Troy-Bilt TB590 EC Operator's Manual

Operator’s Manual

Electric Start Capable

4-Cycle Gas Trimmer

TB590 EC

TABLE OF CONTENTS

Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Rules for Safe Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Know Your Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Oil and Fuel Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Starting and Stopping Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Maintenance and Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Cleaning and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Optional Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

SAVE THESE INSTRUCTIONS

SERVICE INFORMATION

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

For assistance regarding the assembly, controls, operation or maintenance of the unit, please call the Customer Support Department at 1-800-828-5500 in the United States or 1-800-668-1238 in Canada. Additional information about the unit can be found on our website at www.troybilt.com or www.troybilt.ca.

For service, please call the Customer Support Department to obtain a list of authorized service dealers near you. Service on this unit, both within and after the warranty period, should only be performed by an authorized and approved service dealer. When servicing, use only identical replacement parts.

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.

769-07575 P00 12/11

RULES FOR SAFE OPERATION

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 #753-05245 Muffler

Read the Operator’s Manual 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 1-800-828-5500 IN U.S. OR 1-800-668-1238 in CANADA

The

our

nge

The

on a

SYMBOL MEANING

und

nge

The

ols i

ng.

a The

ons

ion

ions

ngs

o not

SAFETY ALERT: 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.

DANGER: Failure to obey a safety warning will result in serious

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

WARNING: Failure to obey a safety warning can result in injury

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

CAUTION: Failure to obey a safety warning may result in

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

NOTE: Advises you of information or instructions vital to the operation or

maintenance of the equipment.

• IMPORTANT SAFETY INSTRUCTIONS •

CALIFORNIA PROPOSITION 65

WARNING: Engine exhaust, some of its constituents and

certain finished components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

READ ALL INSTRUCTIONS BEFORE OPERATING

WARNING:

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.

• 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.

When using the unit, you must follow the safety

• 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

WARNING:

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

our

not

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.

Gasoline is highly flammable, and its vapors can

RULES FOR SAFE OPERATION

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.

• 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

• 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, maintenance, and repair information.

SYMBOL MEANING

• SAFETY ALERT SYMBOL

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

• READ OPERATOR'S MANUAL

WARNING: 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.

SYMBOL MEANING

• UNLEADED FUEL

Always use clean, fresh unleaded fuel

DO NOT USE E85 FUEL IN THIS UNIT

•

WARNING: It has been proven that fuel containing

greater than 10% ethanol will likely damage this engine and void the warranty.

• ON/OFF CONTROL

ON / START / RUN

• ON/OFF CONTROL

• OIL

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

• CHOKE CONTROL

1. • FULL choke position

2. • PARTIAL choke position

3. • RUN choke position

• 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.

• KEEP BYSTANDERS AWAY

WARNING: Keep all bystanders, especially children

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

• 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.

• 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.

• SHARP BLADE

WARNING: Sharp blade on cutting attachment

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

• BRUSHCUTTERS• REPLACE DULL BLADE

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

KNOW YOUR UNIT

PPLICATIONS

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.

Shoulder Strap Loop

Brushcutter Blade

On/Off Control

J-Handle

haft

Cutting Attachment

uffler

Starter Rope Grip

Throttle Lockout

EZ-LINK®

Cutting Attachment Shield

Spark Plug

Throttle Control

Oil Fill Plug

haft Grip

Air Filter Cover

Line Cutting Blade

Fuel Cap

Choke Lever

Primer Bulb

ASSEMBLY INSTRUCTIONS

ig. 1

Fig. 2

Fig. 3

J Handle

Top Clamp

Middle Clamp

Bottom Clamp

INSTALL AND ADJUST THE J-HANDLE

On some units, the J-handle may be pre-

Screws

installed. In this case you must loosen screws and adjust the handle to fit the operator. Go to step 5 if the J-handle is pre-installed.

1. Place the J-handle between the top and

middle clamp pieces (Fig. 1).

2. While holding the three pieces together, install

uts

the four (4) screws through the top clamp and into middle clamp.

