BP406 - Brush cutter POULAN - Free user manual and instructions

USER MANUAL BP406 POULAN

Please do not return unit to retailer.

IMPORTANT MANUAL - Do not throw away

MANUAL IMPORTANTE - No lo descarte

MANUEL IMPORTANT - À Conserver

WARNING:

Read the operator's manual and follow all warnings and safety instructions. Failure to do so can result in serious injury. Always wear eye protection.

ADVERTENCIA:

1030 Stevens Creek Road

Augusta, GA 30907

Poulan PRO

5855 Terry Fox Way

Mississauga, Ontario L5V 3E4

SAFETY RULES

WARNING: Failure to follow all Safety Rules and Precautions can result in serious injury.

KNOW YOUR UNIT

• Read your instruction manual carefully until you completely understand and can follow all warnings and safety rules before operating the unit.
• Restrict unit to users who understand and will follow all warnings and safety rules in this manual.

WARNING: Inspect area before starting unit. Remove all debris and hard objects such as rocks, glass, wire, etc. that can ricochet, be thrown, or otherwise cause injury or damage during operation.

Use your unit as a blower for:

• Sweeping debris or grass clippings from driveways, sidewalks, patios, etc.
• Blowing grass clippings, straw, or leaves into piles, around joints, or between bricks.

PLAN AHEAD

• Always wear eye protection when operating, servicing, or performing maintenance on unit. Wearing eye protection will help to prevent rocks or debris from being blown or ricocheting into eyes and face which can result in blindness and/or serious injury. Eye protection should be marked Z87.
  Always wear foot protection. Do not go barefoot or wear sandals.
  Always wear respirator or face mask when working with unit in dusty environments.
• Secure hair above shoulder length. Secure or remove jewelry, loose clothing, or clothing with loosely hanging straps, ties, tassels, etc. They can be caught in moving parts.
• Do not operate unit when you are tired, ill, upset, or if you are under the influence of alcohol, drugs, or medication.
• Keep children, bystanders, and animals away from work area a minimum of 30 feet (10 meters) when starting or operating unit. Do not point the blower nozzle in the direction of people or pets.

HANDLE FUEL WITH CAUTION, IT IS HIGHLY FLAMMABLE

• Eliminate all sources of sparks or flame (including smoking, open flames, or work that can cause sparks) in the areas where fuel is mixed, poured, or stored.
• Mix and pour fuel in an outdoor area; store fuel in a cool, dry, well ventilated place; use an approved, marked container for all fuel purposes.
• Do not smoke while handling fuel or while operating the unit.
• Make sure the unit is properly assembled and in good operating condition.

• Do not fill fuel tank while engine is hot or running.

• Avoid spilling fuel or oil. Wipe up fuel spills before starting engine.

• Move at least 10 feet (3 meters) away from fuel and fueling site before starting engine.
• Always store gasoline in a container approved for flammable liquids.

OPERATE YOUR UNIT SAFELY

• Inspect unit before each use for worn, loose, missing, or damaged parts. Do not use until unit is in proper working order.
• Keep outside surfaces free of oil and fuel.
• Never start or run engine inside a closed room, building or other unventilated area. Breathing exhaust fumes can kill.
• To avoid static electricity shock, do not wear rubber gloves or any other insulated gloves while operating unit.
• Do not set unit on any surface except a clean, hard area while engine is running. Debris such as gravel, sand, dust, grass, etc. could be picked up by the air intake and thrown out through discharge opening, damaging unit, property, or causing serious injury to bystanders or operator.
• Avoid dangerous environments. Do not use in unventilated areas or where explosive vapors or carbon monoxide build up could be present.
• Do not overreach or use from unstable surfaces such as ladders, trees, steep slopes, rooftops, etc. Keep firm footing and balance at all times.
• Never place objects inside the blower tubes; always direct the blowing debris away from people, animals, glass, and solid objects such as trees, automobiles, walls, etc. The force of air can cause rocks, dirt, or sticks to be thrown or to ricochet which can hurt people or animals, break glass, or cause other damage.
• Never run unit without the proper equipment attached. When using your unit as a blower, always install blower tubes.
• Check air intake opening and all blower tubes frequently, always with engine stopped and spark plug disconnected. Keep vents and discharge tubes free of debris which can accumulate and restrict proper air flow.
• Never place any object in the air intake opening as this could restrict proper air flow and cause damage to the unit.
• Never use for spreading chemicals, fertilizers, or other substances which may contain toxic materials.
• To avoid spreading fire, do not use near leaf or brush fires, fireplaces, barbecue pits, ashtrays, etc.
• Use only for jobs explained in this manual.

