Troy-Bilt TB490BC User Manual

Operator’s Manual

PART NO. 769-02058A (2/06)

TB490BC

IMPORTANT: READ SAFETY RULES AND INSTRUCTIONS CAREFULLY

4-Cycle Gas Trimmer/ Brushcutter

INTRODUCTION

Copy the serial number

here:

THANK YOU

Thank you for buying this quality product. This modern outdoor power tool will provide many hours of useful service. You will find it to be a great labor-saving device. This operator’s manual provides you with easy-tounderstand operating instructions. Read the whole manual and follow all the instructions to keep your new outdoor power tool in top operating condition.

PRODUCT REFERENCES, ILLUSTRATIONS AND SPECIFICATIONS

All information, illustrations, and specifications in this manual are based on the latest product information available at the time of printing. We reserve the right to make changes at any time without notice.

SERVICE INFORMATION

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

For service call 1-800-520-5520 to obtain a list of authorized service dealers near you. For more details about your unit, visit our website at www.troybilt.com.

DO NOT RETURN THE UNIT TO THE RETAILER. PROOF OF PURCHASE WILL BE REQUIRED FOR WARRANTY SERVICE.

Before beginning, locate the unit’s model plate. It lists the model and serial numbers of your unit. Refer to the sample plate below and copy the information for future reference.

Make sure you carefully read and understand this manual before starting or operating this equipment.

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

TABLE OF CONTENTS

Service Information . . . . . . . . . . . . . . . . . . . . . . . . .2

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

Know Your Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . .8

Oil and Fuel Information . . . . . . . . . . . . . . . . . . . . .11

Starting/Stopping Instructions . . . . . . . . . . . . . . . .13

Operating Instructions . . . . . . . . . . . . . . . . . . . . . .14

Maintenance and Repair Instructions . . . . . . . . . . .17

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

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

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

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

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E29

Copy the model and parent

part number here:

SPARK ARRESTOR NOTE

NOTE: For users on U.S. Forest Land and in the states of California, Maine, Oregon and Washington.

All U.S. Forest Land and the state of California (Public Resources Codes 4442 and 4443), Oregon and Washington require, by law that certain internal combustion engines operated on forest brush and/or grass-covered areas be equipped with a spark arrestor, maintained in effective working order, or the engine be constructed, equipped and maintained for the prevention of fire. Check with your state or local authorities for regulations pertaining to these requirements. Failure to follow these requirements could subject you to liability or a fine. This unit is factory equipped with a spark arrestor. If it requires replacement, ask your LOCAL SERVICE DEALER to install the Accessory Part

#180890 Spark Arrestor Kit.

CALIFORNIA PROPOSITION 65 WARNING

WARNING

THE ENGINE EXHAUST FROM THIS

PRODUCT CONTAINS CHEMICALS

KNOWN TO THE STATE OF CALIFORNIA

TO CAUSE CANCER, BIRTH DEFECTS

OR OTHER REPRODUCTIVE HARM.

RULES FOR SAFE OPERATION

SYMBOL MEANING

The purpose of safety symbols is to attract your attention to possible dangers. The safety symbols, and their explanations, deserve your careful attention and understanding. The safety warnings do not by themselves eliminate any danger. The instructions or warnings they give are not substitutes for proper accident prevention measures.

NOTE: Advises you of information or instructions vital to

the operation or maintenance of the equipment.

SYMBOL MEANING

Failure to obey a

safety warning can result in injury to yourself and others. Always follow the safety precautions to reduce the risk of fire, electric shock and personal injury.

WARNING:

Failure to obey a

safety warning will result in serious injury to yourself or to others. Always follow the safety precautions to reduce the risk of fire, electric shock and personal injury.

DANGER:

Failure to obey a

safety warning may result in property damage or personal injury to yourself or to others. Always follow the safety precautions to reduce the risk of fire, electric shock and personal injury.

CAUTION:

Indicates

danger, warning or caution. Attention is required in order to avoid serious personal injury. May be used in conjunction with other symbols or pictographs.

SAFETY ALERT:

Read the Operator’s Manual(s) and follow all

warnings and safety instructions.

Failure to do so can result in serious injury to the

operator and/or bystanders.

FOR QUESTIONS, CALL 1-800-520-5520

READ ALL INSTRUCTIONS

BEFORE OPERATING

• Read the instructions carefully. Be familiar with the controls and proper use of the unit.

• Do not operate this unit when tired, ill, or under the influence of alcohol, drugs, or medication.

• Children and teens under the age of 15 must not use the unit, except for teens guided by an adult.

• All guards and safety attachments must be installed properly before operating the unit.

• Inspect the unit before use. Replace damaged parts. Check for fuel leaks. Make sure all fasteners are in place and secure. Replace parts that are cracked, chipped, or damaged in any way. Do not operate the unit with loose or damaged parts.

• Carefully inspect the area before starting the unit. Remove all debris and hard or sharp objects such as glass, wire, etc.

• Be aware of the risk of injury to the head, hands and feet.

• Clear the area of children, bystanders, and pets. At a minimum, keep all children, bystanders, and pets outside a 50 feet (15 m.) radius; there still may be a risk to bystanders from thrown objects. Bystanders should be encouraged to wear eye protection. If you are approached, stop the unit immediately.

• Use only 0.105 inch,

2.67 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

• Store fuel only in containers specifically designed and

approved for the storage of such materials.

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

When using the unit,

you must follow the safety rules. Please read these instructions before operating the unit in order to ensure the safety of the operator and any bystanders. Please keep these instructions for later use.

WARNING:

• IMPORTANT SAFETY INSTRUCTIONS •

Gasoline is highly

flammable, and its vapors can explode if ignited. Take the following precautions:

WARNING:

RULES FOR SAFE OPERATION

• Always stop the engine and allow it to cool before filling the fuel tank. Never remove the fuel tank cap or add fuel when the engine is hot. Never operate the unit without the fuel cap securely in place. Loosen the fuel tank cap slowly to relieve any pressure in the tank.

• Add fuel in a clean, well-ventilated outdoor area where there are no sparks or flames. Remove the fuel cap slowly, and only after the engine stops. Do not smoke while fueling. Wipe up any spilled fuel from the unit immediately.

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

• Move the unit at least 30 feet (9.1 m) from the fueling source and site before starting the engine. Do not smoke. Keep sparks and open flames away from the area while adding fuel or operating the unit.

WHILE OPERATING

• Never start or run the unit inside a closed room or building. Breathing exhaust fumes can be fatal. Operate this unit only in a well-ventilated outdoor area.

• Wear safety glasses or goggles that meet ANSI Z87.1 standards and are marked as such. Wear ear/hearing protection when operating this unit. Wear a face or dust mask if the operation is dusty.

• Wear heavy long pants, boots, gloves and a long sleeve shirt. Do not wear loose clothing, jewelry, short pants, sandals or go barefoot. Secure hair above shoulder level.

• The cutting attachment shield must always be in place while operating the unit as a trimmer. Do not operate unit without both trimming lines extended, and the proper line installed. Do not extend the trimming line beyond the length of the shield.

• This unit has a clutch. The cutting attachment remains stationary when the engine is idling. If it does not, have the unit adjusted by an authorized service technician.

• Adjust the handle to your size in order to provide the best grip.

• Be sure the cutting attachment is not in contact with anything before starting the unit.

