TB4920CC - Saw TROY-BILT - Free user manual and instructions

USER MANUAL TB4920CC TROY-BILT

SAVE THESE INSTRUCTIONS DO NOT THROW AWAY

WARNING • PLEASE READ

Beware of kickback. Hold chain saw firmly with both hands when using. For your own safety, please read and follow the safety precautions in this manual before attempting to operate your chain saw. Improper use can cause serious injury. This product has been tested at a computed kickback angle (CKA) and conforms to ANSI B175.1-2000, Annex C. CAN/CSA-Z62.1-03 2-Cycle Gas Chainsaws Model TB4620CC

Model TB4920CC2 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-to- understand 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. Copyright© 2004 MTD SOUTHWEST INC, All Rights Reserved. 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. S/N :ITEM :MODEL : 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.

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 Spark Arrestor Kit.

• Read the instructions carefully. Be familiar with thecontrols and proper use of the unit.• Do not operate this unit when tired, ill or under theinfluence of alcohol, drugs or medication.• Only responsible individuals who are familiar with theinstructions may operate the chain saw (no one underthe age of 16). Provide parental supervision at all times.• Inspect the unit before use. Replace damaged parts.Check for fuel leaks. Make sure all fasteners are inplace and secure. Replace parts that are cracked,chipped or damaged in any way. • Know the controls and know how to stop the chainsaw quickly.• Carry the chain saw with the engine stopped, theguide bar and saw chain to the rear, and the muffleraway from your body.• When transporting your chain saw, use theappropriate guide-bar scabbard (sheath). WHILE OPERATING
• Keep all parts of your body away from the chain whenthe engine is running.• Never start or run the unit inside a closed room orbuilding. Breathing exhaust fumes can kill. Operatethis unit only in a well ventilated outdoor area. • Wear safety glasses or goggles that are marked asmeeting ANSI Z87.1-1989 standards. Also wearear/hearing protection when operating this unit. Weara face or dust mask if the operation is dusty. Longsleeve shirts are recommended.• Wear heavy, long pants, boots or safety footwear andprotective gloves. Do not wear loose clothing, jewelry,short pants, sandals or go barefoot. Secure hair aboveshoulder level.• Use the unit only in daylight or good artificial light.• Avoid accidental starting. Be in the starting positionwhenever pulling the starter rope. The operator andunit must be in a stable position while starting. SeeStarting/Stopping Instructions.• Before you start the engine, make sure that the saw’schain is not contacting anything. Do not cut nearelectrical cables or power lines.• Keep all parts of your body away from the chain whenthe engine is running.• Do not start cutting until you have a clear work area,secure footing, and a planned retreat path from thefalling tree.

RULES FOR SAFE OPERATION

SYMBOL MEANINGThe purpose of safety symbols is to attract yourattention to possible dangers. The safety symbols,and their explanations, deserve your careful attentionand understanding. The safety warnings do not bythemselves eliminate any danger. The instructions orwarnings they give are not substitutes for properaccident prevention measures.NOTE: Advises you of information or instructions vital tothe operation or maintenance of the equipment.SYMBOL MEANING If correctly used, the chain saw is a quick, easy to handle and efficient tool; if used improperly or without the due precautions it could become a dangerous tool. For pleasant and safe work,always strictly comply with the safety rules that follow and throughout this manual.

• IMPORTANT SAFETY INSTRUCTIONS • 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.

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.

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 allwarnings and safety instructions.Failure to do so can result in serious injury to theoperator and/or bystanders.

• Do not operate a chain saw that is damaged, improperly adjusted, or not completely and securely assembled. Be sure that the saw’s chain stops moving when the throttle control trigger is released.

• Shut off the engine before setting the chain saw down.

• Use extreme caution when cutting small-sized brush and saplings because slender material may catch the chain saw and whip towards you or pull you off balance.

• When cutting a limb that is under tension, be alert for springback so that you will not be struck when the tension in the wood fibers is released

• Do not cut through nails, rods in the tree, railroad ties or pallates. Inspect a tree that you are going to cut for foreign objects that could cause injury or damage to your chain saw.

• After striking a foreign object, stop the engine and thoroughly inspect for damage. Repair as necessary.

• Keep the handles dry, clean and free of the oil/fuel mixture

• We do not recommend using the chain saw in a tree or on a ladder.

• All chain saw service, other that the items listed in this instruction manual maintenance instructions, should be performed by competent chain saw service personnel.

• Use the right tool. Only use this chain saw for its intended purpose, to cut wood.

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

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

• Apply chain brake prior to any repositioning of the operator in the cutting area. As an additional safety precaution, apply the chain brake prior to setting down the saw.

• Never touch the chain or attempt to service the saw while the engine is running. Make sure all moving parts have stopped. Allow the chain saw to cool, as the chain can be hot.

• Check the bar and chain at frequent intervals for proper adjustment. Make sure the bar and chain are properly tightened and sharpened. Visually inspect for damage. Repair any damage before restarting or operating the chain saw.

KICKBACK SAFETY PRECAUTIONS

• With a basic understanding of kickback, you can reduce or eliminate the element of surprise. Sudden surprise contributes to accidents. Be alert to the potential for kickback at all times.

• Keep a good firm grip on the saw with both hands, the right hand on the rear handle and the left hand on the front handle, when the engine is running. Use a firm grip with thumbs and fingers encircling the chain saw handles. A firm grip will help you reduce kickback and maintain control of the saw. Don’t let go.

• Make sure that the area in which you are cutting is free from obstructions. Do not let the nose of the guide bar contact a log, branch, fence, or any other obstruction that could be hit while you are operating the saw.

• Always cut with the engine running at full speed. Fully squeeze the throttle trigger and maintain a steady cutting speed.

• Use only the correct original equipment manufacturer replacement bars, chains and other parts and accessories. 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 will void your warranty.

• Follow the manufacturer’s sharpening and maintenance instructions for the saw chain.

• Use only the replacement guide bars and low kickback chains specified for your saw to avoid injury. KICKBACK may occur when the nose or tip of the guide bar touches an object, or when the wood closes in and pinches the saw chain in the cut. Tip contact in some cases may cause a lightning-fast reverse reaction, kicking the guide bar up and back towards the operator. Pinching the saw chain along the top of the guide bar may push the guide bar rapidly back toward the operator. Either of these reactions may cause you to lose control of the saw, which could result in serious personal injury. Do not rely exclusively upon the safety devices built into your saw. As a chain saw user, you should take several steps to keep your cutting jobs free from accident or injury.

• Do not operate a chain saw with one hand! Serious injury to the operator, helpers, bystanders, or any combination of these persons may result from one- handed operation. A chain saw is intended for two- handed use.

• Do not operate a chain saw if you are fatigued.

• Use safety footwear; snug-fitted clothing; protective gloves; and eye, hearing, and head protection devices.

• Do not allow other persons to be near the chain saw when starting or cutting with the chain saw. Keep bystanders and animals out of the work area.

• Do not remove, damage or de-activate any of the safety devices. Never use a damaged, modified, or improperly repaired or assembled chain saw. Check their proper operation regularly. Only use bars and chains of the length indicated in the table herein.

• Never carry out operations or repairs on your own that are other than routine maintenance. For information, contact specialized and authorized workshops only.

• If your chain saw is no longer usable, dispose of it properly without damaging the environment by handing it in to your local dealer who will arrange for its correct disposal.

• Use caution when felling a tree. Make sure you have planned an escape path when felling, and keep all bystanders away.

• Be alert; stop the machine if anyone enters the cutting area, which is usually 3 to 4 feet around the operator.

• Use caution when working in a crew to avoid injury to a fellow worker who may enter the cutting area.

• Only loan your saw to experienced users who are completely familiar with saw operation and correct use. Give other users this manual, which they should read before using the saw. Provide them the operating instructions.

• Shut off the engine before setting down the saw. Do not leave the engine running unattended.

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

• Allow the engine to cool before storing or transporting the chain saw over long distances. For example, let the engine cool before placing the chain saw in an automobile. Also, be sure to secure the unit while transporting.

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

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

• 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.

• Do not use the unit in the rain, in a storm or in inclement weather. Wait until the storm danger has passed before operation of this product. FUEL SAFETY

• Store fuel only in containers specifically designed and approved for the storage of such materials.

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

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

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

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

RULES FOR SAFE OPERATION

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

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

• 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, HEARING AND HARDHAT 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. Wear a hard hat. Use a full face shield when needed.

• UNLEADED FUEL Always use clean, fresh unleaded fuel.

• OIL Refer to operator's manual for the proper type of oil. SYMBOL MEANING

• GUIDE BAR WARNING: Contact of the guide bar tip with any object should be avoided. Tip contact may cause the guide bar to move suddenly upward and backward, which may cause serious injury.

• USE BOTH HANDS Always use both hands while operating the chain saw. Never use only one hand to operate the saw. Avoid bar nose contact.

SAFETY FEATURES Numbers preceding the descriptions correspond with the numbers above to help you locate the safety feature. 2 LOW KICKBACK SAW CHAIN helps significantly reduce kickback, or the intensity of kickback, due to specially designed depth gauges and guard links. 4 SPARK ARRESTER SCREEN retains carbon and other flammable particles over 0.023 inches (0.6mm) in size from engine exhaust flow. Compliance with local, state and federal laws and/or regulations governing the use of a spark arrester screen is the user’s responsibility. See Safety Precautions for additional information. 5 CHAIN BRAKE® LEVER / HAND GUARD protects the operator’s left hand in the event it slips off the front handle while saw is running. 5 CHAIN BRAKE® is a safety feature designed to reduce the possibility of injury due to kickback by stopping a moving saw chain in milliseconds. It is activated by the CHAIN BRAKE® lever. 10 STOP SWITCH immediately stops the engine when tripped. Stop switch must be pushed to ON position to start or restart engine. 11 SAFETY TRIGGER prevents accidental acceleration of the engine. Throttle trigger (19) cannot be squeezed unless the safety latch is depressed. 20 CHAIN CATCHER reduces the danger of injury in the event saw chain breaks or derails during operation. The chain catcher is designed to intercept a whipping chain.

23. CARRY CASE (Available on some models)

KICKBACK SPECIFICS Beware of: Rotational Kickback Kickback can lead to dangerous loss of control of the chain saw and result in serious or fatal injury to the saw operator or to anyone standing close by. Always be alert. Rotational kickback and pinch-kickback are major chain saw operational dangers and the leading cause of most accidents.

A = Kickback path B = Kickback reaction zone Fig. 1 KICKBACK SPECIFICS Beware of: Pinch Kickback Fig. 2 A = Pull B = Solid objects C = Push KICKBACK may occur when the NOSE or TIP of the guide bar touches an object, or when wood closes in and pinches the saw chain in the cut. Tip contact in some cases may cause a lightning-fast reverse reaction, kicking the guide bar up and back toward the operator. PINCHING the saw chain along the BOTTOM of the guide bar may PULL the saw forward away from the operator. PINCHING the saw chain along the TOP of the guide bar may PUSH the guide bar rapidly back toward the operator. Any of these reactions may cause you to lose control of the saw, which could result in serious personal injury.9

OIL AND FUEL INFORMATION

NOTE: Dispose of the old fuel/oil mix in accordance toFederal, State and Local regulations.

OIL AND FUEL MIXING INSTRUCTIONS

Old and/or improperly mixed fuel are the main reasonsfor the unit not running properly. Be sure to use fresh,clean unleaded fuel. Follow the instructions carefully forthe proper fuel/oil mixture. Definition of Blended Fuels Today's fuels are often a blend of gasoline andoxygenates 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. It formsacids when stored. When using alcohol-blended fuel,use fresh fuel (less than 60 days old). Using Blended Fuels If you choose to use a blended fuel, or its use isunavoidable, follow recommended precautions:• Always use the fresh fuel mix explained in youroperator's manual• Always agitate the fuel mix before fueling the unit• Drain the tank and run the engine dry before storingthe unit Using Fuel Additives The bottle of 2-cycle oil that came with your unitcontains a fuel additive which will help inhibit corrosionand minimize the formation of gum deposits. It isrecommended that you use our 2-cycle oil with this unit. If unavailable, use a good 2-cycle oil designed forair-cooled engines along with a fuel additive, such asSTA-BIL Gas Stabilizer or an equivalent. Add 0.8 oz.(23 ml.) of fuel additive per gallon of fuel according to theinstructions on the container. NEVER add fuel additivesdirectly to the unit's fuel tank.Thoroughly mix the proper ratio of 2-cycle engine oilwith unleaded gasoline in a separate fuel can. Use a 40:1fuel/oil ratio. Do not mix them directly in the engine fueltank. See the table below for specific gas and oil mixingratios.NOTE: One gallon (3.8 liters) of unleaded gasoline mixedwith one 3.2 oz. (95 ml.) bottle of2-cycle oil makes a 40:1 fuel/oil ratio.UNLEADED GAS 2 CYCLE OIL1 GALLON US(3.8 LITERS)3.2 FL. OZ.(95 ml) 1 LITER 25 ml MIXING RATIO - 40:1Add fuel in a clean,well ventilatedoutdoor area. Wipe up any spilled fuelimmediately. Avoid creating a source ofignition for spilt fuel. Do not start the engineuntil fuel vapors dissipate.

Gasoline isextremelyflammable. Ignited Vapors may explode.Always stop the engine and allow it to coolbefore filling the fuel tank. Do not smokewhile filling the tank. Keep sparks and openflames at a distance from the area.

Remove fuel capslowly to avoid injuryfrom fuel spray. Never operate the unitwithout the fuel cap securely in place

For proper engineoperation andmaximum reliability, pay strict attention tothe oil and fuel mixing instructions on the2-cycle oil container. Using improperly mixedfuel can severely damage the engine. CAUTION:10

STARTING/STOPPING INSTRUCTIONS

Operate this unit only in a well- ventilated outdoor area. Carbon monoxide exhaust fumes can be lethal in a confined area.

Never operate the saw without the bar and chain properly installed.

1. Mix gas with oil. Fill fuel tank (Fig. 3) with fuel/oil

mixture. See Oil and Fuel Mixing Instructions.

2. Fill the oil tank (B) with correct chain and bar oil (Fig. 3).

3. Be certain the Chain Brake® is disengaged (C) before

Lever (H) has 3 positions: Positions 1, 2 and 3 (Fig. 6).

5. Fully press and release the primer bulb (G) 10 times,

slowly. Some amount of fuel should be visible in the primer bulb (Fig. 5). 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.

6. Move the lever (H) to Position 1 (Fig. 6).

NOTE: This unit will not run with the lever in Position 1.

7. Place the saw on a firm flat surface. Hold saw firmly

8. Hold down safety trigger (E) and squeeze the throttle

trigger (D). With thumb, press down on the throttle latch (F). This will lock the throttle into wide open position (Fig. 3). Pull the rope with a controlled and steady motion 4 times. NOTE: The unit uses Spring Assist Starting™, which significantly reduces the effort required to start the engine. You must pull the starter rope out far enough to hear the engine attempt to start. There is no need to pull the rope briskly-- there is no harsh resistance when pulling. Be aware that this starting method is vastly different from (and much easier than) what you may be used to.

Then move the lever (H) to Position 2, being sure to keep the throttle control locked. Hold saw firmly and pull rope until saw starts. This could take 4 more pulls.

10. Let the saw warm up for 10 seconds. Depress and

release trigger (F) for idle.

11. Move lever (H) to Position 3. If engine fails to start,

repeat these instructions. STARTING INSTRUCTIONS

Fig. 3Fig. 4Fig. 5Fig. 6Fig. 711 NOTE: In some cases due to operating conditions(altitude, temperature etc.) your chain saw mayneed a slight adjustment to the idle speed. If unitdoes not Idle after restarting 2 times, follow thesesteps to adjust idle.1. Idle adjustment access (L) - the symbol "T" (forthrottle) is below the adjustment hole (Fig. 8).2. Using a Phillips or slotted screwdriver - turn screw1/4 to 1/2 turn clockwise (to the right). Unit shouldthen idle properly (Fig. 9).NOTE: If chain turns while idling - turn screw back to theleft until chain stops and unit continues to idle.NOTE: When starting a warm engine, go back to Step 3.Follow the steps until Step 8. Then, move thelever to Position 3 and release the throttle trigger. STOPPING INSTRUCTIONS 1. Release the trigger and allow the engine to return tothe idle speed.2. Move the STOP switch to the STOP position.NOTE: For emergency stopping, simply activate the Chain Brake® and move the STOP switch down. Fig. 8Fig. 9

Activate the CHAIN BRAKE® slowly and deliberately. Keep the chain from touching anything; don’t let the saw tip forward.

If chain does not stop, turn engine off and take your unit to the nearest Authorized Service Center for service.

OTHER INSTRUCTIONS Chain Brake® Test 1. Place saw on a clear, firm, flat surface.2. Start engine.3. Grasp the rear handle (A) with your right hand (Fig. 10).4. With your left hand, hold the front handle (B) [notChain Brake® lever (C)] firmly (Fig. 10).5. Squeeze the throttle trigger to 1/3 throttle, then imm-ediately activate the Chain Brake® lever (C) (Fig. 10).6. Chain should stop abruptly. When it does,immediately release the throttle/trigger.7. If Chain Brake® functions properly, turn the engineoff and return the Chain Brake® to the DISENGAGEDposition. Chain Lubrication Adequate lubrication of the saw chain is essential at alltimes to minimize friction with the guide bar. Never starvethe bar and chain of oil. Running the saw with too little oilwill decrease cutting efficiency, shorten saw chain life,cause rapid dulling of chain, and cause excessive wearof bar from overheating. Too little oil is evidenced bysmoke, bar discoloration or pitch build-up. Automatic Oiler Your chain saw is equipped with an automatic gear drivenoiler system. The oiler automatically delivers the properamount of oil to the bar and chain. As the engine speedincreases, so does the oil flow to the bar pad. The amountof oil flowing to the bar and chain may be changed byturning the adjustment screw (D) as shown in Fig. 11.Turn the screw clockwise to DECREASE oil flow andcounterclockwise to INCREASE the flow.

Do not cut down a tree during high or changing winds or if there is a danger to property. Consult a tree professional.Do not cut down a tree if there is a danger of striking utility wires; notify the utility company before making any cuts.

FELLING Felling is the term for cutting down a tree. Small trees up to 6-7 inches (15-18cm) in diameter are usually cut in a single cut. Larger trees require notch cuts. Notch cuts determine the direction the tree will fall. NOTE: Direction of fall (B) is controlled by the notching cut. Before any cuts are made, consider the location of larger branches and natural lean of the tree to determine the way the tree will fall. A retreat path (A) should be planned and cleared as necessary before cuts are started. The retreat path should extend back and diagonally to the rear of the expected line of fall, as illustrated in Fig. 12.

If felling a tree on sloping ground, the chain saw operator should keep on the uphill side of the terrain, as the tree is likely to roll or slide downhill after it is felled. CAUTION: Fig. 12Fig. 13 Normally felling consists of 2 main cutting operations, notching (C) and making the felling cut (D). Start making the upper notch cut (C) on the side of the tree facing the felling direction (E). Be sure you don t make the lower cut too deep into the trunk. The notch (C) should be deep enough to create a hinge (F) of sufficient width and strength. The notch should be wide enough to direct the fall of the tree for as long as possible. Never walk in front of a tree that has been notched.

Never saw completely through the trunk. Always leave a hinge. The hinge guides the tree. If the trunk is completely cut through, control over the felling direction is lost. Insert a wedge or felling lever in the cut well before the tree becomes unstable and starts to move. This will prevent the guidebar from binding in the felling cut if you have misjudged the falling direction. Make sure no bystanders have entered the range of the falling tree before you push it over. Before making the final cut, always recheck the area for bystanders, animals or obstacles.

Make the felling cut (D) from the other side of the tree and 1.5 - 2.0 inches (3-5 cm) above the edge of the notch (C) (13 9).

1. Use wooden or plastic wedges (G) to prevent binding

the bar or chain (H) in the cut. Wedges also control felling (Fig. 14).

2. When diameter of wood being cut is greater than the

bar length, make 2 cuts as shown (Fig. 15). As the felling cut gets close to the hinge, the tree should begin to fall. When tree begins to fall, remove saw from cut, stop engine, put chain saw down, and leave area along retreat path (Fig. 12).

LIMBING Limbing a tree is the process of removing the branches from a fallen tree. Do not remove supporting limbs (A) until after the log is bucked (cut) into lengths (Fig. 16). Branches under tension should be cut from the bottom up to avoid binding the chain saw. BUCKING Bucking is cutting a fallen log into lengths. Make sure you have a good footing and stand uphill of the log when cutting on sloping ground. If possible, the log should be supported so that the end to be cut off is not resting on the ground. If the log is supported at both ends and you must cut in the middle, make a downward cut halfway through the log and then make the undercut. This will prevent the log from pinching the bar and chain. Be careful that the chain does not cut into the ground when bucking as this causes rapid dulling of the chain. Fig. 16Fig. 17 Never cut tree limbs while standing on a tree trunk.

When bucking on a slope, always stand on the uphill side.

1. Log supported along entire length: Cut from top

(overbuck), being careful to avoid cutting into the ground (Fig. 17).

2. Log supported on 1 end: First, cut from bottom

(underbuck) 1/3 diameter of log to avoid splintering. Second, cut from above (overbuck) to meet first cut and avoid pinching (Fig. 18).

3. Log supported on both ends: First, overbuck 1/3

diameter of log to avoid splintering. Second, underbuck to meet first cut and avoid pinching (Fig. 19). NOTE: The best way to hold a log while bucking is to use a sawhorse. When this is not possible, the log should be raised and supported by the limb stumps or by using supporting logs. Be sure the log being cut is securely supported.

BUCKING USING A SAWHORSE

For personal safety and ease of cutting, the correct position for vertical bucking is essential (Fig. 20). A. Hold the saw firmly with both hands and keep the saw to the right of your body while cutting. B. Keep the left arm as straight as possible. C. Keep weight on both feet. Fig. 20Fig. 19Fig. 18

While the saw is cutting, be sure the chain and bar are being properly lubricated. CAUTION:14

MAINTENANCE AND REPAIR INSTRUCTIONS

MAINTENANCE SCHEDULE Perform these required maintenance procedures at the frequency stated in the table. These procedures should also be a part of any seasonal tune-up. NOTE: Some maintenance procedures may require special tools or skills. If you are unsure about these procedures take your unit to any non-road engine repair establishment, individual or authorized service dealer. NOTE: Maintenance, replacement, or repair of the emission control devices and system may be performed by any non-road engine repair establishment, individual or authorized service dealer. 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.

1. Make sure the Chain Brake® lever is pulled back intothe DISENGAGED position (Fig. 21).2. Remove the 2 bar retaining nuts (B) at front of theChain Brake® cover (C). Remove outer guide barplate (M, Fig. 27) by pulling straight out (Fig. 22).3. Place the slotted end of the guide bar over the 2 barbolts (D). Fig. 23

INSTALL THE SAW CHAIN

1. Spread chain out in a loop with cutting edges (E)pointing CLOCKWISE around loop (Fig. 24).2. Slip the chain around the sprocket (F) behind theclutch (G). Make sure the links fit between thesprocket teeth (Fig. 25).3. Guide the drive links into the groove (H) and aroundthe end of the bar (Fig. 25).4. The chain will be tight so you will have to rotate theclutch clockwise by hand so the chain engages thebar sprocket.5. Replace the outer guide bar plate (I) so the bentedges (top and bottom) are directed away from thechain (Fig. 27).6. Install spike on Chain Brake® cover as shown inFig. 27 (Optional accessory).7. Install the Chain Brake® cover (Fig. 27). Make surethe chain does not slip off of the bar. Install the 2nuts hand tight and follow instructions in Saw ChainTension Adjustment.NOTE: The guide bar retaining nuts are installed onlyhand tight at this point because saw chainadjustment is required. Follow instructions inSaw Chain Tension Adjustment.Always useprotective gloveswhen handling the saw chain.

To ensure the bar and chain receive oil, ONLY USE THE ORIGINAL STYLE BAR with the oil passage hole (A) as illustrated in Fig. 21. CAUTION:

SAW CHAIN TENSION ADJUSTMENT

Proper tension of saw chain is extremely important andmust be checked before starting, as well as during anycutting operation.Taking the time to make needed adjustments to the sawchain will result in improved cutting performance andprolonged chain life.To asjust the saw chain:1. Loosen the bar retaining nut(s) (B, Fig. 22). Hold noseof guide bar up and turn adjustment screw (D)CLOCKWISE to increase chain tension. Turningscrew COUNTERCLOCKWISE will decrease amountof tension on chain. Ensure the chain fits snugly allthe way around the guide bar (Fig. 28).Always useprotective gloveswhen handling the saw chain.

Fig. 292. After making adjustment, and while still holding noseof bar in the uppermost position, tighten the barretaining nut securely. Chain has proper tensionwhen it has a snug fit all around and can be pulledaround by gloved hand.NOTE: If chain is difficult to rotate on guide bar or if itbinds, too much tension has been applied. Thisrequires minor adjustment as follows:A. Loosen the bar retaining nut so it is finger tight.Decrease tension by turning the bar adjustmentscrew COUNTERCLOCKWISE slowly. Move chainback and forth on bar. Continue to adjust until chainrotates freely, but fits snugly. Increase tension byturning bar adjustment screw CLOCKWISE.B. When saw chain has proper tension, hold nose of barin uppermost position and tighten the bar retainingnut securely. A new saw chain stretches, requiring adjustment after as few as 5 cuts. This is normal with a new chain, and the interval between future adjustments will lengthen quickly. CAUTION: If saw chain is TOO LOOSE or TOO TIGHT, the sprocket, bar, chain, and crankshaft bearings will wear more rapidly. Study Fig. 29 for information concerning correct cold tension (A), correct warm tension (B), and as a guide for when saw chain needs adjustment (C). CAUTION: Fig. 30

CHAIN BRAKE MECHANICAL TEST

Your chain saw is equipped with a Chain Brake® thatreduces possibility of injury due to kickback. The brakeis activated if pressure is applied against brake leverwhen, as in the event of kickback, operator’s handstrikes the lever. When the brake is actuated, chainmovement stops abruptly.To Test the Chain Brake®:

1. The Chain Brake® is DISENGAGED (chain can

move) when BRAKE LEVER IS PULLED BACK ANDLOCKED (A, Fig. 24).2. The Chain Brake® is ENGAGED (chain is stopped) when brake lever is in forward position. You shouldnot be able to move chain (B, Fig. 30).NOTE: The brake lever should snap into both positions.If strong resistance is felt, or lever does not moveinto either position, do not use your saw. Take itimmediately to a Authorized Service Center forrepair. Call 1-800-520-5520 for more information. The purpose of the Chain Brake® is to reduce the possibility of injury due to kickback; however, it cannot provide the intended measure of protection if the saw is operated carelessly. Always test the Chain Brake® before using your saw and periodically while on the job.

1. Remove air box cover and air filter as shown in Fig. 31.

Disconnect fuel hose (A) from carburetor fitting (Fig. 32).

3. Pull fuel filter (C) out of tank with a bent wire (D) or

long needle nosed pliers. Disconnect filter and discard (Fig. 32). NOTE: Do not pull hose completely out of tank.

4. Install a new fuel filter on hose and pull hose/filter

assembly back into tank so filter is positioned in front right corner.

5. Reconnect fuel hose (A) to carburetor fitting (B) (Fig. 32).

Replace air filter and air box cover.

6. Fill tank with fresh fuel / oil mixture. See Oil and Fuel

1. Remove the top cover (A) by loosening the cover

retaining screws. Cover will lift off (Fig. 31).

2. Clean air filter. Wash filter in clean, warm, soapy

water. Rinse in clear, cool water. Air dry completely. NOTE: It is advisable to have a supply of spare filters.

3. Install air filter. Install engine / air filter cover. Make

sure cover fits properly. Tighten the cover retaining screws securely. Never operate saw without the air filter. Dust and dirt wil be drawn into engine and damage it. Keep the air filter clean. CAUTION: To avoid serious personal injury, always turn your unit off and allow it to cool before you clean or service it.

Never operate saw without the fuel filter. The fuel filter should be replaced after each 20 hours of use. Drain fuel tank before changing. CAUTION:

OIL FILTER NOTE: Drain oil tank before changing filter

1. Disconnect oil hose (A) from pump fitting (B) (Fig. 33).

2. Use a wire with a hook (C) and pull oil filter (D) from

tank. Remove filter and hose completely.

3. Insert a length of hose into tank and pull it through

4. Install a new filter on hose and pull hose back into

tank so filter is positioned in bottom of tank.

5. Cut hose to fit and push it on to oil pump fitting.

SPARK PLUG NOTE: For efficient operation of saw engine, spark plug must be kept clean and properly gapped.

1. Push STOP switch up.

2. Remove top Cover. Disconnect the wire connector

from the spark plug by pulling and twisting at the same time (Fig. 35).

3. Remove spark plug with spark plug socket wrench.

DO NOT USE ANY OTHER TOOL.

4. Check electtrode gaps with wire feeler gauge and set

gaps to .025” (.635mm) if necessary.

5. Reinstall a new spark plug.

NOTE: A resistor spark plug must be used for replacement (part no. 9295-320001). NOTE: This spark ignition system meets all requirements of the Canadian Interferen-Causing Equipment Regulations. Do not sand blast, scrape or clean electrodes. Grit in the engine could damage the cylinder.

Fig. 35 CARBURETOR ADJUSTMENT The carburetor was pre-set at the factory for optimum performance. If further adjustments are necessary, please take your unit to the nearest Authorized Service Center listed in the Yellow Pages. Call 1-800-520-5520 for more information.

NOTE: A clogged spark arrester screen will dramatically reduce engine performance.

1. Remove 2 muffler retaining nuts (E), Lock plate (F)

and muffler cover(G) (Fig. 34).

2. Remove spark arrester screen (H) from the metal

baffle (J). Replace screen with new one.

3. Reassemble the muffler components and tighten nuts

Storing a chain saw for longer than 30 days requiresstorage maintenance. Unless the storage instructions arefollowed, fuel remaining in the carburetor will evaporate,leaving gum-like deposits. This could lead to difficultstarting and result in costly repairs.1. Remove the fuel tank cap slowly to release anypressure in tank. Carefully drain the fuel tank.2. Start the engine and let it run until the unit stops toremove fuel from carburetor.3. Allow the engine to cool (approx. 5 minutes).4. Using a spark plug wrench, remove the spark plug.5. Pour 1 teaspoon of clean 2-cycle oil into thecombustion chamber. Pull starter rope slowly severaltimes to coat internal components. Replace sparkplug (Fig. 36).NOTE: Store the unit in a dry place and away frompossible sources of ignition such as a furnace,gas hot water heater, gas dryer, etc.Fig. 36

REMOVING A UNIT FROM STORAGE

1. Remove spark plug.2. Pull starter rope briskly to clear excess oil fromcombustion chamber.3. Clean and gap spark plug or install a new spark plugwith proper gap.4. Prepare unit for operation.5. Fill fuel tank with proper fuel / oil mixture. See Oiland Fuel Information. Never store a chain saw for longer than 30 days without performing the following procedures. CAUTION: Sprocket Tip Lubrication The Lube Gun (optional) is recommended for applyinggrease to the guide bar sprocket tip. The Lube Gun isequipped with a needle nose tip which is necessary forthe efficient application of grease to the sprocket tip. The sprocket tip on your new saw has been pre-lubricated at the factory. Failure to lubricate the guide bar sprocket tip as explained below will result in poor performance and seizure, voiding the manufacturer’s warranty. Lubrication of the sprocket tip is recommended after 10 hours of use or once a week, which ever occurs first. Always thoroughly clean guide bar sprocket tip before lubrication. CAUTION: Fig. 37To lubricate the sprocket tip:1. Move the STOP switch down.NOTE: It is not necessary to remove the saw chain tolubricate the guide bar sprocket tip. Lubricationcan be done on the job.2. Clean the guide bar sprocket tip.3. Using the Lube Gun (optional), insert tip of lube guninto the lubrication hole and inject grease until itappears at outside edge of sprocket tip (Fig. 37).4. Rotate saw chain by hand. Repeat lubrication procedureuntil the entire sprocket tip has been greased.

SAW CHAIN / BAR LUBRICATION

Adequate lubrication of the saw chain is essential at alltimes to minimize friction with the guide bar.Never starve the bar and chain of oil. Running the sawwith too little oil will decrease cutting efficiency, shortensaw chain life, cause rapid dulling of chain, and causeexcessive wear of bar from overheating. Too little oil isevidenced by smoke, bar discoloration or pitch build-up.NOTE: Saw chain stretches during use, particularly whenit is new, and it will occasionally be necessary toadjust and tighten it. New chain will requireadjustment after about 5 minutes of operation. AUTOMATIC OILER Refer to Section Other Instructions: Automatic Oiler for information on the automatic oiler.

GUIDE BAR MAINTENANCE

Frequent lubrication of the guide bar (railed bar whichsupports and carries the saw chain) sprocket tip isrequired. Proper maintenance of the guide bar, asexplained in this section, is essential to keep your saw ingood working condition.20 GUIDE BAR MAINTENANCE: Most guide bar problems can be prevented merely bykeeping the chain saw well maintained.Insufficient guide bar lubrication and operating the sawwith chain that is too tight will contribute to rapid bar wear.To help minimize bar wear, the following guide barmaintenance procedures are recommended.BAR WEAR - Turn guide bar frequently at regularintervals (for example, after 5 hours of use), to ensureeven wear on top and bottom of bar.BAR GROOVES - Bar grooves (or rails which support andcarry the chain) should be cleaned if saw has been usedheavily or if saw chain appears dirty. Rails should alwaysbe cleaned every time saw chain is removed.OIL PASSAGES - Oil passages on the bar should becleaned to ensure proper lubrication of the bar and chainduring operation.NOTE: The condition of the oil passages can be easilychecked. If the passages are clear, the chain willautomatically give off a spray of oil withinseconds of starting the saw. Your saw isequipped with an automatic oiler system. CHAIN MAINTENANCE Chain Tension Check the chain tension frequently and adjust as often asnecessary to keep the chain snug on the bar, but looseenough to be pulled around by hand. Breaking in a New Saw Chain A new chain and bar will need chain readjustment afteras few as 5 cuts. This is normal during the break-inperiod, and the interval between future adjustments willbegin to lengthen quickly.

MAINTENANCE AND REPAIR INSTRUCTIONS

Never have more than 3 links removed from a loop of chain. This could cause damage to the sprocket.

CHAIN REPLACEMENT INFORMATION

There may be other quality equivalent replacementcomponents for achieving kickback protection.

INERTIA CHAIN BRAKE® ACTION

NOTE: THIS SAW IS EQUIPPED WITH AN INERTIACHAIN BRAKE. IF THE SAW KICKS BACKWHILE IN USE, THE INERTIA OF THE MOVINGSAW WILL ACTIVATE THE BRAKE. A BRAKEBAND AROUND THE CLUTCH DRUMACTIVATES AND STOPS THE MOVING CHAIN. Bar Length Drive Links Part Number 20” Bar 78 DL 49M2078P753

CHAIN REPLACEMENT INFORMATION

There may be other quality equivalent replacementcomponents for achieving kickback protection. Chain Lubrication Always make sure the automatic oiler system is workingproperly. Keep the oil tank filled with Genuine FactoryParts Chain, Bar and Sprocket Oil.Adequate lubrication of the bar and chain during cuttingoperations is essential to minimize friction with the guide bar.Never starve the bar and chain of lubricating oil. Runningthe saw dry or with too little oil will decrease cuttingefficiency, shorten saw chain life, cause rapid dulling ofchain, and lead to excessive wear of bar fromoverheating. Too little oil is evidenced by smoke or bardiscoloration. Chain Sharpening Chain sharpening requires special tools to ensure thatcutters are sharpened at the correct angle and depth. Forthe inexperienced chain saw user, we recommend thatthe saw chain be professionally sharpened by thenearest Authorized Service Center. If you feelcomfortable sharpening your own saw chain, specialtools are available from your Authorized Service Center.21 TROUBLESHOOTING If further assistance is required, contact your authorized service dealer. Call 1-800-520-5520 for more information. CAUSE ACTION Incorrectly gapped spark plug Clean / gap or replace plug CAUSE ACTION Incorrect carburetor mixture adjustment setting Have carburetor adjusted by Authorized Service Center CAUSE ACTION Incorrect starting procedures Follow instructions in the Starting/Stopping section Incorrect carburetor mixture adjustment setting Have carburetor adjusted by Authorized Service Center Fouled spark plug Clean / gap or replace plug UNIT WON’T START OR STARTS BUT WILL NOT RUN UNIT STARTS, BUT ENGINE HAS LOW POWER ENGINE HESITATES

CAUSE ACTION Fuel filter is plugged Replace the fuel filter Incorrect lever position Move to Position 3 Dirty spark arrester screen Replace spark arrester screen. Dirty air filter Remove, clean and reinstall filter. Incorrect carburetor mixture adjustment setting Have carburetor adjusted by Authorized Service Center CAUSE ACTION Incorrect carburetor mixture adjustment setting Have carburetor adjusted by Authorized Service Center RUNS ERATICALLY CAUSE ACTION Incorrect carburetor mixture adjustment setting Have carburetor adjusted by Authorized Service Center Incorrect fuel mixture Use properly mixed fuel (40:1 mixture) SMOKES EXCESSIVELYMANUFACTURER’S LIMITED WARRANTY FOR: No implied warranty, including any implied warranty of merchantability or fitness for a particular purpose, applies after the applicable period of express written warranty above as to the parts as identified. No other express warranty or guaranty, whether written or oral, except as mentioned above, given by any person or entity, including a dealer or retailer, with respect to any product shall bind Troy-Bilt LLC During the period of the Warranty, the exclusive remedy is repair or replacement of the product as set forth above. (Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.) The provisions as set forth in this Warranty provide the sole and exclusive remedy arising from the sales. Troy- Bilt LLC shall not be liable for incidental or consequential loss or damages including, without limitation, expenses incurred for substitute or replacement lawn care services, for transportation or for related expenses, or for rental expenses to temporarily replace a warranted product. (Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.) In no event shall recovery of any kind be greater than the amount of the purchase price of the product sold. Alteration of the safety features of the product shall void this Warranty. You assume the risk and liability for loss, damage, or injury to you and your property and/or to others and their property arising out of the use or misuse or inability to use the product. This limited warranty shall not extend to anyone other than the original purchaser, original lessee or the person for whom it was purchased as a gift. How State Law Relates to this Warranty: This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. To locate your nearest service dealer dial 1-800-520-5520. Troy-Bilt LLC P.O. Box 361131 Cleveland, OH 44136-0019 The limited warranty set forth below is given by Troy-Bilt LLC with respect to new merchandise purchased and used in the United States, its possessions and territories. Troy-Bilt LLC warrants this product against defects in material and workmanship for a period of One (1) year commencing on the date of original purchase and will, at its option, repair or replace, free of charge, any part found to be defective in material or workmanship. This limited warranty shall only apply if this product has been operated and maintained in accordance with the Operator’s Manual furnished with the product, and has not been subject to misuse, abuse, commercial use, neglect, accident, improper maintenance, alteration, vandalism, theft, fire, water or damage because of other peril or natural disaster. Damage resulting from the installation or use of any accessory or attachment not approved by Troy-Bilt LLC for use with the product(s) covered by this manual will void your warranty as to any resulting damage. This warranty is limited to ninety (90) days from the date of original retail purchase for any Troy-Bilt product that is used for rental or commercial purposes, or any other income-producing purpose. HOW TO OBTAIN SERVICE: Warranty service is available, WITH PROOF OF PURCHASE THROUGH YOUR LOCAL AUTHORIZED SERVICE DEALER. To locate the dealer in your area, visit our website at www.troybilt.com, check for a listing in the Yellow Pages, call 1-800-520- 5520 or write to P.O. Box 361131, Cleveland, OH 44136-

This limited warranty does not provide coverage in the following cases: A. Tune-ups - Spark Plugs, Carburetor Adjustments, Filters B. Wear items - Bump Knobs, Outer Spools, Cutting Line, Inner Reels, Starter Pulley, Starter Ropes, Drive Belts C. Troy-Bilt LLC does not extend any warranty for products sold or exported outside of the United States of America, its possessions and territories, except those sold through Troy-Bilt’s authorized channels of export distribution. Troy-Bilt LLC reserves the right to change or improve the design of any Troy-Bilt Product without assuming any obligation to modify any product previously manufactured.F9

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