MAINTAIN YOUR UNIT PROPERLY

• Have all maintenance other than the recommended procedures described in the instruction manual performed by an authorized service dealer.

• Disconnect spark plug before performing maintenance except for carburetor adjustments.

• Use only recommended Poulan PRO replacement parts; use of any other parts may void your warranty and cause damage to your unit.
• Empty fuel tank before storing the unit. Use up fuel left in carburetor by starting engine and letting it run until it stops.
• Do not use any accessory or attachment other than those recommended by manufacturer for use with your unit.
• Do not store the unit or fuel in a closed area where fuel vapors can reach sparks or an open flame from hot water heaters, electric motors or switches, furnaces, etc.
• Store in a dry area out of reach of children. SPECIAL NOTICE: This unit is equipped with a temperature limiting muffler and spark arresting screen which meets the requirements of California Codes 4442 and 4443. All U.S. forest land and the states of California, Idaho, Maine, Minnesota, New Jersey, Oregon, and Washington require by law that many internal combustion engines be

equipped with a spark arresting screen. If you operate in a locale where such regulations exist, you are legally responsible for maintaining the operating condition of these parts. Failure to do so is a violation of the law. Refer to the MAINTENANCE section for information on maintenance of the muffler and spark arresting screen.

SAFETY NOTICE: Exposure to vibrations through prolonged use of gasoline powered hand tools could cause blood vessel or nerve damage in the fingers, hands, and joints of people prone to circulation disorders or abnormal swelling. Prolonged use in cold weather has been linked to blood vessel damage in otherwise healthy people. If symptoms occur such as numbness, pain, loss of strength, change in skin color or texture, or loss of feeling in the fingers, hands, or joints, discontinue the use of this tool and seek medical attention. An antivibration system does not guarantee the avoidance of these problems. Users who operate power tools on a continual and regular basis must monitor closely their physical condition and the condition of this tool.

ASSEMBLY

CARTON CONTENTS

1. Spark plug
2. Choke
3. Air filter
4. Starter handle
5. Fuel tank
6. Harness
7. Muffler
8. Control handle
9. Air nozzle
10. Blower outlet tube
11. Flexible tube
12. Throttle control
13. ON/STOP switch
14. Throttle adjuster

WARNING: If you receive your unit assembled, check each step to insure your unit is properly assembled and all fasteners are secure. Follow all safety information in the manual and on the unit.

1. Locate and identify all components.
2. Connect the flexible tube to the outlet tube on the engine. Tighten the hose clamp.

3. Remove bottom screw from control handle. Install the control handle against the flared area on the base tube with the ON/ STOP switch facing the engine.

4. Connect the base tube to the flexible tube. Tighten the hose clamp.

5. Assemble the air nozzle to the middle tube and connect the assembly to the base tube by pushing the tubes together and turning them until they lock in place.
6. Remove throttle cable clamp from flexible tube. Place throttle cable in clamp and reinstall on flexible tube.

KNOW YOUR BLOWER

READ THIS INSTRUCTION MANUAL AND SAFETY RULES BEFORE OPERATING YOUR UNIT.

Compare the illustrations with your unit to familiarize yourself with the location of the various controls and adjustments. Save this manual for future reference.

ON/STOP SWITCH

The ON/STOP SWITCH is used to stop the engine. To stop the engine, move the switch to the STOP position.

PRIMER BUTTON

The PRIMER BUTTON removes air from the carburetor and fuel lines and fills them with fuel. This allows you to start the engine with fewer pulls on the starter rope. Activate primer button by pressing it and allowing it to return to its original position.

CHOKELVER

The CHEME helps to supply fuel to the engine to aid in cold starting. Activate the choke by moving the choke lever to the CLOSE position. Once engine starts, move choke lever to the OPEN position.

THROTTLE ADJUSTER

The THROTTLE ADJUSTER can be used to select the speed of air flow. To avoid holding your finger on the throttle trigger all the time, the required speed can be set with the throttle adjuster. Full throttle is obtained by squeezing the throttle trigger and moving the throttle adjuster clockwise until it stops.

OPERATING POSITION

OPERATING TIPS

• To reduce the risk of hearing loss associated with sound level(s), hearing protection is required.