• Use the unit only in daylight or good artificial light.

• Avoid accidental starting. Be in the starting position whenever pulling the starter rope. The operator and unit must be in a stable position while starting. Refer to Starting/Stopping Instructions.

• Use the right tool. Only use this tool for its intended purpose.

• Do not overreach. Always keep proper footing and balance.

• Always hold the unit with both hands when operating. Keep a firm grip on both handles or grips.

• Keep hands, face, and feet at a distance from all moving parts. Do not touch or try to stop the cutting attachment when it rotates.

• Do not touch the engine, gear housing or muffler. These parts get extremely hot from operation, even after the unit is turned off.

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

• Always stop the engine when cutting is delayed or when walking from one cutting location to another.

• If you strike or become entangled with a foreign object, stop the engine immediately and check for damage. Do not operate before repairing damage. Do not operate the unit with loose or damaged parts.

• Stop the unit, switch the engine to off, and disconnect the spark plug for maintenance or repair.

• Use only original equipment manufacturer replacement parts and accessories for this unit. These are available from your authorized service dealer. Use of any unauthorized parts or accessories could lead to serious injury to the user, or damage to the unit, and void your warranty.

• Keep unit clean of vegetation and other materials. They may become lodged between the cutting attachment and shield.

• To reduce fire hazard, replace a faulty muffler and spark arrestor. Keep the engine and muffler free from grass, leaves, excessive grease or carbon build up.

WHILE OPERATING WITH CUTTING BLADE

• Read and understand all safety warnings before operating this unit.

• Always use the shoulder harness when using the brush blade accessory.

• Keep the J-handle between the operator and cutting attachment or blade at all times.

• NEVER cut when the cutting blade is 30 inches (76 cm) or more above the ground level.

• Blade thrust may occur when the spinning blade contacts an object that it does not immediately cut. Blade thrust can be violent enough to propel the unit and/or operator in any direction, possibly causing a loss of control. Blade thrust can occur without warning if the blade snags, stalls or binds. This is more likely to occur in areas where it is difficult to see the material being cut.

• For operation with the brush blade, do not cut anything thicker than 1/2 inch or a violent kickback could occur.

• Do not attempt to touch or stop the blade when it is rotating.

RULES FOR SAFE OPERATION

• A coasting blade can cause injury while it continues to spin after the engine is stopped or the throttle trigger is released. Maintain proper control until the blade has completely stopped rotating.

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

• If you strike or become entangled with a foreign object, stop the engine immediately and check for damage. Have any damage repaired before attempting further operations. Do not operate unit with a bent, cracked or dull blade. Discard blades that are bent, warped, cracked or broken.

• Do not sharpen the cutting blade. Sharpening the blade can cause the blade tip to break off while in use. This can result in severe personal injury. Replace the blade.

• Do not use the cutting blade for edging or as an edger; severe personal injury to yourself or others may incur. Use the cutting blade only for the purpose described in this manual.

• Stop the engine IMMEDIATELY if you feel excessive vibration. Vibration is a sign of trouble. Inspect thoroughly for loose nuts, bolts or damage before continuing. Repair or replace affected parts as necessary.

After Use

• Clean cutting blades with a household cleaner to remove any gum buildup. Oil the blade with machine oil to prevent rust.

• Lock up and store the cutting blade in an appropriate area to protect the blade from unauthorized use or damage.

OTHER SAFETY WARNINGS

• Never store a fueled unit inside a building where fumes may reach an open flame or spark.

• Allow the engine to cool before storing or transporting. Be sure to secure the unit while transporting.

• Store the unit in a dry area, locked up or up high to prevent unauthorized use or damage, out of the reach of children.

• Never douse or squirt the unit with water or any other liquid. Keep handles dry, clean and free from debris. Clean after each use, see Cleaning and Storage instructions.

• Keep these instructions. Refer to them often and use them to instruct other users. If you loan someone this unit, also loan them these instructions.

SAVE THESE

INSTRUCTIONS

RULES FOR SAFE OPERATION

SYMBOL MEANING

• SAFETY ALERT SYMBOL

Indicates danger, warning, or caution. May be used in conjunction with other symbols or pictographs.

• WARNING - READ OPERATOR'S MANUAL

Read the Operator’s Manual(s) and follow all warnings and safety instructions. Failure to do so can result in serious injury to the operator and/or bystanders.

• WEAR EYE AND HEARING PROTECTION

WARNING: Thrown objects and

loud noise can cause severe eye injury and hearing loss. Wear eye protection meeting ANSI Z87.1-1989 standards and ear protection when operating this unit.

Use a full face

shield when needed.

• KEEP BYSTANDERS AWAY

WARNING: Keep all bystanders,

especially children and pets, at least 50 feet (15 m.) from the operating area.

• UNLEADED FUEL

Always use clean, fresh unleaded fuel.

• THROWN OBJECTS AND ROTATING CUTTER CAN CAUSE SEVERE INJURY

WARNING:Do not

operate without the cutting attachment shield in place. Keep away from the rotating cutting attachment.

SAFETY AND INTERNATIONAL SYMBOLS

This operator's manual describes safety and international symbols and pictographs that may appear on this product. Read the operator's manual for complete safety, assembly, operating and maintenance and repair information.

SYMBOL MEANING

• ON/OFF STOP CONTROL

ON / START / RUN

• ON/OFF STOP CONTROL

OFF or STOP

• HOT SURFACE WARNING

Do not touch a hot muffler or cylinder. You may get burned. These parts get extremely hot from operation. When turned off they remain hot for a short time.

• REPLACE DULL BLADE

Do not sharpen the cutting blade. Sharpening the blade can cause the blade tip to break off while in use. This can result in severe personal injury.

• TRIMMER/ BRUSHCUTTER SAFETY

WARNING:Thrown

objects and rotating cutter can cause severe injury. Keep bystanders, especially children and pets, at least 50 feet (15 m) away from the cutting area. The cutting attachment shield must be used when using the trimmer cutting attachment.

• OIL

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

KNOW YOUR UNIT

Primer

Bulb

Oil Fill Plug /

Dipstick

Air Filter

Cover

Engine

Feet

Spark Plug

Cutting Attachment

Shield

Fuel Cap

Throttle

Control

Throttle Lock-Out

J-Handle

Cutting Attachment

Gear

Housing

Shaft Grip

On/Off Stop Control

Shaft

Housing

Starter Rope Grip

EZ-Link™

Blade Shield /

Shield Mount

Brush Blade

Line Cutting Blade

Spark Plug

Muffler

Muffler Guard

Spark Arrestor

Shoulder Strap Clip

APPLICATIONS

As a trimmer:

• Cutting grass and light weeds

• Edging

• Decorative trimming around trees, fences, etc. As a brushcutter:

• Cutting weeds and light brush of up to 1/2 inch in diameter

Other optional accessories may be used with your unit. Refer to Operating the EZ-Link System for a list of add-ons.

ASSEMBLY INSTRUCTIONS

2. While holding the three pieces together, install the four (4) screws through the top clamp and into middle clamp.

NOTE: The holes in the top and middle clamp will line up

only when assembled correctly.

3. Place the clamps and the J-handle over the shaft housing and onto the bottom clamp.

4. Hold each hex nut in the bottom clamp recess with a finger. Start screws with a large Phillips screwdriver. Do not tighten until you make the handle adjustment.