NOTE: The holes in the top and middle clamp

Decal

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.

While holding the unit in the operating position (Fig. 23), 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 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

ASSEMBLY INSTRUCTIONS

REMOVE AND INSTALL THE CUTTING ATTACHMENT SHIELD

WARNING:

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

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

WARNING:

personal injury, never operate the unit as a trimmer without the cutting attachment shield in place.

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.

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 AND INSTALL THE CUTTING BLADE

NOTE: To make cutting blade removal and

installation easier, place the unit on the ground or on a work bench.

Remove the Cutting Attachment Shield

See Remove and Install the Cutting Attachment Shield.

Remove the Cutting Attachment

DANGER:

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.

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. 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.

DANGER:

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

Install the Cutting Blade

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

5. Make sure that the cutting blade is centered on the pilot step and sitting flat against the output shaft bushing (Fig. 10).

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 (Fig. 10). Make sure that the blade is installed correctly.

8. Tighten nut counterclockwise against the blade while holding the locking rod (Fig. 11):

• If using a torque wrench and a 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. 11).

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

WARNING:

not start or operate this unit with the locking rod in the locking rod slot.

The cutting attachment shield should NOT be installed

To prevent serious

Screws (3)

Shield Mount

Bushing Hole

Locking Rod Slot

Locking

Rod

Cutting Attachment

Shield

Fig. 6

Output Shaft

Bushing

ig. 7

The gear housing gets hot

Fig. 8

utting Attachment

Fig. 9

Blade

If the cutting blade is off-

Retainer

Output

Shaft

Pilot Step

Fig. 10

To avoid serious personal injury or damage to the unit, do

Nut

Fig. 4

Fig. 5

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.

ASSEMBLY INSTRUCTIONS

REMOVE THE CUTTING BLADE AND 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. 8).

3. While holding the locking rod, loosen the nut on the blade by turning it clockwise with a 13 mm closed-end or socket wrench (Fig. 11).

4. Remove the nut, blade retainer and blade (Fig. 10). Store the nut and blade together for future use in a secure place. Store out of children’s reach.

Install the Cutting Attachment

Cutting Attachment

5. 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

Blade

Bushing

surface against the output shaft bushing (Fig. 12). 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 (Fig. 12).

6. Remove the locking rod.

7. Install the cutting attachment shield. Refer to Remove and Install the

Cutting Attachment Shield.

OPERATING THE EZ-LINK® SYSTEM

WARNING:

Before beginning to use any attachment, read and understand the manual that came with the attachment. Follow all safety information contained within.

The EZ-LINK® system enables the use of these optional Add-Ons:

Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AF720

Hedge Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AH720

Brushcutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC720*

Cultivator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GC720

Edger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LE720

Pole Saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PS720

Straight Shaft Trimmer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS725

Turbo Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB720

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

Installing the Cutting Attachment or Add-On

WARNING:

To avoid serious

Z-LINK® Coupler

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

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. 15). While firmly holding the add-on, push it straight into the EZ-LINK® coupler (Fig. 14).

NOTE: Aligning the release button with the guide recess will help installation (Fig. 13).

3. Turn the knob clockwise to tighten (Fig. 15).

CAUTION:

Lock the release

Primary Hole

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

For edging (when using the line head cutting attachment with EZ-LINK® models), lock the release button of the cutting attachment into

Upper Shaft

Housing

the 90° edging hole (Fig. 15).

90˚ Edging Hole

CAUTION:

Add-ons are to be used

(Trimmer Only)

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

Removing the Cutting Attachment or Add-On

1. Turn the knob counterclockwise to loosen (Fig. 15).

2. Press and hold the release button (Fig. 13).

3. While firmly holding the upper shaft housing, pull the cutting attachment or add-on straight out of the EZ-LINK® coupler (Fig. 14).

Loosen

Top View

Fig. 11

ig. 12

Fig. 13

Fig. 14

Fig. 15

Tighten

elease

Button

Guide Recess

Lower Shaft

Housing

Knob

OIL AND FUEL INFORMATION

WARNING:

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.