• To reduce the risk of injury associated with contacting rotating parts, stop the engine before installing or removing attachments. Do not operate without guard(s) in place.

• Operate power equipment only at reasonable hours-not early in the morning or late at night when people might be disturbed. Comply with times listed in local ordinances. Usual recommendations are 9:00 a.m. to 5:00 p.m., Monday though Saturday.

• To reduce noise levels, limit the number of pieces of equipment used at any one time.
  To reduce noise levels, operate power blowers at the lowest possible throttle speed to do the job.
• Use rakes and brooms to loosen debris before blowing.
• In dusty conditions, slightly dampen surfaces or use a mister attachment when water is available.
• Conserve water by using power blowers instead of hoses for many lawn and garden applications, including areas such as gutters, screens, patios, grills, porches, and gardens.

• Watch out for children, pets, open windows, or freshly washed cars. Blow debris away safely.

• Use the full blower nozzle extension so the air stream can work close to the ground.
  After using blowers and other equipment, CLEAN UP! Disposethe debris in trash receptacles.

BEFORE STARTING ENGINE

WARNING: Be sure to read the fuel information in the safety rules before you begin. If you do not understand the safety rules, do not attempt to fuel your unit. Contact your authorized service dealer or call 1-800-554-6723.

FUELING ENGINE

WARNING: Remove fuel cap slowly when refueling.

This engine is certified to operate on unleaded gasoline. Before operation, gasoline must be mixed with a good quality synthetic 2-cycle air-cooled engine oil designed to be mixed at a ratio of 50:1. A 50:1 ratio is obtained by mixing 2.6 ounces of oil with 1 gallon of unleaded gasoline. DO NOT USE automotive oil or boat oil. These oils will cause engine damage. When mixing fuel, follow the instructions printed on container. Once oil is added to gasoline, shake container momentarily to assure that the fuel is thoroughly mixed. Always read and follow the safety rules relating to fuel before fueling your unit.

IMPORTANT

Experience indicates that alcohol blended fuels (called gasohol or using ethanol or methanol) can attract moisture which leads to separation and formation of acids during storage. Acidic gas can damage the fuel system of an engine while in storage. To avoid engine problems, empty the fuel system before storage for 30 days or longer. Drain the gas tank, start the engine and let it run until the fuel lines and carburetor are empty. Use fresh fuel next season. Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur.

TO STOP THE ENGINE

• To stop the engine, move the ON/STOP switch to the STOP position.

WARNING: You MUST make sure the tubes are secure before using the unit.

WARNING: Try on the unit and adjust the shoulder straps for fit and comfort before starting the engine to avoid losing control of the unit. Always start and run the unit in an upright position.

• Fuel engine. Move at least 10 feet (3 meters) away from the fueling site.
• Hold the unit in the starting position as shown. Make sure the blower end is directed away from people, animals, glass, and solid objects.

STARTING POSITION

WARNING: When starting engine, hold the unit as illustrated. Do not set unit on any surface except a clean, hard area when starting engine or while engine is running. Debris such as gravel, sand, dust, grass, etc. could be picked up by the air intake and thrown out through the discharge opening, damaging the unit or property, or causing serious injury to bystanders or the operator.

WARNING: Avoid contact with the muffler. A hot muffler can cause serious burns.

STARTING A COLD ENGINE (or warm engine that has run out of fuel)

1. Move ON/STOP switch to the ON position.
2. Move the choke lever to the CLOSE position.
3. Slowly press the primer button (located under the carburetor) 6 times.

1. Squeeze throttle trigger and turn throttle adjuster clockwise until it stops.

1. Pull starter rope sharply until engine runs. NOTE: Only short pulls are necessary. Never pull the starter cord to its fullest extension. Never let go of the starter handle until it is at the fully returned position.
2. Once the engine has started, slowly move the choke lever to the OPEN position.
3. Turn throttle adjuster counterclockwise to release throttle trigger and allow unit to idle.

STARTING A WARM ENGINE

1. Move the choke lever to the OPEN position.
2. Squeeze throttle trigger and turn throttle adjuster clockwise until it stops.
3. Pull starter rope sharply until engine runs.
4. Turn throttle adjuster counterclockwise to allow unit to idle.

DIFFICULT STARTING (or starting a flooded engine)

1. Move the choke lever to the OPEN position.
2. Squeeze throttle trigger and turn throttle adjuster clockwise until it stops.

3. Pull rope to clear engine of excess fuel. This could require pulling the starter rope many times. Continue to pull rope until engine starts.