5. Slide the J-handle in or out until the arrow/white line on the decal touches the clamp assembly (Fig. 2). You must first loosen the screws if the handle is pre-installed.

Fig. 1

Fig. 2

6. While holding the unit in the operating position (Fig. 26), position the J-handle to the location that provides you the best grip.

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

INSTALL AND ADJUST THE J-HANDLE

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

Decal

INSTALL THE HARNESS

1. Push the strap through the center of the buckle.

2. Pull the strap over the cross bar and down through the slot in the buckle (Fig. 3).

3. Put the harness on over head and onto shoulder. Snap it on to the support fitting (Fig. 4).

4. Adjust length to fit the operator’s size. Pull tab to lengthen, pull strap to shorten (Fig 5).

Support Fitting

Fig. 3

Fig. 4

Fig. 5

REMOVE AND INSTALL THE CUTTING ATTACHMENT SHIELD

Remove the cutting attachment shield when using the unit as a brushcutter

Remove the cutting attachment shield from the shield mount by removing the three (3) screws with a flat blade screwdriver (Fig. 6). Store parts for future use.

The cutting

attachment shield should NOT be installed when operating the unit with a blade. Remove the cutting attachment shield before removing or installing the blade.

WARNING:

Always use the

shoulder harness when using the cutting blade to avoid serious personal injury.

WARNING:

(4) Screws

Top Clamp

J-Handle

Middle Clamp

Bottom Clamp

Nuts

ASSEMBLY INSTRUCTIONS

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

Install the cutting attachment shield on the shield mount by inserting the three (3) screws into the shield mount. Tighten securely with a flat blade screwdriver (Fig. 6).

REMOVE THE CUTTING ATTACHMENT & INSTALL CUTTING BLADE

NOTE: To make cutting blade removal and installation easier,

place the unit on the ground or on a work bench

Remove the Cutting Attachment Shield

See Remove and Install the Cutting Attachment Shield.

Remove the Cutting Attachment

Align the shaft bushing hole with the locking rod slot and insert the locking rod into the shaft bushing hole (Fig. 7).

(3) Screws

Cutting

Attachment

Shield

Shield Mount

Gear Housing

Fig. 6

Cutting Attachment

Locking Rod

Slot

Locking Rod

Shaft Bushing Hole

Locking Rod Slot

Output Shaft

Bushing

Locking Rod

Output Shaft

2. Hold the locking rod in place by grasping it next to the boom of the unit (Fig. 8).

3. While holding the locking rod, remove the cutting attachment by turning it clockwise off of the output shaft (Fig. 9). Store the cutting attachment for future use.

NOTE: The blade retainer under the cutting attachment

will be used when installing the cutting blade.

Fig. 7

Fig. 9

Fig. 8

Install the Cutting Blade

4. Place the cutting blade on the output shaft bushing (Fig. 10).

Shield Mount

Locking Rod

Cutting

Blade

Blade Retainer

Nut

Output Shaft

Bushing

Pilot Hole

Fig. 10

The gear housing

gets hot with use. It can result in injury to the operator. The housing remains hot for a short time even after the unit is turned off. Do not touch the gear housing until it has cooled.

WARNING:

To avoid serious

personal injury, the cutting attachment shield MUST be in place at all times while operating the unit as a grass trimmer.

WARNING:

To avoid serious

personal injury, always wear gloves while handling or installing the blade.

WARNING:

ASSEMBLY INSTRUCTIONS

Fig. 14

Fig. 11

Pilot Step

REMOVE CUTTING BLADE & INSTALL THE CUTTING ATTACHMENT

Remove the Cutting Blade

1. Align the shaft bushing hole with the locking rod slot and insert the locking rod into the bushing hole (Fig. 7).

2. Hold the locking rod in place by grasping it next to the boom of the unit (Fig. 13).

3. While holding the locking rod, loosen the nut on the blade by turning it clockwise with a 13 mm closedend or socket wrench (Fig. 13).

Fig. 12

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

1/4-1/2 turn

Counterclockwise

6. Align the shaft bushing hole with the locking rod slot and insert the locking rod into the bushing hole (Fig. 7).

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 13 mm socket tighten

to: 325 - 335 in•lb, 27 - 28 ft.•lb, 37 - 38 N•m.

• Without a torque wrench, use a 13 mm 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. 12).

Cutting Attachment

Locking Rod

Clockwise

6. Remove the locking rod.

7. Install the cutting attachment shield. Refer to Remove

and Install the Cutting Attachment Shield.

Blade Retainer

Output Shaft

Bushing

Fig. 13

5. Make sure that the cutting blade is centered on the pilot step and sitting flat against the output shaft bushing (Fig. 11).

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

Align the shaft bushing hole with the locking rod slot and insert the locking rod into the shaft bushing hole (Fig. 7). Place the blade retainer on the output shaft with the flat surface against the output shaft bushing (Fig. 14). Screw the cutting attachment counterclockwise onto the output shaft. Tighten securely.

NOTE: The blade retainer must be installed on the output

shaft in the position shown for the cutting attachment to work correctly.

If the cutting blade

is off-center, the unit will vibrate and the blade may fly off, causing possible serious personal injury.

WARNING:

To avoid serious

personal injury, always wear gloves while handling or installing the blade.

WARNING:

Do not sharpen the

cutting blade. Sharpening the blade can cause the blade tip to break off while in use. This can result in severe personal injury. Replace the blade.

WARNING:

To avoid serious

personal injury or damage to the unit, do not start or operate this unit with the locking rod in the locking rod slot.

WARNING:

To avoid serious

personal injury, the cutting attachment shield MUST be in place at all times while operating the unit as a trimmer.

WARNING:

OIL AND FUEL INFORMATION

RECOMMENDED OIL TYPE

Using the proper type and weight of oil in the crankcase is extremely important.

Check the oil before each use and change the oil regularly. Failure to use the correct oil, or using dirty oil, can cause premature engine wear and failure.

Use a high-quality SAE 30 weight oil of API (American Petroleum Institute) service class SF, SG, SH.

ADDING OIL TO CRANKCASE: INITIAL USE

NOTE: This unit is shipped without oil. In order to avoid

damage to the unit, put oil in the crankcase before you attempt to start the unit.

Your unit is supplied with one 3.0 fl oz (90 ml.) bottle of SAE 30 SF, SG, SH oil (Fig. 15).

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. 15).

2. Place the unit on a flat level surface (Fig. 17).

3. Remove the oil plug / dipstick from the crankcase (Fig. 16).

Fig. 15

Fig. 17

Oil Fill

NOTE: Never add oil to the fuel or fuel tank.

5. Wipe up any oil that may have spilled and reinstall the oil fill plug / dipstick.

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

Oil Fill Plug/Dipstick

Oil Fill Hole

Fig. 16

4. Pour the entire bottle of oil into the oil fill hole (Fig. 17).

O-Ring

Funnel Spout

OVERFILLING OIL

CRANKCASE MAY CAUSE SERIOUS PERSONAL INJURY. Check and maintain the proper oil level in the crank case; it is important and cannot be overemphasized. Check the oil before each use and change it as needed. See

Changing the Oil.

WARNING:

OIL AND FUEL INFORMATION

FUELING THE UNIT

1. Remove the fuel cap (Fig. 18).

Fig. 18

Fuel Cap

Fuel Tank

Gas Can Spout

2. Place the gas container’s spout into the fill hole on the fuel tank (Fig. 18) and fill the tank.

NOTE: Do not overfill the tank.

3. Wipe up any gasoline that may have spilled.

4. Reinstall the fuel cap.

5. Move the unit at least 30 ft. (9.1 m) from the fueling source and site before starting the engine.

NOTE: Dispose of the old gasoline in accordance to

Federal, State and Local regulations.

RECOMMENDED FUEL TYPE

Old fuel is the primary reason for improper unit performance. Be sure to use fresh, clean, unleaded gasoline.

NOTE: This is a four cycle engine. In order to avoid

damage to the unit, do not mix oil with

gasoline.

Definition of Blended Fuels

Today's fuels are often a blend of gasoline and oxygenates such as ethanol, methanol or MTBE (ether). Alcohol-blended fuel absorbs water. As little as 1% water in the fuel can make fuel and oil separate or form acids when stored. Use fresh fuel (less than 60 days old), when using alcohol-blended fuel.

Using Blended Fuels

If you choose to use a blended fuel, or its use is unavoidable, follow recommended precautions:

• Always use fresh unleaded gasoline

• Use the fuel additive STA-BIL

or an equivalent

• Drain tank and run the engine dry before storing unit

Using Fuel Additives

The use of fuel additives, such as STA-BIL®Gas Stabilizer or an equivalent, will inhibit corrosion and minimize the formation of gum deposits. Using a fuel additive can keep fuel from forming harmful deposits in the carburetor for up to six (6) months. Add 0.8 oz. (23 ml.) of fuel additive per gallon of fuel according to the instructions on the container. NEVER add fuel additives directly to the unit's gas tank.

Unleaded

Gasoline

Add fuel in a clean,

well ventilated outdoor area. Wipe up any spilled fuel immediately. Avoid creating a source of ignition for spilt fuel. Do not start the engine until fuel vapors dissipate.

WARNING:

Gasoline is

extremely flammable. Ignited Vapors may explode. Always stop the engine and allow it to cool before filling the fuel tank. Do not smoke while filling the tank. Keep sparks and open flames at a distance from the area.

WARNING:

Remove fuel cap

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

WARNING:

STARTING/STOPPING INSTRUCTIONS

STARTING INSTRUCTIONS

STOPPING INSTRUCTIONS

1. Release your hand from the throttle control. Allow the engine to cool down by idling.

2. Put the On/Off Stop Control in the OFF (O) position.

Start/On (I)

Stop/Off (O)

Throttle Lock-Out

Throttle Control

Primer

Bulb

Starter Rope

Throttle Control

Cold Weather

Start Lever

(Fig. 22)

Cold

Weather

Start Lever

Run/ Open

Close/ Start

Fig. 19

Fig. 22

Fig. 21

Fig. 20

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. 21).

To avoid serious injury, the operator and unit

must be in a stable position while starting. Make sure that any Add-On item is installed correctly

and secure before starting the unit.

WARNING:

1. Check the oil level in the crankcase. Refer to

Checking the Oil Level.

2. Fill the fuel tank with fresh, clean unleaded gasoline. Refer to Fueling the Unit.

NOTE: There is no need to turn the unit on. The On/Off

Stop Control is in the ON (I) position at all times (Fig. 19).

IF COLD... For cold weather conditions (below 40°F),

flip the Cold Weather Start Lever (Fig. 22) down to the start/closed position and continue to step 3. DO NOT flip this lever down if the temperature is above 40°F.

3. Fully press and release the primer bulb 10 times, slowly. Some amount of fuel should be visible in the primer bulb and fuel lines (Fig. 20). If you can’t see fuel in the bulb, press and release the bulb as many times as it takes before you can see fuel in it.

4. With the unit in the starting position, do not squeeze the throttle control (Fig. 21). Pull the starter rope out a short distance, until you feel some resistance. This is usually around 2-4 inches. Then pull the rope smoothly and briskly. Repeat this 5 times. The engine should start

IF COLD... For cold weather conditions (below 40°F),

flip the Cold Weather Start Lever back up to the run/open position.

5. Squeeze the throttle control and squeeze the throttle lock-out to warm up the engine for 15 to 30 seconds. In cold weather, let the engine warm up for 30 to 60 seconds.

...

The engine does not start, go back to step 3.

IF... The engine stops while you are squeezing the

throttle, go back to step 4.

OPERATING INSTRUCTIONS

For edging (when using the line head cutting attachment with EZ-Link™ models), lock the release button of the cutting attachment into the 90° edging hole (Fig. 25).

OPERATING THE EZ-LINK™SYSTEM

The EZ-Link™ system enables the use of these optional Add-Ons:

Cultivator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TBGC

Edger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TBLE

Hedge Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . TBAH

Straight Shaft Trimmer . . . . . . . . . . . . . . . . . . . . . . TBSS

Turbo Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TBTB

Pole Saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TBPS

Brushcutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TBBC*

*Do NOT use this attachment with an electric powered unit.

Removing the Cutting Attachment or Add-On

1. Turn the knob counterclockwise to loosen (Fig. 25).

2. Press and hold the release button (Fig. 23).

3. While firmly holding the upper shaft housing, pull the cutting attachment or add-on straight out of the EZ-Link™ coupler (Fig. 24).

Installing the Cutting Attachment or Add-On

NOTE: Place the unit on the ground or on a work bench

to make add-on installation or removal easier.

1. Turn knob counterclockwise to loosen (Fig. 25).

Fig. 23

EZ-Link™ Coupler

Release Button

Guide Recess

Knob

Primary Hole

Upper Shaft Housing

EZ-Link™ Coupler

2. While firmly holding the add-on, push it straight into the EZ-Link™ coupler (Fig. 24).

NOTE: Aligning the release button with the guide recess

will help installation (Fig. 23).

3. Turn the knob clockwise to tighten (Fig. 25).

Fig. 24

Fig. 25

Knob

Lower Shaft Housing

Release Button

90˚ Edging Hole

(Trimmer Only)

To avoid serious

personal injury and damage to the unit, shut the unit off before removing or installing add-ons.

WARNING:

Add-ons are to be

used in the primary hole only. Using the wrong hole could lead to personal injury or damage to the unit.

CAUTION:

Lock the release

button in the primary hole and securely tighten the knob before operating this unit.

CAUTION:

Before you begin

using any attachment, read and understand the manual that came with the attachment. Follow all safety information contained within.

WARNING:

OPERATING INSTRUCTIONS

HOLDING THE TRIMMER

Before operating the unit, stand in the operating position (Fig. 26). Check for the following:

• The operator is wearing eye protection and proper clothing

• With a slightly-bent right arm, the operator’s right hand is holding the shaft grip

• The operator’s left arm is straight, the left hand holding the handle

• The unit is at waist level

• The cutting attachment is parallel to the ground and easily contacts the grass without the need to bend over

After starting the unit and standing in the operating position, hook the shoulder strap to the unit.

Fig. 26

ADJUSTING TRIMMING LINE LENGTH

The Bump Head™ cutting attachment allows you to release trimming line without stopping the engine. To release more line, lightly tap the cutting attachment on the ground (Fig. 27) while operating the trimmer at high speed.

