Troybilt 41ADT49C063 Owner’s Manual
TRnV:BILT
m iwm m mmm r®
Operator's Manual
4-Cycle Gasoline
Trimmer / Brushcutter
Model TB490BC
IMPORTANT:READ SAFETY RULES AND INSTRUCTIONS CAREFULLY
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 Iaw 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, Accessory Part 791-
180890 Spark Arrestor Screen is available by contacting the service department at Troy-Biff LLC, P.O. Box 36t 131 Cleveland, Ohio 44I 36-0019.
TROY-BILT LLC, P.O. BOX 361131, CLEVELAND, OH 44136-0019
P!N 771-10661 (11/01 rev. P00)
PRINTED IN USA
Content Page
Calling Customer Support .................................................... 2
Rules for Safe Operation ..................................................... 3
Know Your Unit ............................................................ 7
Assembly Instructions ....................................................... 8
Oil and Fuel Information ..................................................... 11
Starting/Stepping Instructions ................................................. 13
Operating Instructions ....................................................... 14
Maintenance and Repair Instructions ........................................... 17
Accessories and Replacement Parts ........................................... 24
Cleaning and Storage ....................................................... 25
Troubleshooting Chart ....................................................... 26
Specifications ............................................................. 27
Warranty Information ........................................................ 32
This Operator's Manual is an important part of your new Trimmer/Brushcutter. It will help you assemble, prepare and
maintain the unit for best performance. Please read and understand what it says.
Before you start assembling your new equipment, please locate the model plate on the equipment and copy the information
from it in the space provided below. This information is very important if you need help from our Customer Support
Department or an authorized dealer.
• You can locate the model number by looking at the side of the engine housing. A sample model plate is explained
below. For future reference, please copy the model number and the serial number of the equipment in the space
below
Serial Number Model/Parent Part Number
Copy the model / parent part
number here:
Copy the serial number here:
lllllill!,H%r!l!llL,LtL
If you have difficulty assembIing this product or have any questions regarding the controls, operation or maintenance of this
unit, please call the Customer Support Department.
Call 1- (330) 558-7220 or 1- (866) 840-6483 to reach a Customer Support representative. Please have your
unit's model number and serial number ready when you call. See previous section to locate this information.
You will be asked to enter the serial number in order to process your call.
Thepurposeofsafetysymbolsistoattractyour
attentiontopossibledangers.Thesafety 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.
SYMBOL MEANING
SAFETY ALERT SYMBOL: 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.
NOTE: Advises you of information or instructions vital
to the operation or maintenance of the equipment.
DANGER: 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.
WARNING: 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.
CAUTION: Failure to obey a safety warning
may result in property damage or personal
injury to yourself or to others. Always fellow
the safety precautions to reduce the risk of
fire, electric shock, and personal injury.
California Proposition 65 Warning:
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.
• Inspect the unit before use. Replace damaged parts.
Check for fue! leaks. Make sure all fasteners are in
place and secure. Replace cutting attachment parts
that are cracked, chipped, or damaged in any way.
Make sure the cutting attachment is properly installed
and securely fastened. Be sure the cutting attachment
shield is properly attached, and positioned as
recommended. Failure to so can result in personal
injury to the operator and bystanders, as well as
damage to the unit.
• Use only 0.105 inch (2.667 mm) diameter genuine
Troy-BiIt LLC replacement line. Never use metal-
reinforced line, wire, or rope, etc. These can break off
and become a dangerous projectile.
• Be aware of the risk of injury to the head, hands and
feet.
• Clear the area to be cut before each use. Remove all
objects such as rocks, broken glass, nails, wire, or
string which can be thrown or become entangled in
the cutting attachment. 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 sdll may be a risk to bystanders from thrown
objects. Bystanders should be encouraged to wear
eye protection. If you are approached, stop the engine
and cutting attachment immediately.
• 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 TRIMMERS
WARNING: Gasoline is highly flammable, and its vapors
can explode if ignited. Take the following precautions:
• Store fuel only in containers specifically designed and
approved for the storage of such materials.
• Always stop the engine and allow it to cool before
filling the fue_tank. Never remove the cap of the fuel
tank, 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 fueI in a clean, well-ventilated area outdoors
where there are no sparks or flames. Slowly remove
the fuel cap only after stopping engine. Do not smoke
while fueling or mixing fue!. 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 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 kilt. Operate
this unit only in a well ventilated area outdoors.
• Wear safety glasses or goggles that are marked as
meeting ANSI Z87.1 standards, and ear/hearing
protection when operating this unit. Wear a face or
dust mask if the operation is dusty.
3
• 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. 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 J-Handle to your size 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. See
Starting!Stopping Instructions.
• Use the right tool. Only use this tool for the purpose
intended.
• Do not overreach. Always keep proper footing and
balance.
• Always hold the unit with both hands when operating.
Keep a firm grip on both the front and rear handle 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 is rotating.
• Do not touch the engine, gear housing or muffler,
These parts get extremely hot from operation. When
turned off they remain hot for a short time.
• 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 and switch the engine to off for maintenance,
repair, or for changing the cutting attachment or other
attachments.
• Use only genuine manufacturer's replacement parts
and accessories for this unit. These are available from
your authorized service dealer. Use of any non Troy-
Bilt LLC 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 faulty muffler and spark
arrestor, keep the engine and muffler free from grass,
leaves, excessive grease or carbon build up.
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 with the cutting blade located over 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 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.
• For operation with the brush blade, do not cut
anything thicker than 1/2 inch or a violent kickback
could occur.
• 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. De 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 can
occur. Use the cutting blade only for the purpose as
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 the unit, with fuel in the tank, 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.
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
• 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.
• 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
i
e
5-7x
• FOR SERVICE INFORMATION, CALL:
1-866-840-6483 or
1-330-558-7220
• 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 standards and ear protection when
operating this unit.
• KEEP BYSTANDERS AWAY
WARNING: Keep all bystanders, especially children and pets, at least 50 feet (15 m)
from the operating area.
• PRIMER BULB
Push primer bulb, fully and slowly, 5 to 7 times.
• UNLEADED FUEL
Always use clean, fresh unleaded fue!.
5
SYMBOL MEANING
• OIL
Refer to operator's manual for the proper type of oil.
* 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.
• ON/OFF STOP CONTROL
ON / START / RUN
• ON/OFF STOP CONTROL
OFF OR STOP
• HOT SURFACE WARNING
Do not touch a hot muffler, gear housing or cylinder. You may get burned. These parts get
extremely hot from operation. When turned off they remain hot for a short time.
• SHARP BLADE
WARNING: Sharp blade on cutting attachment shield. To prevent serious injury, do not
touch line cutting blade.
A B C
I+1I'qI+1
• CHOKE CONTROL
A ° FULL choke position.
B • PARTIAL choke position.
C ° RUN position,
• 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.
• 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.
WARNING: The operation of any power tool can cause foreign objects to be thrown into your
eyes. This can lead to severe eye damage. Before commencing power tool operation, always
wear safety glasses or goggles that are marked as meeting ANSI Z87.1 standards, and a full
face shield when needed+
APPLICATIONS
AS a trimmer:
• CuRing gross and light weeds.
• Edging.
• Decorative trimming around trees, fences, etc.
AS a brushcu_er;
• Cutting weeds and light bush of up to 1/2 inch in
diameter.
Other optional accessories may be used with the
TB490BC. See list of add-ons on page 14,
On/Off Stop
Shoulder Strap Clip
Spark Arrestor
•=p---Spark Plug
Muffler Guard -->
Fuel Cap
Starter Rope
Shaft Grip
Throt'de
Throttle
Control
Brush
Blade
Gear Housing
Blade Shield /
Shield Mount
EZ-Unk TM
Shaft
Housing
Cutting Attachment
Shield
/
Air Filter Cover
\
Engine Feet
J-Handle
Choke Lever
Spark Plug
Oil Fill Plug / Dipstick
Cutting Attachment
Line Cuffing Blade
7
INSTALLINGANDADJUSTINGTHEJ-HANDLE
1. Place the J-handle between the top and middle
clamp pieces (Fig. 1).
J-Handle
(4)
6, While holding the unit in the operating position
(Fig. 3), 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.
INSTALLING THE HARNESS
Top Clamp
Middle Clamp
Bottom Clamp
Nuts
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 tine up
only when assembled correctly.
3. Place the clamps and J-handle the over the shaft
housing and onto the bottom clamp.
4. Hold each hex nutin 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. 2).
IA WARNING: Always use the shoulder harness
personalwhenus nginjury.thecutt ng bade to avo d ser cue
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).
\
\
Fig,4 ................................
3. Put the harness on over head and onto shoulder.
Snap it on to the support fitting (Fig. 5).
Support Fitting
\
S
Fig. 3
Fig, 5
4. Adjust length to fit the operator's size. Pull tab to
lengthen, pull strap to shorten (Fig 6).
#
\
Fig. 6
REMOVING AND INSTALLING CUTTING
ATTACHMENT SHIELD
Remove the cutting attachment shield when using
the unit as a brushcutter.
WARNING: The cutting attachment shield I
should NOT be installed when operating the
unit with a blade. Remove the cutting
attachment shield before removing or
installing the blade.
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.
OutputShaft
I
j OutputSh
• _ | Bushing
Locking Rod i _ _dl_m_mmm.__
Cutting
Attachment
Shield
Shield Mount
............ Fig. 7
Install the cutting attachment shield when using the
unit as a grass trimmer.
WARNING: To avoid serious personal injury,
the cutting attachment shield SHALL be in
place at all times while operating 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).
REMOVE THE CUTTING ATTACHMENT AND
INSTALL THE CUTTING BLADE
NOTE: To make removing or installing the cutting blade
or cutting attachment easier, place the unit on
the ground or on a work bench.
Remove the Cutting Attachment Shield
See Removing and Installing Cutting Attachment Shield,.
Remove the Cutting Attachment
WARNING: The gear housing gets hot with
use and can result in injury to the operator.
When the unit is turned off it remains hot for
a short time. Do not touch the gear housing
until it has cooled.
1. Align the shaft bushing hole with the locking rod slot
and insert the locking rod into the shaft bushing hole
(Fig. 8).
Screws
Gear Housing
........ Fig, 8
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
wil! be used when installing the cutting blade.
Fig. g .......
Cutting Attachment
Locking Rod
Slot
r
Locking Rod
....... Fig. 10
9
Install the Cutting Blade
WARNING: To avoid serious personal injury,
always wear gloves while handling or
installing the blade.
4. Place the cutting blade on the output shaft bushing
(Fig. 11).
5. Make sure that the cutting blade is centered on the
pilot step and sitting flat against the output shaft
bushing (Fig. 12).
WARNING: If the cutting blade is oft-center,
the unit will vibrate, and the blade may fly
off, which can cause serious personal injury.
Blade Retainer
Pilot Hole
Nut
Cutting
Blade
Shield
Mount
I
6. Align the shaft bushing hole with the locking rod
slot and insert the locking rod into the bushing hole
(Fig. 8, Pg. 9).
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. (Fig. 13)
• If using a torque wrench and an 5/8 inch socket tighten
to: 325 - 335 inolb, 27 - 28 ft.-Ib, 37 - 38 Nora.
• Without a torque wrench, use a 5/8 inch closed-end or
socket wrench, turning the nut until the blade retainer
issnug 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).
9, Remove the locking rod from the locking rod slot.
WARNING: To avoid serious personal injury I
or damage to the unit, do not start or
operate this unit with the locking rod in the
locking rod slot.
I
Output Shaft
Bushing
Locking Rod __--
Fig. 11 .............
Pilot Step
Fig. 12 ..............
Sharpening the blade can cause the blade tip I
l,_ WARNING: Do not sharpen the cutting blade. I
REMOVE THE CUTTING BLADE AND INSTALL
THE CUTTING ATTACHMENT
Remove the Cutting Blade
[,_ ARNING: To avoid serious personal injury,
1, Align the shaft bushing hole with the locking rod
2. Hold the locking rod in place by grasping it next to
to break off while in use. This can result in
severe personal injury. Rep ace the bade.
always wear gloves while handling or
installing the blade.
slot and insert the locking rod into the bushing hole
(Fig, 8, Pg. 9).
the boom of the unit (Fig. 14).
1/4-1/2 turn
Counterclockwise
10
Clockwise
Fig. 13 ...... Fig. !4
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