4. Turn throttle adjuster counterclockwise to release throttle trigger and allow unit to idle. If unit still doesn't start, refer to the TROUBLESHOOTING TABLE or call 1-800-554-6723.

BLOWER OPERATION

When the engine has warmed up, the blower can be positioned on the back of the operator. Once the blower is positioned and ready for operation, utilize the throttle trigger to maintain an operating speed necessary to accomplish the task.

NOTE: Always run the engine at idle speed for a few minutes to allow cooling before stopping the engine.

SERVICE AND ADJUSTMENTS

PERIODIC MAINTENANCE CHART

WARNING: Accidental engine starting can cause injury. Always remove the spark plug cap before servicing the engine to prevent accidental starting.

Maintenance	Daily	First 20 hours	Every 20 hours	Every 50 hours	Every 100 hours	Every 200 hours
Check and replenish fuel	✓
Check for fuel leakage	✓
Check bolts, nuts and screws for looseness and loss	✓
Check throttle lever operation	✓
Check engine switch operation	✓
Check shoulder harness condition	✓
Clean fuel filter			✓
* Clean air filter element					✓
Tighten bolts, nuts and screws		✓		✓
Clean spark plug and adjust electrode gap				✓
Remove dust and dirt from cylinder fins					✓
* Remove carbon deposits on piston head and inside cylinder						✓
Remove carbon deposits in the exhaust pipe of muffler					✓
Clean spark arrester screen				✓
* Check the sliding portion of crankshaft, connecting rod, etc.						✓
Fuel tube	Replacement is recommended every 3 years.

These items must be performed with proper tools. See your authorized Poulan PRO dealer for service.
The service intervals indicated are to be used as a guide. Service with an asterisk () should be performed more frequently if required by operating conditions.

WARNING: Avoid touching muffler unless engine and muffler are cold. A hot muffler can cause serious burns.

GENERAL RECOMMENDATIONS

The warranty on this unit does not cover items that have been subjected to operator abuse or negligence. To receive full value from the warranty, the operator must maintain unit as instructed in this manual. Various adjustments will need to be made periodically to properly maintain your unit.

CHECK FOR LOOSE

FASTENERS AND PARTS

• Spark Plug Boot

Air Filter
- Housing Screws

CHECK FOR DAMAGED OR WORN PARTS

Contact an authorized service dealer for replacement of damaged or worn parts.

• ON/STOP Switch - Ensure ON/STOP switch functions properly by moving the switch to the STOP position. Make sure engine stops; then restart engine and continue.
• Fuel Tank - Do not use unit if fuel tank shows signs of damage or leaks.

INSPECT AND CLEAN UNIT AND DECALS

• After each use, inspect complete unit for loose or damaged parts. Clean the unit and decals using a damp cloth with a mild detergent.
• Wipe off unit with a clean dry cloth.

CLEAN AIR FILTER

Cleaning the air filter:

A dirty air filter decreases engine performance and increases fuel consumption and harmful emissions. Always clean or replace air filter after every 20 hours of operation or yearly, whichever comes first.

NOTE: To avoid damage, do not wash the paper air filter with water. Do not use pressurized air to clean or dry the air filter. Always replace a damaged air filter.

1. Clean the cover and the area around it to keep debris from falling into the carburetor chamber when the cover is removed.
2. Remove parts as illustrated.
3. Clean the air filter by gently tapping to remove dust and debris.
4. Replace parts.

INSPECT MUFFLER AND SPARK ARRESTING SCREEN

WARNING: The muffler on this product contains chemicals known to the State of California to cause cancer.
WARNING: Avoid touching muffler unless engine and muffler are cold. A hot muffler can cause serious burns.

As the unit is used, carbon deposits build up on the muffler and spark arresting screen, and must be removed to avoid creating a fire hazard or affecting engine performance.

Replace the spark arresting screen every 50 hours of operation or if any damage or breaks in the screen are noted.

NOTE: Do not attempt to clean the spark arresting screen.

1. Loosen and remove two screws from the heat shield. Remove the heat shield.
2. Loosen and remove both muffler screws and the muffler from the unit.

1. Remove the spark arresting screen.

1. Install new spark arresting screen.
2. Reinstall muffler and both muffler screws. Tighten screws securely.
3. Reinstall heat shield and two screws. Tighten screws securely.

NOTE: If any part of the muffler is cracked, broken or damaged, we recommend that the muffler be replaced.

REPLACE SPARK PLUG

Replace spark plug each year to ensure the engine starts easier and runs better. Set spark plug gap at 0.034 inch (0.85 mm). Ignition timing is fixed, nonadjustable.

1. Twist, then pull off spark plug boot.
2. Remove spark plug from cylinder and discard.
3. Replace with NGK BPMR71-9 spark plug and tighten securely with a 3/4 inch (19 mm) socket wrench.
4. Reinstall the spark plug boot.

CARBURETOR ADJUSTMENTS

Your carburetor is equipped with limiter caps. Carburetor adjustment is a complicated task. We recommend that you take your unit to an authorized service dealer. Damage may occur if you turn the needles beyond the limiter stops.

TROUBLESHOOTING TABLE

WARNING: Always stop unit and disconnect spark plug before performing any of the recommended remedies below other than remedies that require operation of the unit.

TROUBLE	CAUSE	REMEDY
Engine will not start.	1. Engine flooded.2. Fuel tank empty.3. Spark plug not firing.4. Fuel not reaching carburetor.5. Compression low.	1. See "Starting a Flooded Engine" in Operation section.2. Fill tank with correct fuel mixture.3. Install new spark plug.4. Check for dirty fuel filter; replace. Check for kinked or split fuel line; repair or replace.5. Contact an authorized service dealer.
Engine will not idle properly.	1. Fuel not reaching carburetor.2. Carburetor requires adjustment.3. Crankshaft seals worn.4. Compression low.	1. Check for dirty fuel filter; replace. Check for kinked or split fuel line; repair or replace.2. See "Carburetor Adjustment" in Service and Adjustments section.3. Contact an authorized service dealer4. Contact an authorized service dealer.
Engine will not accelerate, lacks power, or dies under a load.	1. Air filter dirty.2. Fuel not reaching carburetor.3. Spark plug fouled.4. Carburetor requires adjustment.5. Carbon build up.6. Compression low.	1. Clean or replace air filter.2. Check for dirty fuel filter; replace. Check for kinked or split fuel line; repair or replace.3. Clean or replace spark plug and re-gap.4. See "Carburetor Adjustment" in Service and Adjustments section.5. Contact an authorized service dealer.6. Contact an authorized service dealer.
Engine smokes excessively.	1. Choke partially on.2. Fuel mixture incorrect.3. Air filter dirty.4. Carburetor requires adjustment.	1. Adjust choke.2. Empty fuel tank and refill with correct fuel mixture.3. Clean or replace air filter.4. See "Carburetor Adjustment" in Service and Adjustments section.
Engine runs hot.	1. Fuel mixture incorrect.2. Spark plug incorrect.3. Carburetor requires adjustment.4. Carbon build up.	1. See "Fueling Engine" in Operation section.2. Replace with correct spark plug.3. See "Carburetor Adjustment" in Service and Adjustments section.4. Contact an authorized service dealer.

LIMITED WARRANTY

Poulan PRO warrants to the original purchaser that each new Poulan PRO brand gasoline tool or attachment is free from defects in material and workmanship and agrees to repair or replace under this warranty any defective gasoline product or attachment as follows from the original date of purchase.

2 YEARS - Parts and Labor, when used for household purposes.

90 DAYS - Parts and Labor, when used for commercial, professional, or income producing purposes.

30 DAYS - Parts and Labor, if used for rental purposes.

This warranty is not transferable and does not cover damage or liability caused by improper handling, improper maintenance, or the use of accessories and/or attachments not specifically recommended by Poulan PRO for this tool. Additionally, this warranty does not cover tune-ups, spark plugs, filters, starter ropes, starter springs, cutting line, or rotating head parts that will wear and require replacement with reasonable use during the warranty period. This warranty does not cover predelivery setup or normal adjustments explained in the instruction manual.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.

NO CLAIMS FOR CONSEQUENTIAL OR OTHER DAMAGES WILL BE ALLOWED, AND THERE ARE NO OTHER EXPRESS WARRANTY EXCEPTIONS EXCEPT THOSE EXPRESSLY STIPULATED HEREIN.

SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS OR THE EXCLUSION OR LIMITATIONS OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATIONS OR EXCLUSION MAY NOT APPLY TO YOU.

The policy of Poulan PRO is to continuously improve its products. Therefore, Poulan PRO reserves the right to change, modify, or discontinue models, designs, specifications, and accessories of all products at any time without notice or obligation to any purchaser.