NOTE: Always keep the trimming line fully extended.

Line release becomes more difficult as the cutting line becomes shorter.

Each time the head is bumped, about 1 inch (25.4 mm) of trimming line is released. A blade in the cutting attachment shield will cut the line to the proper length if excess line is released.

For best results, tap the Bump Head™ on bare ground or hard soil. If line release is attempted in tall grass, the engine may stall. Always keep the trimming line fully extended. Line release becomes more difficult as the cutting line becomes shorter.

NOTE: Do not rest the Bump Head™ on the ground

while the unit is running.

Fig. 27

Some line breakage will occur from:

• Entanglement with foreign matter

• Normal line fatigue

• Attempting to cut thick, stalky weeds

• Forcing the line into objects such as walls or fence posts

TIPS FOR BEST TRIMMING RESULTS

• For best trimming results, operate unit at full throttle.

• Keep the cutting attachment parallel to the ground.

• Do not force the cutting attachment. Allow the tip of the line to do the cutting, especially along walls. Cutting with more than the tip will reduce cutting efficiency and may overload the engine.

• Cut grass over 8 inches (200 mm) by working from top to bottom in small increments to avoid premature line wear or engine drag.

• For the brushcutter, cut from left to right whenever possible. Cutting to the right improves the unit's cutting efficiency. Clippings are thrown away from the operator. For the other units, cut from right to left.

• Slowly move the trimmer into and out of the cutting area at the desired height. Move either in a forwardbackward or side-to-side motion. Cutting shorter lengths produces the best results.

• Trim only when grass and weeds are dry.

• The life of your cutting line is dependent upon:

• Proper adherence of explained trimming techniques

• What vegetation is cut

• Where vegetation is cut

For example, the line will wear faster when trimming against a foundation wall as opposed to trimming around a tree.

Do not remove or alter

the line cutting blade assembly. Excessive line length will make the clutch overheat. This may lead to serious personal injury or damage to the unit.

CAUTION:

Always wear eye,

hearing, foot and body protection to reduce the risk of injury when operating this unit.

WARNING:

Fig. 28

Fig. 29

Fig. 30

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. 28).

USING THE CUTTING BLADE

Before operating the unit with the cutting blade, stand in the operating position (Fig. 29). Refer to Holding the Trimmer.

Cutting Blade Operating Tips

To establish a rhythmic cutting procedure:

• Plant feet firmly, comfortably apart.

• Bring the engine to full throttle before entering the material to be cut. At full throttle the blade has maximum cutting power and is less likely to bind, stall or cause blade thrust (which can result in serious personal injury to the operator or others).

• Cut while swinging the upper part of your body from left to right.

• Always release the throttle trigger and allow the engine to return to idle speed when not cutting.

• When you are finished, always unsnap the unit from the harness before taking off the harness.

• Swing the unit in the opposite direction as the blade spins, which increases the cutting action.

• After the return swing, move forward to the next area to be cut plant your feet again.

• The cutting blade is designed with a second cutting edge. You can use it by removing the blade, turning it upside down, and reinstalling it.

To reduce the chance of material wrapping around the blade, follow these steps:

• Cut at full throttle

• Swing the unit into material to be cut from your left to your right (Fig. 30)

• Avoid the material just cut as you make the return swing

Always wear eye,

hearing, foot, body protection and the shoulder strap to reduce the risk of injury when operating this unit.

WARNING:

Do not use the

cutting blade for edging or as an edger. Severe personal injury to yourself or others can result.

WARNING:

The blade continues

to spin after the engine is turned off. The coasting blade can seriously cut you if accidentally touched.

WARNING:

Do not sharpen the

cutting blade. Sharpening the blade can cause the blade tip to break off while in use. This can result in severe personal injury to yourself or others. Replace the blade.

WARNING:

ade thrust may

occur when the spinning blade contacts an object that it does not immediately cut. Blade thrust can be violent enough to cause the unit and/or operator to be propelled in any direction, and possibly lose control of the unit. Blade thrust can occur without warning if the blade snags, stalls or binds. This is more likely to occur in areas where it is difficult to see the material being cut.

WARNING:

Do not clear away

any cut material with the engine running or blade turning. To avoid serious personal injury, turn off the engine. Allow the blade to stop before removing materials wrapped around the blade shaft.

WARNING:

OPERATING INSTRUCTIONS

MAINTENANCE AND REPAIR INSTRUCTIONS

To prevent serious

injury, never perform maintenance or repairs with unit running. Always service and repair a cool unit. Disconnect the spark plug wire to ensure that the unit cannot start.

WARNING:

MAINTENANCE SCHEDULE

Perform these required maintenance procedures at the frequency stated in the table. These procedures should also be a part of any seasonal tune-up.

NOTE: Some maintenance procedures may require

special tools or skills. If you are unsure about these procedures take your unit to any non-road engine repair establishment, individual or authorized service dealer.

NOTE: Maintenance, replacement, or repair of the

emission control devices and system may be performed by any non-road engine repair establishment, individual or authorized service dealer.

FREQUENCY MAINTENANCE REQUIRED REFER TO

Before starting engine

Fill fuel tank with fresh fuel Check oil

Page 12 Page 19

Every 10 hours Clean and re-oil air filter Page 20 First change at 10 hours

Every 25 hours thereafter Every 25 hours

Change oil Change oil Clean spark arrestor

Page 20 Page 20 Page 24

10 hours on new engine Every 25 hours Every 25 hours

Check rocker arm to valve clearance and adjust Check rocker arm to valve clearance and adjust Check spark plug condition and gap

Page 22 Page 22 Page 24

LINE INSTALLATION

This section covers both SplitLine™ and standard single line installation.

Always use 0.105 in. (2.67 mm) original equipment manufacturer replacement line. Line other than the specified may make the engine overheat or fail.

There are two methods to replace the trimming line:

• Wind the inner reel with new line

• Install a prewound inner reel

Winding the Existing Inner Reel

1. Hold the outer spool with one hand and unscrew the Bump Knob clockwise (Fig. 31). Inspect the bolt inside the bump knob to make sure it moves freely. Replace the bump knob if damaged.

BUMP HEAD

Never use metal-

reinforced line, wire, chain or rope. These can break off and become dangerous projectiles.

WARNING:

Indexing Teeth

Fig. 32

Fig. 33

Inner Reel

Spring

Outer Spool

Bump Knob

Bolt

Fig. 31

2. Remove the inner reel from the outer spool (Fig. 31).

3. Remove spring from the inner reel (Fig. 31).

4. Use a clean cloth to clean the the inner reel, spring, shaft and inner surface of the outer spool (Fig. 32).

5. Check the indexing teeth on the inner reel and outer spool for wear (Fig. 33). If necessary, remove burrs or replace the reel and spool.

MAINTENANCE AND REPAIR INSTRUCTIONS

Fig. 35

Fig. 36

Fig. 37

Fig. 38

Fig. 39

Fig. 34

NOTE: SplitLine™ can only be used with the inner reel

with the slotted holes. Single line can be used on either type of inner reel. Use Figure 34 to identify the inner reel you have.

NOTE: Always use the correct line length when installing

trimming line on the unit. The line may not release properly if the line is too long.

