line Spool Diameter: TB425CS & TB475SS: .............................................................................. 3 inches (76.2 mm)
TB490BC:............................................................................................... 4 inches (101.6 mm)
Trimming Line Diameter: TB425CS & TB475SS......................................................................... 0.095 inches (2.41 mm)
TB490BC:...................................................................................... 0.105 inchches (2.66 mm)
TB425CS & TB475SS Cutting Path Diameter...................................................................................... 17 inches (43.18 cm)
TB490BC Cutting Path Diameter, Cutting Attachment ......................................................................... 18 inches (45.7 cm)
TB490BC Cutting Path Diameter, Cutting Blade..................................................................................... 8 Inches (204 mm)
TB490BC Shoulder Harness .................................................................................................................... Single Quick-Snap
Engine Type........................................................................................................................................... Air-Cooled, 4-Cycle
Displacement .......................................................................................................................................... 1.6 cu. in. (26.2 cc)
Clutch Type........................................................................................................................................................... Centrifugal
Operating RPM......................................................................................................................................... 6,800 - 9,300 rpm
Idle Speed RPM........................................................................................................................................ 2,800 - 3,600 rpm
Ignition Type........................................................................................................................................................... Electronic
Ignition Switch..................................................................................................................................................Rocker Switch
Valve clearance (intake) .......................................................................................................... .003–.006 in. (.076–.152 mm)
Valve clearance (exhaust) ....................................................................................................... .013–.016 in. (.330–.406 mm)
Spark Plug Gap.................................................................................................................................. 0.025 inch (0.655 mm)
Lubrication............................................................................................................................................................. SAE 30 Oil
Crankcase Oil Capacity ................................................................................................................................. 3.4 oz (100 ml)
Fuel......................................................................................................................................................................... Unleaded
Carburetor ........................................................................................................................................ Diaphragm, All-Position
Starter ................................................................................................................................................................ Auto Rewind
Muffler....................................................................................................................................................... Baffled with Guard
Throttle ................................................................................................................................................ Manual Spring Return
Fuel Tank Capacity ......................................................................................................................................... 12 oz (355 ml)
29
California / EPA Emission Control Warranty Statement
Your Warranty Rights and Obligations
The California Air Resources Board, the Environmental Protection Agency and MTD LLC (MTD) are pleased to explain
the emission control system warranty on your 2000 and later small off-road engine. New small off-road engines must be
designed, built and equipped to meet stringent anti-smog standards. MTD 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 or fuel-injected system, the ignition system, and
catalytic converter. Also included may be hoses, belts, connectors and other emission-related assemblies.
Where a warrantable condition exists, Troy-Bilt will repair your small off-road engine at no cost to you including
diagnosis, parts and labor.
The 2000 and later small off-road engines are warranted for two years. If any emission-related part on your engine is
defective, the part will be repaired or replaced by Troy-Bilt.
Owners Warranty Responsibilities
• As the small off-road engine owner, you are responsible for the performance of the required maintenance listed in your
operator’s manual. Troy-Bilt recommends that you retain all receipts covering maintenance on your small off-road
engine, but Troy-Bilt cannot 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 however should be aware that Troy-Bilt may deny you warranty coverage if
your small off-road engine or a part has failed due to abuse, neglect, improper maintenance or unapproved
modifications.
• You are responsible for presenting your small off-road engine to a Troy-Bilt Authorized Service Center as soon as a
problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.
If you have any questions regarding your warranty rights and responsibilities, you should call 1-800-520-5520.
Manufacturer’s Warranty Coverage
• The warranty period begins on the date the engine or equipment is delivered to the retail purchaser.
• The manufacturer warrants to the initial owner and each subsequent purchaser, that the engine is free from defects in
material and workmanship which cause the failure of a warranted part for a period of two years.
• Repair or replacement of warranted part will be performed at no charge to the owner at an Authorized Troy-Bilt Service
Center. For the nearest location please contact Troy-Bilt at: 1-800-520-5520.
• Any warranted part which is not scheduled for replacement, as required maintenance or which is scheduled for only
for regular inspection to the effect of “Repair or Replace as Necessary” is warranted for the warranty period. Any
warranted part which is scheduled for replacement as required maintenance will be warranted for the period of time up
to the first scheduled replacement point for that part.
• The owner will not be charged for diagnostic labor which leads to the determination that a warranted part is defective,
if the diagnostic work is performed at an Authorized Troy-Bilt Service Center.
• The manufacturer is liable for damages to other engine components caused by the failure of a warranted part still
under warranty.
• Failures caused by abuse, neglect or improper maintenance are not covered under warranty.
• The use of add-on or modified parts can be grounds for disallowing a warranty claim. The manufacturer is not liable to
cover failures of warranted parts caused by the use of add-on or modified parts.
• In order to file a claim, go to your nearest Authorized Troy-Bilt Service Center. Warranty services or repairs will be
provided at all Authorized Troy-Bilt Service Centers.
• Any manufacturer approved replacement part may be used in the performance of any warranty maintenance or repair
of emission related parts and will be provided without charge to the owner. Any replacement part that is equivalent in
performance or durability may be used in non-warranty maintenance or repair and will not reduce the warranty
obligations of the manufacturer
• The following components are included in the emission related warranty of the engine, air filter, carburetor, primer, fuel
lines, fuel pick up/ fuel filter, ignition module, spark plug and muffler.
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