Troybilt 41BDT25C063 Owner’s Manual

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Operator's Manual

2-Cycle Gasoline

Trimmer

Model TB25CS

IMPORTANT: READ SAFETY RULES AND INSTRUCTIONS CAREFULLY

P/N 769-00493 (12/02)

PRINTED IN USA

Content Page

Calling Customer Support .................................................... 2

Rules for Safe Operation ..................................................... 3

<now Your Unit ...................................................... 6

Assembly Instructions ................................................. 7

Oil and Fuel Information ...................................................... 8

Starting/Stopping Instructions ................................................. 9

Operating Instruet=ons ...................................................... 10

Maintenance and Repair Instructions ...................................... 12

Cleaning and Storage ....................................................... 18

Accessories and Replacement Parts ....................................... 18

Troubleshooting Chart ...................................................... 19

Specifications ........................................................... 20

Warranty Information ....................................................... 22

Paris Dst .................................................... Inside Back Cover

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, !f
it requires replacement, Accessory Part #182747 Spark Arrestor Screen is available by contacting the service department.

This operator's manual is an important part of your new trimmer. 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.

If you have difficulty assembling this product or have any questions regarding the controls, operation or maintenance of

this unit, please call the Customer Support Department.

Call 1-800-520-5520 to reach a Customer Support representative. Please have your unit's model number

(,'_ and serial number ready when you call. See the previous section to locate this information. You will be asked

to enter the serial number in order to process your call.

2

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.

SYMBOL MEANING

4_ ' i ' SAFETY ALERT SYMBOL: Indicates

NOTE: Advises you of information or instructions vital

Idanger, warning or caution. Attention is

! irequired in order to avoid serious personal

mjury_ May be used in conjunction with
other symbols or pictographs.

to the operation or maintenance of the

equipment.

SYMBOL MEANING

_;i DANGER: Failure to Obey a safety warning

_k WARNING: Failureto obey a safety

4Hll

_ I i CAUTION: Failure to 0bey 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 Can result in injury to yourself and
others. Always follow the safety

precautions to reduce the risk of fire,

electric shock and personal injury.

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.

California Proposition 65 Warning:

THE ENGINE EXHAUST FROM THIS

PRODUCT CONTAINS CHEMICALS

KNOWN TO THE STATE OF CALIFORNIA

TO CAUSE CANCER, BIRTH DEFECTS

OR OTHER REPRODUCTIVE HARM.

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 fuel 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 do so can result in personal

injury to the operator and bystanders, as well as

damage to the unit.

• Use only 0.095 inch (2.41 mm) diameter Genuine

Factory Parts rMreplacement line. Never use metal-
reinforced line, wire or rope. These can break off and

become dangerous projectiles.

• 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. They 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-foot (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 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.

• This unit was not designed to be used as a
brushcutter. Do not attach or operate this unit with any
type of brushcutting blade or brushcutting attachment.

SAFETY WARNINGS FOR GAS TRIMMERS

its vapors can explode if ignited. Take the

WARNING: Gasoline is highly flammable, and
fo ow ng precaut ons:

• 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 fuel 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 fuel in a clean, well-ventilated outdoor area where
there are no sparks or flames. Slowly remove the fuel

cap only after stopping engine. Do not smoke while
fueling or mixing fuel. 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.

3

WHILE OPERATING

• Never start or run the unit inside a closed room or
building. Breathing exhaust fumes can kill. Operate

this unit only in a well ventilated outdoor area.

• Wear safety glasses or goggles that are marked as
meeting ANSI Z87.1-1989 standards. Also wear

ear/hearing protection when operating this unit. Wear

a face or dust mask if the operation is dusty. Long
sleeve shirts are recommended.

• Wear heavy, long pants, boots and gloves. 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 D-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 or muffler. These parts get

extremely hot from operation. They remain hot for a

short time after you turn off the unit.

• Do not operate the engine faster than the speed
needed to cut, trim or edge. Do not run the engine at

high speed when you are 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 Factory Parts rMreplacement 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 faulty muffler and spark
arrestor, keep the engine and muffler free from grass,
leaves, excessive grease or carbon build up.

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.
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 the 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

4

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 SYMBOL

Indicates danger, warning, or //._..._

caution. May be used in conjunction

• SAFETY ALERT SYMBOL __
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. Usea fullface

shield when needed.

MEANING

• 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 or
cylinder. You may get burned. These

parts get extremely hot from
operation. When turned off they

remain hot for a short time.

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.

• OIL

Refer to operator's manual for the
proper type of oil.

SHARPBLADE

WARNING: Sharp blade on cutting
attachment shield. To prevent
serious injury, do not
touch line cutting blade.

5

APPLICATIONS
As a trimmer:

Cutting grass and light weeds

Edging
Decorative trimming around trees, fences, etc.

Other optional accessories may be used with the
TB25CS. Refer to Operating the EZ-Link System for a list

of add-ons.

On/Off Stop Contrc

EZ*Start TM Lever.

Fuel Cap

Starter Rope Grip--

Shaft Grip

Muffler Guard

/

Muffler

Spark Plug

Shaft Housing

Shoulder Strap Clip

Cutting Attachment

Shield

/

/

/

D-Handle

Air Filter/Muffler

Cover

Throttle

Control

EZ-Start

Lever

Line Cutting Blade

6

_\ Cutting Attachment

Engine Stand

Spark Plug

\\ Muffler

\

\

\

Primer Bulb

Onsomeunits,theD-handlemaybepre-installed,
requiringonlylooseningscrewsandsomeadjustment.If

thisisthecase,gotostep4.

INSTALLING AND ADJUSTING THE D-HANDLE

1. Remove the screws and bottom clamp piece that
were installed on the D-handle for shipping.

2. Place D-handle the over the shaft housing and onto

the bottom clamp (Fig. 1). Place it a minimum of 6

inches (15.24 cm) from the end of the shaft grip.

3. Start screws with a large Flat-head or T-25 Torx
screwdriver. Do not tighten until you make the

handle adjustment.

4. If it was pre-installed, loosen the screws on the
D-handle just enough to move the D-handle.

Shaft Grip

(4) Screws_

Shaft _----_-!

Housing I

I

INSTALL THE CUTTING ATTACHMENT SHIELD

Use the following instructions if the cutting attachment
shield on your unit is not installed.

IWARNING: TOpreventseriouspersonal

1,

Place the cutting attachment shield onto the shaft
housing above the clamp assembly (Fig. 3).

2.

Push the cutting attachment shield down to the top of

the cutting attachment assembly and then rotate the

cutting attachment shield until the screw holes align
and the guard fits into the recessed pocket (Fig. 4).

3. Install the screws with a Phillips screwdriver (Fig. 5).

injury, never operate the trimmer without |
the cutting attachment shield in place. J

Clamp _ Shaft Housing

Assembly

On/Off Stop Control

Minimum 6 inches

(15.24 cm)

D-Handh

Bottom Clamp

Fig, 1

5. While holding the unit in the operating position
(Fig. 2), position the D-handle to the location that

provides you the best grip.

6. Tighten the clamp screws evenly, until the D-handle
is secure.

\

\

Attachment

Assembly - _-

Cutting __

Fig. 3

Recessed

Pocket

CuttingAttachment

Shield

Fig. 4

Fig. 2 Fig. 5

7

OIL AND FUEL MIXING INSTRUCTIONS

Old and/or improperly mixed fuel are the main reasons
for the unit not running properly. Be sure to use fresh,
clean unleaded fuel. Follow the instructions carefully for
the proper fuel/oil mixture.

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. It forms

acids when stored. When using alcohol-blended fuel,
use fresh fuel (less than 60 days old).

Using Blended Fuels

If you choose to use a blended fuel, or its use is

unavoidable, follow recommended precautions:

• Always use the fresh fuel mix explained in your
operator's manual

• Always agitate the fuel mix before fueling the unit

• Drain the tank and run the engine dry before storing
the unit

Thoroughly mix the proper ratio of 2-cycle engine oil
with unleaded gasoline in a separate fuel can. Use a 40:1

fuel/oil ratio. Do not mix them directly in the engine fuel
tank. See the table below for specific gas and oil mixing

ratios.
NOTE: One gallon (3.8 liters) of unleaded gasoline mixed

with one 3.2 oz. (95 ml.) bottle of
2-cycle oil makes a 40:1 fuel/oil ratio.

UNLEADED GAS 2 CYCLE OIL

1 US. GALLON + 3.2 FL OZ.

(3.8 LITERS) (95 ml)

1 LITER + 25 ml

Using Fuel Additives

The bottle of 2-cycle oil that came with your unit
contains a fuel additive which will help inhibit corrosion
and minimize the formation of gum deposits. It is
recommended that you use our 2-cycle oil with this unit.

If unavailable, use a good 2-cycle oil designed for

air-cooled engines along with a fuel additive, such as

STA-BIL ' Gas Stabilizer or an equivalent. 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 fuel tank.

_k. CAUTION: For proper engine operation and I

A" maximum reliability, pay strict attention to I

the oil and fuel mixing instructions on the

2-cycle oil container. Using improperly
mxed rue can severe y damage the eng ne.

MIXING RATIO - 40:1

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.

A WARNING: Remove fuel cap Slowly to avoid

injury from fuel spray. Never Operate the unit

_l without the fuel cap securely in place. J

WARNING: Add fuel in a clean, Well ]
ventilated area outdoors. Wipe up any |

spilled fuel immediately. Avoid creating a |
source of ignition for spilt fuel. Do not start |

the engine until fuel vapors dissipate. J

NOTE: Dispose of the old fuel/oil mix in accordance to

Federal, State and Local regulations.

8