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. 16).

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. 16).

2. Tip unit so that the back of the engine is

facing up in a vertical position.

3. Remove the oil fill plug from the crankcase (Fig. 18).

4. Pour the entire bottle of oil into the oil fill hole (Fig. 17). NOTE: Never add oil to the fuel or fuel tank.

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

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

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.

FUELING THE UNIT

WARNING:

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

WARNING:

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. 19).

WARNING:

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. 19) and fill the tank.

NOTE: Do not overfill the tank.

OVERFILLING OIL CRANKCASE MAY CAUSE

unnel

Spout

Fig. 16

Fig. 17

Oil Fill Plug

-Ring

Oil Fill Hole

Fig. 18

Add fuel in a clean, well ventilated outdoor area. Wipe

Gasoline is extremely flammable. Ignited vapors may

Gas Can Spout

Remove fuel cap slowly

Fuel Tank

Fig. 19

Fuel Cap

OIL AND FUEL INFORMATION

FUELING THE UNIT

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.

STARTING AND STOPPING INSTRUCTIONS

WARNING:

Carbon monoxide exhaust fumes can be lethal in a confined area.

WARNING:

starting position when pulling the starter rope (Fig. 22). 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.

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

On/Off Control is in the ON ( I ) position at all times (Fig. 20).

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.

21). 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. Place the choke lever in Position 1 (Fig. 21).

5. Crouch in the starting position (Fig. 22). Press the throttle lockout in and squeeze the throttle control lever. Pull the starter rope 5 times.

6. Place the choke lever in Position 2 (Fig. 21).

While pressing the throttle lockout in and squeezing the throttle control, pull the starter rope 3 to 5 times to start the engine.

8. Keep the throttle squeezed and allow the engine to warm up for 30 to 60 seconds.

9. Continue squeezing the throttle control, move the choke lever to Position 3 (Fig. 21) and continue warming the engine for an additional 60 seconds. The unit may be used during this time.

NOTE: Unit is properly warmed up when engine accelerates without hesitation. IF...the engine hesitates, return the choke lever to Position 2 (Fig. 21) and

continue warm-up.

IF...the engine does not start, go back to step 3. 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 out with a controlled and steady motion 3 to 8 times. The engine should start. If not, repeat.

IF THE ENGINE IS HOT... Move the choke lever to Position 2, press the

primer bulb 10 times, squeeze the throttle control and pull the starter rope until the unit starts. Run the unit for 2-5 minutes. The unit may be used during this time. Then 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. Press and hold the On/Off Stop Control switch in the OFF (O) position

until the unit comes to a complete stop (Fig. 11).

IF USING THE OPTIONAL ELECTRIC STARTER

HOW TO START THE UNIT USING THE ELECTRIC STARTER OR POWER START BIT™ ACCESSORY.

NOTE-

This Unit Can Use an Electric Start or Power Start Bit™ Optional Accessory!

Please refer to the Electric Starter or Power Start Bit operator’s manual for proper use of this feature. (Items Sold Separately! Please refer to page 10 of this manual about purchasing these accessories.)

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.

Operate this unit only in a well-ventilated outdoor area.

Avoid accidental starting. Make sure you are in the

ON (I)

Throttle

Lockout

Choke Lever

Position 1

Starter

ope

Throttle Control

OR POWER START BIT™ ACCESSORY

Fig. 20

Fig. 21

ig. 22

FF (O)

Throttle

Control

rimer Bulb

Starting Position

STARTING AND STOPPING INSTRUCTIONS

IF USING THE OPTIONAL ELECTRIC STARTER

OR POWER START BIT™ ACCESSORY

NOTE:

There is no need to turn the unit on. The On/Off Control is in the ON ( I )

position at all times (Fig. 20).

3. Fully press and release the primer bulb 10 times, slowly. Some amount of fuel should be visible in the primer bulb (Fig. 21). If fuel cannot be seen in the bulb, press and release the bulb until fuel is visible.