Single Line Installation

Go To Step 8 for SplitLine™ Installation

6. Take approximately 20 feet (6 m) of new trimming line, loop it into two equal lengths. Insert each end of the line through one of the two holes in the inner reel (Fig. 35). Pull the line through the inner reel so that the loop is as small as possible.

7. Wind the lines in tight even layers, onto the reel (Fig. 36). Wind the line in the direction indicated on the inner reel. Place your index finger between the two lines to stop the lines from overlapping. Do not overlap the ends of the line. Proceed to step 11.

Spring

SplitLine™ Installation

8. Take approximately 9 feet (3 m) of new trimming line. Insert one end of the line through one of the two holes in the inner reel (Fig. 37). Pull the line through the inner reel until only about 4 inches is left out.

9. Insert the end of the line into the open hole in the inner reel and pull the line tight to make the loop as small as possible (Fig. 37).

10. Before winding, split the line back about 6 inches.

11. Wind the line in tight even layers in the direction indicated on the inner reel.

NOTE: Failure to wind the line in the direction indicated will

cause the cutting attachment to operate incorrectly.

Loop

Slotted

Holes

For Use with SplitLine™

or Single Line

For Use with Single

Line ONLY

Loop

Holding Slots

NOTE: The spring must be assembled on the inner reel

before reassembling the cutting attachment.

14. Hold the inner reel in place and install the bump knob by turning counterclockwise. Tighten securely.

12. Insert the ends of the line into the two holding slots (Fig. 38).

13. Insert the ends of the line through the eyelets in the outer spool and place inner reel with spring inside the outer spool (Fig. 39). Push the inner reel and outer spool together. While holding the inner reel and outer spool, grasp the ends and pull firmly to release the line from the holding slots in the reel.

MAINTENANCE AND REPAIR INSTRUCTIONS

INSTALLING A PREWOUND REEL

1. Hold the outer spool with one hand and unscrew the bump knob clockwise (Fig. 31). Inspect the bolt inside the bump knob to make sure it moves freely. Replace the bump knob if damaged.

2. Remove the old inner reel from the outer spool (Fig. 31).

3. Remove the spring from the old inner reel (Fig. 31).

4. Place the spring in the new inner reel.

NOTE: The spring must be assembled on the inner reel

before reassembling the cutting attachment.

5. Insert the ends of the line through the eyelets in the outer spool (Fig. 39).

6. Place the new inner reel inside the outer spool. Push the inner reel and outer spool together. While holding the inner reel and outer spool, grasp the ends and pull firmly to release the line from the holding slots in the spool.

7. Hold the inner reel in place and install the bump knob by turning counterclockwise. Tighten securely.

CHECKING THE OIL LEVEL

The importance of checking and maintaining the proper oil level in the crankcase cannot be overemphasized. Check oil before each use:

1. Stop the engine and allow oil to drain into the crankcase.

2. Place the unit on a flat, level surface to get a proper oil level reading.

3. Keep dirt, grass clippings and other debris out of the engine. Clean the area around the oil fill plug/dipstick before removing it.

4. Remove the oil fill plug/dipstick and wipe off oil. Reinsert it all the way back in.

5. Remove the oil fill plug/dipstick and check the oil level. Oil should be up to the top of the dipstick (Fig. 40).

6. If the level is low, add a small amount of oil to the oil

fill hole and recheck (Fig. 41). Repeat this procedure until the oil level reaches the top of the dipstick.

NOTE: Do not overfill the unit.

Top of Dipstick

O-Ring

Oil Fill Plug/Dipstick

Fig. 40

Fig. 41

NOTE: Make sure the O-ring is in place on the oil fill

plug/dipstick when checking and changing the oil (Fig. 41).

Oil Fill Plug/Dipstick

Oil Fill Hole

O-Ring

Full

Add 1.4-1.5 Oz.

(41-44 ml)

To prevent extensive

engine wear and damage to the unit, always maintain the proper oil level in the crankcase. Never operate the unit with the oil level below the bottom of the dipstick.

CAUTION:

MAINTENANCE AND REPAIR INSTRUCTIONS

CHANGING THE OIL

For a new engine, change the oil after the first 10 hours of operation. Change the oil while the engine is still warm. The oil will flow freely and carry away more impurities.

1. Unplug spark plug boot to prevent accidental starting.

2. Remove the oil fill plug/dipstick.

3. Pour the oil out of the oil fill hole and into a container by tipping the unit to a vertical position (Fig. 42). Allow ample time for complete drainage.

Fig. 42

6. Replace the oil fill plug/dipstick.

7. Reconnect the spark plug boot.

4. Wipe up any oil residue on the unit and clean up any oil that may have spilled. Dispose of the oil according to Federal, State and local regulations.

5. Refill the crankcase with 3.0 fluid ounce (90 ml) of SAE 30 SF, SG, SH oil.

NOTE: Use the bottle and spout saved from initial use to

measure the correct amount of oil. The top of the label on the bottle measures approximately 3.0 fl oz (90 ml) (Fig. 43). Check the level with the dipstick. If the level is low, add a small amount of oil and recheck. Do not overfill (Fig. 43).

Fill Level

Fig. 43

Wear gloves to prevent injury when

handling the unit.

CAUTION:

AIR FILTER MAINTENANCE

Cleaning the Air Filter

Clean and re-oil the air filter every 10 hours of operation. It is an important item to maintain. Failure to maintain your air filter properly can result in poor performance or can cause permanent damage to your engine.

1. Open the air filter cover. Push the tab on the right side of the cover inward. Then pull the air filter cover out and to the left (Fig. 44).

NOTE: It may be necessary to remove the fuel cap to

completely remove the air filter cover.

2. Remove the air filter (Fig. 44).

Air Filter

Air Filter Cover

Tab

Fig. 44

To avoid serious

personal injury, always turn the unit off and allow it to cool before you clean or service it.

WARNING:

3. Wash the filter in detergent and water (Fig. 45). Rinse the filter thoroughly and allow it to dry.

4. Apply enough clean SAE 30 motor oil to lightly coat the filter (Fig. 46).

Fig. 45

5. Squeeze the filter to spread and remove excess oil (Fig. 47).

Fig. 48

Back Plate Slot

Slots

6. Replace the filter (Fig. 48). 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. 48).

NOTE: It may be necessary to remove the fuel cap to

reinstall the air filter cover.

8. Swing the cover to the right until the tab on the air filter cover snaps into place in the slot on the back plate (Fig. 48).

9. Replace the fuel cap if it was removed.

Back Plate

CARBURETOR ADJUSTMENT

The idle speed of the engine is adjustable. An idle adjustment screw is reached though a hole in the top of the engine cover (Fig. 49).

NOTE: Careless adjustments can seriously damage your

unit. An authorized service dealer should make carburetor adjustments.

Check Fuel

Old fuel is usually the reason for improper unit performance. Drain and refill the tank with fresh fuel prior to making any adjustments. Refer to Oil and Fuel Information.

Fig. 47

Fig. 46

MAINTENANCE AND REPAIR INSTRUCTIONS

Idle Adjustment Screw

Clean Air Filter

The condition of the air filter is important to the operation of the unit. A dirty air filter will restrict air flow. This is often mistaken for an out of adjustment carburetor. Check the condition of the air filter before adjusting the idle speed screw. Refer to Air Filter Maintenance.

Adjust Idle Speed Screw

If, after checking the fuel and cleaning the air filter, the engine still will not idle, adjust the idle speed screw as follows:

1. Start the engine and let it run at a high idle for a minute to warm up. Refer to Starting/Stopping Instructions.

2. Release the throttle trigger and let the engine idle. If the engine stops, insert a small phillips or flat blade screwdriver into the hole in the air filter/muffler cover (Fig. 49). Turn the idle speed screw in, clockwise, 1/8 of a turn at a time (as needed) until the engine idles smoothly.

NOTE: The cutting attachment should not rotate when

the engine idles.

3. If the cutting attachment rotates when the engine idles, turn the idle speed screw counterclockwise 1/8 of a turn at a time (as needed), to reduce idle speed.

Checking the fuel, cleaning the air filter, and adjusting the idle speed should solve most engine problems. If not and all of the following are true:

• the engine will not idle

• the engine hesitates or stalls on acceleration

• there is a loss of engine power

Have the carburetor adjusted by an authorized service dealer.

Fig. 49

Remove

Screws

Fig. 50

Engine Cover

2. Remove the two (2) screws on top of the engine cover with a Flat-head or T-25 Torx screwdriver (Fig. 51).

Fig. 51

Engine Cover

Muffler

ROCKER ARM CLEARANCE

This requires disassembly of the engine. If you feel unsure or unqualified to perform this, take the unit to an authorized service center.

NOTE: Inspect the valve to rocker arm clearance with a

feeler gauge after the first 10 hours of operation and then every 25 hours of operation thereafter.

• The engine must be cold when checking or adjusting the valve clearance.

• This task should be performed inside, in a clean, dust free area.

1. Remove the muffler cover by pressing down on it, separating it from the engine cover. Using a flat blade screwdriver, disengage the middle and front tabs and slots first. The cover will hinge off from the rear tab (Fig. 50).

Top View Of The Engine

Front Slot

Front Tab

Middle Tab

Middle Slot

Rear Slot

and Tab

MAINTENANCE AND REPAIR INSTRUCTIONS

The cutting

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

WARNING:

To prevent serious

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

WARNING:

MAINTENANCE AND REPAIR INSTRUCTIONS

4. Disconnect the spark plug wire.

5. Clean dirt from around the spark plug. Remove the spark plug from the cylinder head by turning a 5/8 in. socket counterclockwise.

6. Remove the engine cover (Fig. 52).

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

3. Remove the screw behind the engine cover (Fig. 52).

Rocker Arm Cover

Screw

Fig. 52

Fig. 53

Spark Plug Hole

8. Pull the starter rope slowly to bring the piston to the top of its travel, (known as top dead center). Check that:

• The piston is at the top of its travel while looking in the spark plug hole (Fig. 53)

• 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. 54). Measure both the intake and exhaust valves.

Adjusting Nuts

Feeler Gauge

Rocker Arms

Fig. 54

Fig. 55

The recommended clearance for the intake and exhaust is .003 – .006 in. (.076 – 0.152 mm).

Use a standard automotive feeler gauge at .005 in. (0.127mm). The feeler gauge should slide between the rocker arm and valve stem with a slight amount of resistance, without binding. Figure 54 shows how to measure the clearance, while Figure 55 shows the measured clearance.

Feeler Gauge

Exhaust

Adjusting Nut

Exhaust

Rocker Arm

Exhaust

Clearance:

.003–.006 in.

(.076–0.152 mm)

Exhaust Valve Stem

10. If the clearance is not within specification: a. Turn the adjusting nut using a 5/16 inch (8 mm)

wrench or nut driver (Fig. 55).

• 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. 50).

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

15. Replace the spark plug wire.

INTAKE

EXHAUST

Intake Valve

Stem

Intake Clearance:

.003–.006 in.

(.076–0.152 mm)

CLEANING

Use a small brush to clean off the outside of the unit. Do not use strong detergents. Household cleaners that contain aromatic oils such as pine and lemon, and solvents such as kerosene, can damage plastic housing or handle. Wipe off any moisture with a soft cloth.

STORAGE

• Never store the unit with fuel in the tank where fumes may reach an open flame or spark.

• Allow the engine to cool before storing.

• Lock up the unit to prevent unauthorized use or damage.

• Store the unit in a dry, well-ventilated area.

• Store the unit out of the reach of children.

NOTE: Remove the spark plug and drain all of the oil

from the cylinder before attempting to start the trimmer after storage.

4. Change the oil, referring to Changing the Oil. Dispose of the old oil in accordance to Federal, State and Local regulations.

5. Thoroughly clean the unit and inspect for any loose or damaged parts. Repair or replace damaged parts and tighten loose screws, nuts or bolts. The unit is ready for storage.

TRANSPORTING

• Allow the engine to cool before transporting.

• Secure the unit while transporting.

• Drain the gas tank before transporting.

• Tighten gas cap before transporting.

LONG TERM STORAGE

1. Drain all gasoline from the gas tank into a container. Do not use gas that has been stored for more than 60 days. Dispose of the old gasoline in accordance to Federal, State, and Local regulations.

2. Start the engine and allow it to run until it stalls. This ensures that all gasoline has been drained from the carburetor.

3. Allow the engine to cool. Remove the spark plug and put 1 oz. (30 ml) of high quality motor oil into the cylinder. Pull the starter rope slowly to distribute the oil. Reinstall the spark plug.

To avoid serious

personal injury, always turn your unit off and allow it to cool before you clean or service it.

WARNING:

MAINTENANCE AND REPAIR INSTRUCTIONS

0.025 in.

(0.655 mm.)

REPLACING THE SPARK PLUG

Use a replacement part number 180852 spark plug. The correct air gap is 0.025 in. (0.655 mm.). Remove the plug after every 25 hours of operation and check its condition.

1. Stop the engine and allow it to cool. Grasp the plug wire firmly and pull the cap from the spark plug.

2. Clean dirt from around the spark plug. Remove the spark plug from the cylinder head by turning a 5/8 in. socket counterclockwise.

3. Replace cracked, fouled or dirty spark plug. Set the air gap at 0.025 in. (0.655 mm.) using a feeler gauge (Fig. 56).

Fig. 56

4. Install a correctly-gapped spark plug in the cylinder head. Turn the 5/8 in. socket clockwise until snug.

If using a torque wrench torque to:

110-120 in.•lb. (12.3-13.5 N•m)

Do not over tighten.

Fig. 57

Muffler

Spark Arrestor Screen

Spark Arrestor Cover

Screw

Tab

Slot

SPARK ARRESTOR MAINTENANCE

1. Remove the muffler cover. See Rocker Arm Clearance.

2. With a flat blade screwdriver or Torx T-20 bit, remove the screw attaching the spark arrestor cover to the muffler (Fig. 57).

3. Pull the tab on the spark arrestor cover out of the muffler. Remove the spark arrestor cover.

4. Remove the spark arrestor screen from the spark arrestor cover.

5. Clean the spark arrestor screen with a wire brush or replace it.

6. Reinstall the spark arrestor screen, spark arrestor cover and screw.

Do not sand blast,

scrape or clean electrodes. Grit in the engine could damage the cylinder.

WARNING:

TROUBLESHOOTING

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

CAUSE ACTION

Cutting attachment bound with grass Stop the engine and clean cutting attachment Cutting attachment out of line Refill with new line Inner reel bound up Replace the inner reel Cutting head dirty Clean inner reel and outer spool Line welded Disassemble, remove the welded section and rewind Line twisted when refilled Disassemble and rewind the line

Not enough line is exposed Push the bump knob and pull out line until 4 inches

(102 mm) of line is outside of the cutting attachment

CAUSE ACTION

Old fuel Drain gas tank and add fresh fuel Improper carburetor adjustment Take to an authorized service dealer for adjustment Fouled spark plug Replace or clean the spark plug Plugged spark arrestor Clean or replace spark arrestor

CAUSE ACTION

Empty fuel tank Fill fuel tank with new fuel Primer bulb wasn't pressed enough Press primer bulb fully and slowly 10 times Old fuel Drain gas tank and add fresh fuel Fouled spark plug Replace or clean the spark plug Plugged spark arrestor Clean or replace spark arrestor

ENGINE WILL NOT START

ENGINE WILL NOT IDLE

ENGINE WILL NOT ACCELERATE

ENGINE LACKS POWER OR STALLS WHEN CUTTING

CAUSE ACTION

Air filter is plugged Replace or clean the air filter Old fuel Drain gas tank and add fresh fuel Improper carburetor adjustment Adjust carburetor

CAUSE ACTION

Old fuel Drain gas tank and add fresh fuel Improper carburetor adjustment Take to an authorized service dealer for adjustment Cutting attachment bound with grass Stop the engine and clean the cutting attachment Dirty air filter Clean or replace the air filter Plugged spark arrestor Clean or replace spark arrestor

CUTTING ATTACHMENT WILL NOT ADVANCE LINE

CAUSE ACTION

Oil, cleaner or lubricant in cutting head Clean and thoroughly dry the cutting head

CUTTING LINE ADVANCES UNCONTROLLABLY

When it is above 40°F outside & the Cold Weather Start Lever is in the CLOSED / START position

When it is below 40°F outside & the Cold Weather Start Lever is in the RUN / OPEN position

Flip the Cold Weather Start Lever to RUN / OPEN

Flip the Cold Weather Start Lever to CLOSED / START and follow the Starting Instructions

SPECIFICATIONS

ENGINE*

DRIVE SHAFT AND CUTTING ATTACHMENT*

*All specifications are based on the latest product information available at the time of printing. We reserve the right to make changes at any time without notice.

Drive Shaft Housing............................................................................................................................ Steel Tube (EZ-Link™)

Throttle Control.......................................................................................................................................... Finger-Tip Trigger

Approximate Unit Weight (No fuel, with handle, shield and cutting attachment) ........................................... 13.5 lbs (6 kg)

Cutting Mechanism:.................................................................................. 4-Tooth Cutting Blade, Dual String Cutting Head

Line Spool .............................................................................................................................................. Bump Line Releaser

Line Spool Diameter:............................................................................................................................. 4 inches (101.6 mm)

Trimming Line Diameter: ............................................................................................................... 0.105 inchches (2.66 mm)

Cutting Path Diameter, Cutting Attachment ......................................................................................... 18 inches (45.7 cm)

Cutting Path Diameter, Cutting Blade...................................................................................................... 8 Inches (204 mm)

Shoulder Harness..................................................................................................................................... Single Quick-Snap

Engine Type ........................................................................................................................................... Air-Cooled, 4-Cycle

Displacement .......................................................................................................................................... 1.6 cu. in. (26.2 cc)

Clutch Type........................................................................................................................................................... Centrifugal

Operating RPM ......................................................................................................................................... 6,800 - 9,300 rpm

Idle Speed RPM........................................................................................................................................ 2,800 - 3,600 rpm

Ignition Type ........................................................................................................................................................... Electronic

Ignition Switch..................................................................................................................................................Rocker Switch

Valve clearance ....................................................................................................................... .003–.006 in. (.076–.152 mm)

Spark Plug Gap.................................................................................................................................. 0.025 inch (0.655 mm)

Lubrication............................................................................................................................................................. SAE 30 Oil

Crankcase Oil Capacity................................................................................................................................. 3.0 fl 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)

California / EPA Emission Control Warranty Statement

Your Warranty Rights and Obligations

The California Air Resources Board, the Environmental Protection Agency and MTD LLC (MTD) are pleased to explain the emission control system warranty on your 2000 and later small off-road engine. New small off-road engines must be designed, built and equipped to meet stringent anti-smog standards. MTD must warrant the emission control system on your small off-road engine for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your small off-road engine.

Your emission control system may include parts such as the carburetor or fuel-injected system, the ignition system, and catalytic converter. Also included may be hoses, belts, connectors and other emission-related assemblies.

Where a warrantable condition exists, Troy-Bilt will repair your small off-road engine at no cost to you including diagnosis, parts and labor.

The 2000 and later small off-road engines are warranted for two years. If any emission-related part on your engine is defective, the part will be repaired or replaced by Troy-Bilt.

Owners Warranty Responsibilities

• As the small off-road engine owner, you are responsible for the performance of the required maintenance listed in your operator’s manual. Troy-Bilt recommends that you retain all receipts covering maintenance on your small off-road engine, but Troy-Bilt cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

• As the small off-road engine owner, you however should be aware that Troy-Bilt may deny you warranty coverage if your small off-road engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

• You are responsible for presenting your small off-road engine to a Troy-Bilt Authorized Service Center as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

If you have any questions regarding your warranty rights and responsibilities, you should call 1-800-520-5520.

Manufacturer’s Warranty Coverage

• The warranty period begins on the date the engine or equipment is delivered to the retail purchaser.

• The manufacturer warrants to the initial owner and each subsequent purchaser, that the engine is free from defects in material and workmanship which cause the failure of a warranted part for a period of two years.

• Repair or replacement of warranted part will be performed at no charge to the owner at an Authorized Troy-Bilt Service Center. For the nearest location please contact Troy-Bilt at: 1-800-520-5520.

• Any warranted part which is not scheduled for replacement, as required maintenance or which is scheduled for only for regular inspection to the effect of “Repair or Replace as Necessary” is warranted for the warranty period. Any warranted part which is scheduled for replacement as required maintenance will be warranted for the period of time up to the first scheduled replacement point for that part.

• The owner will not be charged for diagnostic labor which leads to the determination that a warranted part is defective, if the diagnostic work is performed at an Authorized Troy-Bilt Service Center.

• The manufacturer is liable for damages to other engine components caused by the failure of a warranted part still under warranty.

• Failures caused by abuse, neglect or improper maintenance are not covered under warranty.

• The use of add-on or modified parts can be grounds for disallowing a warranty claim. The manufacturer is not liable to cover failures of warranted parts caused by the use of add-on or modified parts.

• In order to file a claim, go to your nearest Authorized Troy-Bilt Service Center. Warranty services or repairs will be provided at all Authorized Troy-Bilt Service Centers.

• Any manufacturer approved replacement part may be used in the performance of any warranty maintenance or repair of emission related parts and will be provided without charge to the owner. Any replacement part that is equivalent in performance or durability may be used in non-warranty maintenance or repair and will not reduce the warranty obligations of the manufacturer

• The following components are included in the emission related warranty of the engine, air filter, carburetor, primer, fuel lines, fuel pick up/ fuel filter, ignition module, spark plug and muffler.

+ 61 hidden pages

Troy-Bilt TB490BC User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual