Troybilt 41BDT49C063 Owner’s Manual

n n m mum

Operator's Manual

4-Cycle Gasoline

Trimmer/

Brushcutter

Model TB490BC

IMPORTANT: READ SAFETY RULES AND INSTRUCTIONS CAREFULLY

P/N 769-00386 (10/02)

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 ..................................................... 10

Starting/Stopping Instructions ................................................ 12

Operating Instruct=ons ...................................................... 13

Maintenance and Repair Instructions ...................................... 16

Cleaning and Storage ....................................................... 24

Accessories and Replacement Parts ....................................... 24

Troubleshooting Chart ...................................................... 25

Specifications ........................................................... 26

Warranty Information ....................................................... 28

Parts L=st.................................................... 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 #180890 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.

ri I- " Modei/ParefitPartHunlber

_e 8 NUmDOr

Copy the model / parent part

MDUPPN:

Set.No:

Copy the serial number here:

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.

Ca11,1-(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 the previous section to locate this

information. You will be asked to enter the serial number in order to process your call.

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

_1_ 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.

SYMBOL MEANING

4_ ' i ' SAFETY ALERT SYMBOL: Indicates

NOTE: Advises you of information or instructions vital to

Idanger, warning or caution. Attention is

! irequired in order to avoid serious personal

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

the operation or maintenance of the equipment.

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 0.105 inch (2.66 mm) diameter Genuine Factory Parts rM replacement 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.

• Squeeze the throttle control and check that it returns automatically to the idle position. Make all adjustments

or repairs before using unit.

I_il WARNING: Failureto obey a safety

_1_ CAUTION: Failure to obey a safety warning

• 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.

warning Can result in injury to yourse!f 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.

SAFETY WARNINGS FOR GAS TRIMMERS

_ ARNING: Gasoline is highly flammable, and

• 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.

its Vapors Can explode if ignited. Take the following precautions:

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.

• 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]ines 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 gnp.

• 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 untt.

• 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 entanqled with a foreign object, stop the engine immecqiately 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 TM 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 veqetation 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 spinninq blade contacts an object that it does not tmmediately 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. Blaae 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_he engine is stopped or the throttle trigger

is released. Maintain proper control until the blaae has completely stopped rotating.

• Do not run the unit at high speed when not cutting.

• If you strike or become entangled with a foreiqn object, stop the engine immediately and check for

damage. Have any Llamage 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 wNe 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 yoursdlf or others can occur. Use the cutting blade only for the purpose as

described in this manual.

• Stop the engine IMMEDIATELY ifyou 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 upand 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 otthe

reach of children.

• Never douse or squirt the unit with water or any other liquid. Keep handles dr_v,clean and free from debris.

Clean after each use. bee 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

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 MEANING

• ON/OFF STOP CONTROL

Indicates danger, warning or caution.

• SAFETY ALERT SYMBOL O

May be used in conjunction with other

symbols or pictographs.

• WARNING - READ - Y,,Ik_

OFF or STOP

• THROWN OBJECTS AND ROTATING CUTTER CAN

CAUSE SEVERE INJURY

O OPERATOR'S MANUAL / _-

Read the operator's manual(s) and follow _/

all warnings and safety instructions.

Failureto do so can result in serious injury

to the operator and/or bystanders.

• WEAR EYE AND HEARING

WARNING: Thrown objects and loud

noise can cause severe eye injury and

PROTECTION

hearing loss. Wear eye protection meeting ANSI Z87.1 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.

• OIL Refer to operator's manual for the

proper type of oil.

WARNING: Do not operate without the cutting attachment shield in place. Keep away from the rotating cutting

attachment.

• HOT SURFACE WARNING

Do not touch a hot muffler, gear housing or cylinder. You may get burned. These parts get extremely hot from operation. They remain hot for a short time after the

unit is turned off.

• SHARP BLADE

WARNING: Sharp blade on cutting

attachment shield. To prevent serious injury, do not touch line cutting blade.

• 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.

oTRIMMER/BRUSHCUTTER

SAFETY

• ON/OFF STOP CONTROL

ON / START / RUN

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.

APPLICATIONS

As a trimmer:

Cutting grass and light weeds

Edging Decorative trimming around trees, fences, etc.

As a brushcutter:

Cutting weeds and light bush of up to 112 inch in

diameter

Other optional accessories may be used with the TB490BC. Refer to Operating the EZ-Link System for a

list of add-ons.

On/Off Sto_

Shoulder Strap

Spark Arrestor

.,G_ Spark Plug

Fuel Cap

Starter Rope Grip

Shaft Grip

Throttle

Lock-C

Throttle

Control

Brush Blade

Gear

Housing

EZ.Link TM

Blade Shield /

Shield Mount \\

Shaft

Housing

Cutting Attachment

Shield

Air Filter Cover

Engine Feet

J-Handle

Spark Plug

Primer Bulb

Oil Fill Plug / Dipstick

Cutting Attachment

Line Cutting Blade

On some units, the J-handle may be pre-installed. In this case you must loosen screws and adjust the handle to fit

the operator. Go to step 5 if the J-handle is pre-installed.

INSTALL AND ADJUST THE J-HANDLE

1. Place the J-handle between the top and middle clamp pieces (Fig. 1).

(4)

Top Clamp

-_ Middle Clamp

2. While holding the three pieces together, installthe 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. 2).You must

first loosen the screws if the handle is pre-installed.

Decal

INSTALL THE HARNESS

WARNING: Always use the shoulder I

harness when using the cutting blade to avo d serous persona njury. J

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).

Adjust length to fit the operator's size. Pull tab to lengthen, pull strap to shorten (Fig 6).

)

Fig. 4

J Support Fitting

Fig. 5

Fig. 2

6. While holding the unit in the operating position (Fig. 3), position the J-handle to the location that provides you

the best grip.

Fig. 3

7. Tighten the clamp screws evenly, until the J-handle is secure.

Fig. 6

REMOVE AND INSTALL THE CUTTING ATTACHMENT SHIELD

Remove the cuttingattachment shield when using the unit as abrushcutter

A WARNING: The cutting attachment shield

,_1= should NOT be installed when operating I

the unit with a blade. Remove the cutting attachment shield before removing or

installing the blade. I

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.

Cutting

Attachment

Screws

Shield

Gear Housing

Shield Mount

Fig. 7

Install the cutting attachment shield when using the unit as a grass trimmer

_1_ fWARNING: To avoid serious personal

_, | njury, the cutting attachment shield MUST

_|be in place at all times while operating the I

|unit as a grass trimmer. I

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 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

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. 9

Cutting Attachment

LockingRod

Slot

Locking Rod

Fig. 10

Install the Cutting Blade

use. It can result in injury to the operator. I The housing remains hot for a short time I

_[WARNING: The gear housing gets hot with,

even after the unit is turned off. Do not touch the gear hous ng unt t has coo ed.

1. Align the shaft bushing hole with the locking rod slot and insert the locking rod into the shaft bushing hole (Fig. 8).

Output Shaft

Shaft Bushing Hole__\ _ j

._ _ Output Shaft

_ Bushing

Locking Rod - _ _

Fig. 8

injury, always wear gloves while handling or

WARNING: To avoid Serious personal installing the blade. I

4. Place the cutting blade on the output shaft bushing (Fig. 11).

Blade Retainer

Nut

Cutting

Blade

Shield

Mount

Pilot Hole

Output Shaft

Bushing

Locking Rod

Fig. 11

5. Makesurethatthecuttingbladeiscenteredonthe pilotstepandsittingf!atagainsttheoutputshaft

bushing(Fig.12),

Allk I center, the unit will vibrate and the blade I

I _III_ WARNING: If the Cutting blade is off- I

may fly off, causing possible serious

I personal injury. I

Pilot Step

REMOVE THE CUTTING BLADE AND INSTALL THE CUTTING ATTACHMENT

WARNING: TOavoid serious personal

I Allk l injury, always wear gloves while handling or l_ l installing the blade. 1

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).

Hold the locking rod in place by grasping it next to

the boom of the unit (Fig. 14).

While holding the locking rod, loosen the nut on the blade by turning it clockwise with a 5/8 inch closed-

end or socket wrench (Fig. 14).

Fig. 12

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.,Ib, 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).

1/4-1/2 turn

Counterclockwise

Clockwise

Fig. 14

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 fiat 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.

Cutting Attachment _

Blade Retainer.

Fig. 13

9. Remove the locking rod from the locking rod slot.

A I WARNING: TO avoid serious personal I

Allk I injury or damage to the unit, do not start or I

operate this unit with the locking rod in the

I locking rod slot.

WARNING: Do not sharpen the Cutting blade. 1

Sharpening the blade can cause the blade tip I

to break off while in use. This can result in I

severe personal injury, Replace the blade, l

Output Shaft

Bushing

Locking Rod

Fig. 15

Remove the locking rod.

Install the cutting attachment shield. Refer to Remove

and Install the Cutting Attachment Shield.

WARNING: To avoid serious personal injuryl I the cutting head guard MUST be in place at

a t mes wh e operat ng the unt as a tr miner.

DANGER: OVERFILLING OIL CRANKCASE MAY CAUSE SERIOUS PERSONAL

INJURY. Checking and maintaining the proper oil level in the crank case (_annot is

important and cannot be overemphasized, Check oil before each use and change as

needed. See Changing the Oil.

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 attempting to start 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 to measure the correct amount

for 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.

3. Remove the oil plug / dipstick from the crankcase (Fig. 17).

O-Ring _i

Oil FillPlug/Dipstick- _.._ /

Oil Fill Hole /

Fig. 17

4. Pour the entire bottle of oil into the oil fill hole (Fig. 18).

Funnel Spout_

Fig. 16

Fig. 18

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.

The importance of checking and maintaining the proper oil level in the crankcase cannot be overemphasized.

Check oil before each use and change as needed. Refer to Changing the Oil.

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