4. Move the choke lever to Position 1 (Fig. 21).

5. Crouch in the starting position (Fig. 22). Place the electric starter or drill into the back of the unit. Refer to the Operation section of the Electric Starter or Power Start Bit operator’s manual.

6. Press the throttle lockout in and squeeze the throttle control lever. Press and hold the electric starter or drill ON (I) button for 2 seconds.

7. Move the choke lever to Position 2 (Fig. 21).

8. Press the throttle lockout in and squeeze the throttle control lever, press and hold the electric starter or drill ON (I) button for 2-second intervals until the unit starts.

9. Continue to squeeze the throttle control, remove the electric starter or drill from the unit and allow the engine to warm up for 30 to 60 seconds.

10.Continue squeezing the throttle control, move the choke lever to Position 3 (Fig. 21) and run the unit for an additional 60 seconds. The unit may be used during this time.

NOTE: Unit is properly warmed up when engine accelerates without

hesitation.

IF...the engine hesitates, return the choke lever to Position 2 (Fig. 21) and

continue warm-up.

IF...the engine does not start, go back to step 3. IF...the engine fails to start after a few attempts, place the choke lever in Position

3 and squeeze the throttle control. Press and hold the electric starter or drill

ON (I) button for 2-second intervals until the unit starts.

IF THE ENGINE IS HOT... Move the choke lever to Position 2, press the

STOPPING INSTRUCTIONS

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

2. Press and hold the On/Off Control switch in the OFF (O) position until the unit comes to a complete stop (Fig. 20).

OPERATING INSTRUCTIONS

HOLDING THE TRIMMER

WARNING:

to reduce the risk of injury when operating this unit.

Before operating the unit, stand in the operating position (Fig. 23). 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 assist 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

ADJUSTING TRIMMING LINE LENGTH

WARNING:

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

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. 24) 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

Always wear eye, hearing, foot and body protection

Fig. 23

Do not remove or alter the line cutting blade

Fig. 24

OPERATING INSTRUCTIONS

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. 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.

• Cutting from right to left improves the unit's cutting efficiency. Clippings are thrown away from the operator.

• 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, and where vegetation is cut.

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

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.

25).

USING THE CUTTING BLADE

WARNING:

Always wear eye, hearing, foot and body protection

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.

Before operating the unit with the cutting blade, stand in the operating position (Fig. 26). 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).

WARNING:

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

• 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.

WARNING:

The blade continues to spin after the engine is turned

off. The coasting blade can seriously cut you if accidentally touched.

• 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.

Fig. 25

Fig. 26

OPERATING INSTRUCTIONS

WARNING:

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.

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. 27)

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

WARNING:

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.

Do not sharpen the cutting blade. Sharpening the

Fig. 27

Do not clear away any cut material with the engine

MAINTENANCE AND REPAIR INSTRUCTIONS

MAINTENANCE SCHEDULE

WARNING:

or repairs with unit running. Always service and repair a cool unit. Disconnect the spark plug wire to ensure that the unit cannot start.

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.

NOTE: Please read the California/EPA statement that came with the unit for a

complete listing of terms and coverage for the emissions control devices, such as the spark arrestor, muffler, carburetor, etc.

FREQUENCY MAINTENANCE REQUIRED SEE

Every 10 hours Clean and oil air filter p. 8 Change 1st 10 hours Change oil p. 8

Every 25 hours

LINE INSTALLATION

WARNING:

These can break off and become dangerous projectiles.

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

Always use original equipment manufacturer

0.105 in. (2.67 mm) replacement line. Other types

of line 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. 28). Inspect the bolt inside the bump knob to make sure it moves freely. Replace the bump knob if damaged.

2. Remove the inner reel from the outer spool

(Fig. 28).

3. Remove spring from the inner reel (Fig. 28).

4. Use a clean cloth to clean the the inner reel,

spring, shaft and inner surface of the outer spool (Fig. 29).

5. Check the indexing teeth on the inner reel and

outer spool for wear (Fig. 30). If necessary, remove burrs or replace the reel and spool.

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.

To prevent serious injury, never perform maintenance

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

Never use metal-reinforced line, wire, chain or rope.

Outer Spool

Spring

Inner Reel

Bump Knob

Index Teeth

Bolt

Fig. 28

Fig. 29

Fig. 30

p. 8 p. 9 p. 9

MAINTENANCE AND REPAIR INSTRUCTIONS

SINGLE LINE INSTALLATION

Go To Step 8 for SplitLine™ Installation

6. Take approximately 18 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. 31). 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. 31

(Fig. 32). 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.

SPLITLINE™ INSTALLATION

8. Take approximately 9 feet (3 m) of new trimming line. Insert one end of the line

Fig. 32

through one of the two holes in the inner reel (Fig. 33). 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. 34).

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.

ig. 33

NOTE: Failure to wind the line in the direction

indicated will cause the cutting attachment to operate incorrectly.

12.Insert the ends of the line into the two holding slots (Fig. 34).

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. 35). Push the inner reel and outer spool together. While holding the inner reel and outer spool, grasp

Fig. 34

the ends and pull firmly to release the line from the holding slots in the reel.

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.

Fig. 35

INSTALLING A PREWOUND REEL

1. Hold the outer spool with one hand and unscrew the bump knob clockwise (Fig. 28). 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. 28).

3. Remove the spring from the old inner reel (Fig. 28).

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. 35).

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

WARNING:

To prevent extensive engine wear and damage to the unit, always maintain the proper oil level in the crankcase. Never operate the unit with a low 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 engine on a flat, level surface with the cutting head shield hanging off a work bench or table to get a proper oil level reading (Fig. 36).

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

Fig. 36

Loop

Tab

4. Remove the oil fill plug.

5. Look into the oil fill hole, use a flashlight if needed. The oil should be just touching the inner most thread (Fig. 37).6. If the oil level is not touching the inner most thread on the oil fill hole, add a small amount of oil to the oil fill hole and recheck (Fig. 37). Repeat this procedure until the oil level reaches the inner most thread on the oil fill hole.

NOTE: Do not overfill the unit. NOTE: Make sure the O-ring is in place on the oil fill

il Fill Plug

Max Oil Fill Line

Fig. 37

plug when checking and changing the oil (Fig. 38).

CHANGING THE OIL

CAUTION:

injury when handling the unit.

Wear gloves to prevent

O-Ring

Oil Fill Hole

Fig. 38

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.

3. Pour the oil out of the oil fill hole and into a container by tipping the unit to a vertical

ig. 39

position (Fig. 39). Allow ample time for complete drainage.

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 (Fig. 40).

NOTE:

Use the bottle and spout saved from initial

Fig. 40

use to measure the correct amount of oil. The top of the label on the bottle measures approximately

3.04 ounces (90 ml) (Fig. 41). Check the level, See Checking the Oil Level. If the level is low, add a small amount of oil and recheck. Do not overfill (Fig. 37).

Fill Line

6. Replace the oil fill plug.

7. Reconnect the spark plug boot.

Fig. 41

AIR FILTER MAINTENANCE

WARNING:

To avoid serious personal injury, always turn the

unit off and allow it to cool before you clean or service it.

Cleaning the Air Filter

Air Filter Cover

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

Air Filter

under side of the cover inward. Then pull the air filter cover out and up. (Fig. 42).

2. Remove the air filter (Fig. 46).

3. Wash the filter in detergent and water. Rinse the filter thoroughly and allow it to dry.

Fig. 42

Back Plate

Tab

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

5. Squeeze the filter to spread and remove excess oil.

Air Filter

6. Replace the filter (Fig. 43).

NOTE: If the unit is operated without the air filter,

you will VOID the warranty.

7. Reinstall the air filter cover. Position the slots

Locking Tab

Fig. 43

on the top of the air filter cover onto the tabs at the top of the back plate (Fig. 43).

8. Swing the cover down until the tab on the air filter backplate snaps into place in the slot on the air filter cover (Fig. 42).

Tabs

+ 16 hidden pages

Troy-Bilt TB590 EC Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual