Troy-Bilt TB465SS, RTB415CS User Manual

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Operator’s Manual

TABLE OF CONTENTS

Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Rules for Safe Operation . . . . . . . . . . . . . . . . . . . . . . . . . .2 Know Your Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Oil and Fuel Information . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Starting/Stopping Instructions . . . . . . . . . . . . . . . . . . . . . .7 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Maintenance and Repair Instructions . . . . . . . . . . . . . . . .9 Cleaning and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E16

WARNING: 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.

4-Cycle Gasoline Trimmer

SUPER BRONCO TB415CS/

PONY TB465SS

SAVE THESE INSTRUCTIONS

For service call 1-800-828-5500 in the United States, or 1-800-668-1238 in Canada, 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.

THIS PRODUCT IS COVERED BY ONE OR MORE U.S. PATENTS. OTHER PATENTS PENDING.

Service on this unit both within and after the warranty period should be performed only by an authorized and approved service dealer.

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 #791–180890 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.

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© 2006 MTD SOUTHWEST INC, All Rights Reserved.

P/N 769-01954C

(12/06)

RULES FOR SAFE OPERATION

• IMPORTANT SAFETY INSTRUCTIONS •

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 0.105 inch, 2.667 mm diameter original equipment manufacturer replacement line. Never use metal-reinforced 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

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.

Avoid creating a source of ignition for spilled fuel. Do not start the engine until fuel vapors dissipate.

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 does not have a clutch. The cutting attachment continues rotating 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.

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

2

RULES FOR SAFE OPERATION

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

 

• SAFETY ALERT SYMBOL

 

 

 

 

• ON/OFF STOP CONTROL

 

 

 

 

 

 

Indicates danger, warning or caution. May be used

 

 

 

 

ON / START / RUN

 

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 standards and ear protection when operating this unit. Use a full face shield when needed.

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.

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

OFF or STOP

KEEP BYSTANDERS AWAY

WARNING: Keep all bystanders, especially children and pets, at least 50 feet (15 m) from the operating area.

CHOKE CONTROL

1.• FULL choke position

2.• PARTIAL choke position

3.• RUN choke position

UNLEADED FUEL

Always use clean, fresh unleaded fuel

OIL

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

SHARP BLADE

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

3

KNOW YOUR UNIT

APPLICATIONS

As a trimmer:

Cutting grass and

Edging

Decorative trimming

NOTE: The below your unit. For example, shaft. Your unit may

Spark Arrestor

Spark Plug

Muffler Guard

Oil Fill

Plug/

Dipstick

Primer

Bulb

Line

Cutting

Blade

Cutting Attachment

Cutting

Shield

Attachment

 

Cutting Attachment

4

ASSEMBLY INSTRUCTIONS

INSTALL CUTTING ATTACHMENT SHIELD

Use the following instructions if the cutting attachment shield on your unit is not installed. Use only the instructions that apply to the type of shaft and shield that your unit is equipped with.

WARNING: To prevent serious personal injury, never operate the trimmer without the cutting attachment shield in place.

TB415CS

1.Place the cutting attachment shield onto the shaft housing. Be sure the guard mounting bracket slides into the slot on the edge of the cutting shield. Rotate the shield into place, counterclockwise. The holes in the guard mounting bracket and cutting attachment shield will line up (Fig. 1).

Shaft Housing

Guard

Mounting

Bracket

Cutting

Attachment

Shield

Fig. 1

2.From inside the cutting attachment shield, push the square bolt through the hole until the threaded end protrudes through the guard mounting bracket (Fig. 2).

Guard Mounting Bracket

Washer

Wing Nut

Square

Cutting Attachment Blot

Shield

Fig. 2

3.Put the washer on the bolt, then screw the wing nut onto

the bolt and tighten.

shows the installation

process from underneath

.

 

(4) Screws

Fig. 3

TB465SS

Fig. 4

2.Place a hex lock nut into one of the three recessed holes on the top of the cutting attachment shield (Fig 5).

3.Install a screw into the hole from the bottom of the cutting attachment shield and screw it into the nut installed in step 2 (Fig. 5). Do not tighten.

4.Repeat steps 2 and 3 until all three screws have been started, then tighten securely.

Fig. 5

ADJUSTING THE D-HANDLE

1.Locate the wing nut on the D-Handle. Loosen the wing nut enough to loosen the D-Handle (Fig. 6).

NOTE: Do not remove wing nut, washer, or bolt.

2.Rotate the D-Handle to the upright position on the front side of the shaft housing (Fig. 6).

NOTE: The D-handle should slant towards the powerhead of the unit.

3.Hold the unit in the operating position (Fig. 16). If necessary,

reposition the D- handle to the location that provides the best grip.

4.Tighten the wing nut until the D-Handle is secure.

. 6

1.Slide the cutting attachment shield into the shield mount on the cutting attachment. Align the screw holes in the shield with the holes in the cutting attachment (Fig. 4).

5

OIL AND FUEL INFORMATION

WARNING: 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.

(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

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 3.04 fluid oz. (90 ml) bottle of SAE 30 SF, SG, SH oil (Fig. 7).

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. 7).

Funnel

Spout

Fig. 7

2.Place the unit on a flat level surface (Fig. 8).

Oil Fill

Fig. 8

3.Remove the oil plug / dipstick from the crankcase (Fig. 9).

4.Pour the entire bottle of oil into the oil fill hole (Fig. 9).

O-Ring

Oil Fill Plug/Dipstick

Oil Fill Hole

Fig. 9

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.

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

• 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.

WARNING: 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.

FUELING THE UNIT

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.

1.Remove the fuel cap (Fig. 10).

Unleaded

Gasoline

Gas Can Spout

Fuel Cap

Fuel Tank

Fig. 10

WARNING: Remove fuel cap slowly to avoid injury from fuel spray. Never operate the unit without the fuel cap securely in place.

2.Place the gas container’s spout into the fill hole on the fuel tank (Fig. 10) 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.

6

STARTING AND STOPPING INSTRUCTIONS

WARNING: 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. 13). 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.

STARTING INSTRUCTIONS

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.

3.Make sure the On/Off Stop Control in the ON ( I ) position (Fig. 11).

4. 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. 12). 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.

5.Place the choke lever in Position 1 (Fig. 12).

6.Crouch in the starting position (Fig. 13), squeeze the throttle control, and pull the starter rope briskly 5 times.

7.Place the choke lever in Position 2 (Fig. 14).

8.While squeezing the throttle control, pull the starter rope briskly 1 to 4 times to start the engine.

9.Keep the throttle squeezed and allow the engine to warm up for 15 to 30 seconds.

10.Place the choke lever in Position 3 (Fig. 15). The unit is ready for use.

IF... the engine does not start, go back to step 4.

IF... the engine fails to start after a few attempts, place the choke lever in Position 3 and squeeze the throttle control. Pull the starter rope briskly 3 to 8 times. The engine should start. If not, repeat.

IF WARM... If the engine is already warm, make sure the On/Off Stop control is in the ON position and start the unit with the choke lever in Position 2. After the unit starts, move the choke lever to Position 3.

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.

Stop/Off (O)

Start/On (I)

Throttle Control

Fig. 11

Choke Lever

Position 1

Primer Bulb

Fig. 12

Starter Rope

Throttle Control

Fig. 13

Position 2

 

 

 

Position 3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Fig. 14

 

 

 

Fig. 15

 

 

7

OPERATING INSTRUCTIONS

WARNING: Always wear eye, hearing, foot and body protection to reduce the risk of injury when operating this unit.

HOLDING THE TRIMMER

Before operating the unit, stand in the operating position (Fig. 16). 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

Fig. 16

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.

Cut from right to left.

Slowly move the trimmer into and out of the cutting area at the desired height. Move either in a forward-backward 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. It is normal for some line breakage to occur from regular use.

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. 17).

30°

Fig. 17

WARNING: Never use metal-reinforced line, wire, chain, or rope. These can break off and become dangerous projectiles.

FIXED LINE INSTALLATION

Always use original equipment manufacturer 0.105 inch

(2.667 mm) replacement line. Lines other than those specified may make the engine overheat or fail.

To install the trimming line:

1. Insert each end of the replacement line into the holes on either side of retention hook (Fig. 18).

2.Push the ends through until they stick out of the sides of

the head (Fig. 19).

Fig. 18

 

3.Pull the ends through making sure that the ends are of equal

length and the middle of the line is centered between the

insertion holes (Fig. 20).

4. If the ends are not of equal length, push the longer end

back through the head part way and pull the shorter end to compensate. Repeat until both ends are the same length.

Fig. 19

Fig. 20

5. Push the trimmer line until it lies flat against the cutting head (Fig. 21). Make sure the two lengths of cutting line are of equal length. If they are not, adjust until they are.

Fig. 21

WARNING: Always use the correct line length when installing trimming line on the unit. If the two lengths of cutting line are not of equal length, the unit may develop a vibration.

8

MAINTENANCE AND REPAIR INSTRUCTIONS

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.

WARNING: 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.

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.

CAUTION: 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.

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.

FREQUENCY

MAINTENANCE REQUIRED

SEE

 

 

 

Before starting engine

Fill fuel tank with fresh fuel

Page 6

Check oil

Page 9

 

 

 

 

Every 10 hours

Clean and re-oil air filter

Page 10

 

 

 

First change at 10 hours

Change oil

Page 9

Every 25 hours

Change oil

Page 9

Every 25 hours thereafter

Clean spark arrestor

Page 12

 

 

 

10 hours on new engine

Check rocker arm to valve

 

 

clearance and adjust

Page 11

Every 25 hours

Check rocker arm to valve

 

 

clearance and adjust

Page 11

Every 25 hours

Check spark plug

 

 

condition and gap

Page 12

 

 

 

5.Remove the oil fill plug/dipstick and check the oil level. Oil should be up to the top of the dipstick (Fig. 24).

Oil Fill Plug/Dipstick

O-Ring

Full

Add 1.4-1.5 Oz.

(41-44 ml)

Top of Dipstick

Fig. 24

6.If the level is low, add a small amount of oil to the oil fill hole and recheck (Fig. 25). Repeat this procedure until the oil level reaches the top of the dipstick.

NOTE: Do not overfill the unit.

NOTE: Make sure the O-ring is in place on the oil fill plug/dipstick when checking and changing the oil (Fig. 25).

O-Ring

Oil Fill Plug/Dipstick

Oil Fill Hole

Fig. 25

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. 26). Allow ample time for complete drainage.

9

Troy-Bilt TB465SS, RTB415CS User Manual

MAINTENANCE AND REPAIR INSTRUCTIONS

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 3.04 fluid ounce (90 ml) of SAE 30 SF, SG, SH oil.

CAUTION: Wear gloves to prevent injury when handling the unit.

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 3.04 ounces (90 ml) (Fig. 27). Check the level with the dipstick. If the level is low, add a small amount of oil and recheck. Do not overfill (Fig. 27).

6.Replace the oil fill plug/dipstick.

7.Reconnect the spark plug

boot.

Fig. 26

Air Filter

Air Filter Cover

Tab

Fig. 28

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. 33).

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 Fig. 29 slot on the back plate (Fig. 33).

9.Replace the fuel cap if it was removed.

Fill Level

Fig. 30

Fig. 31

Fig. 27

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.

WARNING: To avoid serious personal injury, always turn the unit off and allow it to cool before you clean or service it.

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. 28).

NOTE: It may be necessary to remove the fuel cap to completely remove the air filter cover.

2.Remove the air filter (Fig. 28).

3.Wash the filter in detergent and water (Fig. 29). Rinse the filter thoroughly and allow it to dry.

4.Apply enough clean SAE 30 motor oil to lightly coat the filter (Fig. 30).

5.Squeeze the filter to spread and remove excess oil (Fig. 31).

6.Replace the filter (Fig. 32).

Back Plate

Back Plate Slot

Slots

Fig. 32

Air Filter

Air Filter Cover

Tab

Fig. 33

10

Idle Adjustment Screw
Fig. 34

MAINTENANCE AND REPAIR INSTRUCTIONS

WARNING: The cutting attachment may spin during idle speed adjustments. Wear protective clothing and observe all safety instructions to prevent serious personal injury.

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. 34).

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.

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. 34). Turn the idle speed screw in, clockwise, 1/8 of a turn at a time (as needed) until the engine idles smoothly.

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.

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.

WARNING: To prevent serious personal injury, make sure the cutting attachment has stopped rotating before you turn it off and set it down.

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. 35).

2.Remove the two (2) screws on top of the engine cover with a Flat-head or T-25 Torx screwdriver (Fig. 36).

3.Remove the screw behind the engine cover (Fig. 37).

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. 36).

Engine Cover

Rear Slot

and Tab

Middle Tab

 

Front Tab

Middle Slot

Front Slot

Fig. 35

Top View Of The Engine

Remove Screws

Engine Cover

Muffler

Fig. 36

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. 38). Remove the rocker arm cover and gasket.

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

 

Screw

travel while looking in the

 

spark plug hole (Fig. 38)

 

• 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. 39). Measure both

the intake and exhaust valves.

Fig. 37

The recommended clearance for

 

the intake and exhaust is .003 –

Rocker

.006 in. (.076 – 0.152 mm). Use a

Arm

standard automotive feeler gauge at

Cover

.005 (0.127mm). The feeler gauge

 

should slide between the rocker arm

Spark

and valve stem with a slight amount

Plug

of resistance, without binding. Figure

Hole

40 shows how to measure the clearance.

Fig. 38

11

MAINTENANCE AND REPAIR INSTRUCTIONS

Rocker Arms

Adjusting Nuts

 

INTAKE

 

EXHAUST

Feeler Gauge

 

Fig. 39

Exhaust

Exhaust

Adjusting Nut

Rocker Arm

Exhaust

 

Clearance:

 

.003-.006 in.

 

(.076-0.152 mm)

 

Intake Valve

 

Stem

Feeler Gauge

Intake Clearance:

 

.003–.006 in.

 

(.076–0.152 mm)

Exhaust Valve Stem

Fig. 40

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. 40).

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. 31).

14.Check the spark plug and reinstall. See Replacing the Spark Plug.

15.Replace the spark plug wire.

REPLACING THE SPARK PLUG

Use a replacement part number 791-180852B spark plug. The correct air gap is 0.025 in. (0.635 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.

WARNING: Do not sand blast, scrape or clean electrodes. Grit in the engine could damage the cylinder.

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. (0.635 mm.) using a feeler gauge (Fig. 41).

4.Install a correctly-gapped spark plug in the cylinder head. Turn the

0.025 in.

(0.635 mm.)

Fig. 41

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.

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. 42).

Muffler

Spark Arrestor Screen

Tab Screw

Spark Arrestor Cover

Slot

Fig. 42

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.

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.

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 5 drops of high quality motor oil into the cylinder. Pull the starter rope slowly to distribute the oil. Reinstall the spark plug.

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.

WARNING: To avoid serious personal injury, always turn your unit off and allow it to cool before you clean or service it.

12

 

 

TROUBLESHOOTING

 

 

 

 

 

 

 

 

 

 

 

 

 

ENGINE WILL NOT START

 

 

 

 

 

 

 

 

 

 

C A U S E

 

 

A C T I O N

 

Empty fuel tank

 

 

Fill fuel tank with fuel

 

 

 

 

 

 

Primer bulb wasn't pressed enough

 

 

Press primer bulb fully and slowly 10 times

 

 

On/Off control in the STOP position

 

 

Turn On/Off control to ON

 

 

 

 

 

 

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 IDLE

 

 

 

 

 

 

 

 

 

 

C A U S E

 

 

A C T I O N

 

Air filter is plugged

 

 

Replace or clean the air filter

 

 

 

 

 

 

 

Old fuel

 

 

Drain gas tank and add fresh fuel

 

 

Improper carburetor adjustment

 

 

Adjust according to the Carburetor Adjustments section or take

 

 

 

 

to an authorized service dealer for an adjustment

 

 

 

 

 

 

 

ENGINE WILL NOT ACCELERATE

 

 

 

 

 

 

 

 

 

 

C A U S E

 

 

A C T I O N

 

Old fuel

 

 

Drain gas tank and add fresh fuel

 

 

 

 

 

 

Improper carburetor adjustment

 

 

Adjust according to the Carburetor Adjustments section or take

 

 

 

 

 

to an authorized service dealer for an 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

 

 

 

 

ENGINE LACKS POWER OR STALLS WHEN CUTTING

 

 

 

 

 

 

C A U S E

 

 

A C T I O N

 

Old fuel

 

 

Drain gas tank and add fresh fuel

 

 

 

 

 

 

Improper carburetor adjustment

 

 

Adjust according to the Carburetor Adjustments section or take

 

 

 

 

 

to an authorized service dealer for an adjustment

 

 

Fouled spark plug

 

 

Replace or clean the spark plug

 

 

 

 

 

 

Plugged spark arrestor

 

 

Clean or replace spark arrestor

 

 

 

 

 

 

 

If further assistance is required, contact your authorized service dealer.

13

 

SPECIFICATIONS

 

 

 

 

 

 

 

ENGINE*

 

 

 

 

 

Engine Type.................................................................................................................................................................

 

Air - Cooled, 4-Cycle

Displacement................................................................................................................................................................

 

1.6 cu. in. (26.2 cc)

Operating RPM...............................................................................................................................................................

 

6,800 - 9,800 rpm

Idle Speed RPM .............................................................................................................................................................

 

3,600 - 4,400 rpm

Ignition Type.................................................................................................................................................................................

 

Electronic

Ignition Switch .......................................................................................................................................................................

 

Rocker Switch

Valve clearance............................................................................................................................................

 

. 003–.006 in. (.076–.152 mm))

Spark Plug Gap .......................................................................................................................................................

 

0.025 inch (0.635 mm)

Lubrication ..................................................................................................................................................................................

 

SAE 30 Oil

Crankcase Oil Capacity .......................................................................................................................................................

 

3.04 oz (90 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)

 

 

DRIVE SHAFT AND CUTTING ATTACHMENT*

 

 

 

 

Drive Shaft Housing ....................................................................................................................................................................

 

Steel Tube

Throttle Control ...............................................................................................................................................................

 

Finger-Tip Trigger

Approximate Unit Weight (No fuel, with handle, shield and cutting attachment)

................................................................. 13.5 lbs (6 kg)

Cutting Mechanism:

TB415CS & TB465SS: .....................................................................................

Fixed String Cutting Head

Line Spool Diameter:

TB415CS & TB465SS: ..............................................................................................

3 inches (76.2 mm)

Trimming Line Diameter:

TB415CS & TB465SS.........................................................

0.105 inches (2.667 mm) square cutting line

TB415CS & TB465SS Cutting Path Diameter ...........................................................................................................

16 inches (40.64 cm)

*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.

14

NOTES

15

MANUFACTURER’S LIMITED WARRANTY FOR:

The limited warranty set forth below is given by Troy-Bilt LLC (Troy-Bilt) with respect to new merchandise purchased and used in the United States, its possessions and territories.

Troy-Bilt warrants this product against defects in material and workmanship for a period of two (2) years commencing on the date of original purchase and will, at its option, repair or replace, free of charge, any part found to be defective in material or workmanship. This limited warranty shall only apply if this product has been operated and maintained in accordance with the Operator’s Manual furnished with the product, and has not been subject to misuse, abuse, commercial use, neglect, accident, improper maintenance, alteration, vandalism, theft, fire, water or damage because of other peril or natural disaster. Damage resulting from the installation or use of any accessory or attachment not approved by Troy-Bilt for use with the product(s) covered by this manual will void your warranty as to any resulting damage. This warranty is limited to ninety (90) days from the date of original retail purchase for any Troy-Bilt product that is used for rental or commercial purposes, or any other income-producing purpose.

HOW TO OBTAIN SERVICE: Warranty service is available, WITH PROOF OF PURCHASE THROUGH YOUR LOCAL AUTHORIZED SERVICE DEALER. To locate the dealer in your area, please check for a listing in the Yellow Pages or contact the Customer Service Department of Troy-Bilt by calling 1- 800-828-5500 or writing to P.O. Box 361131, Cleveland OH 44136-0019 or if in Canada call 1-800-668-1238. No product returned directly to the factory will be accepted unless prior written permission has been extended by the Customer Service Department of Troy-Bilt.

This limited warranty does not provide coverage in the following cases:

A.Tune-ups - Spark Plugs, Carburetor Adjustments, Filters

B.Wear items - Bump Knobs, Outer Spools, Cutting Line, Inner Reels, Starter Pulley, Starter Ropes, Drive Belts

C.Troy-Bilt does not extend any warranty for products sold or exported outside of the United States of America, its possessions and territories, except those sold through Troy-Bilt’s authorized channels of export distribution.

Troy-Bilt reserves the right to change or improve the design of any Troy-Bilt Product without assuming any obligation to modify any product previously manufactured.

No implied warranty, including any implied warranty of merchantability or fitness for a particular purpose, applies after the applicable period of express written warranty above as to the parts as identified. No other express warranty or guaranty, whether written or oral, except as mentioned above, given by any person or entity, including a dealer or retailer, with respect to any product shall bind Troy-Bilt. During the period of the Warranty, the exclusive remedy is repair or replacement of the product as set forth above.

(Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.)

The provisions as set forth in this Warranty provide the sole and exclusive remedy arising from the sales. Troy-Bilt shall not be liable for incidental or consequential loss or damages including, without limitation, expenses incurred for substitute or replacement lawn care services, for transportation or for related expenses, or for rental expenses to temporarily replace a warranted product. (Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.)

In no event shall recovery of any kind be greater than the amount of the purchase price of the product sold. Alteration of the safety features of the product shall void this Warranty. You assume the risk and liability for loss, damage, or injury to you and your property and/or to others and their property arising out of the use or misuse or inability to use the product.

This limited warranty shall not extend to anyone other than the original purchaser, original lessee or the person for whom it was purchased as a gift.

How State Law Relates to this Warranty: This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

To locate your nearest service dealer dial 1-800-828-5500 in the United States or 1-800-668-1238 in Canada.

Troy-Bilt LLC

P.O. Box 361131

Cleveland, OH 44136-0019

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