TB475SS - Grass trimmer TROY-BILT - Free user manual and instructions

USER MANUAL TB475SS TROY-BILT

Operator’s Manual PRINTED IN U.S.A. PART NO. 769-01361 (10/04) TB425CS, TB475SS, TB490BC 4-Cycle Gas Trimmers IMPORTANT: READ SAFETY RULES AND INSTRUCTIONS CAREFULLY2 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 Accessory Part #180890 Spark Arrestor Kit.

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 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.

• 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.• Children and teens under the age of 15 must not usethe unit, except for teens guided by an adult.• All guards and safety attachments must be installedproperly before operating the unit.• 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. Do not operate theunit with loose or damaged parts.• Carefully inspect the area before starting the unit.Remove all debris and hard or sharp objects such asglass, wire, etc.• Be aware of the risk of injury to the head, hands andfeet.• Clear the area of children, bystanders, and pets. At aminimum, keep all children, bystanders, and petsoutside a 50 feet (15 m.) radius; there still may be arisk to bystanders from thrown objects. Bystandersshould be encouraged to wear eye protection. If youare approached, stop the unit immediately.• Use only 0.095 inch,

2.41 mm (for the TB425CS &

TB475SS), or 0.105 inch, 2.67 mm (for the TB490BCbrushcutter), diameter original equipmentmanufacturer replacement line. Never use metal-reinforced line, wire or rope. These can break off andbecome dangerous projectiles. • Squeeze the throttle control and check that it returnsautomatically to the idle position. Make all adjustmentsor repairs before using unit.

SAFETY WARNINGS FOR GAS UNITS

• Store fuel only in containers specifically designed andapproved for the storage of such materials.• Avoid creating a source of ignition for spilled fuel. Donot start the engine until fuel vapors dissipate. When using the unit, you must follow the safety rules. Please read these instructions before operating the unit in order to ensure the safety of the operator and any bystanders. Please keep these instructions for later use.

• IMPORTANT SAFETY INSTRUCTIONS • Gasoline is highlyflammable, and itsvapors can explode if ignited. Take thefollowing precautions:

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

• To reduce fire hazard, replace a faulty muffler and spark arrestor. Keep the engine and muffler free from grass, leaves, excessive grease or carbon build up. TB490BC ONLY: WHILE OPERATING

• 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.5

RULES FOR SAFE OPERATION

• 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 INSTRUCTIONS6

RULES FOR SAFE OPERATION

• SAFETY ALERT SYMBOLIndicates danger, warning, orcaution. May be used in conjunctionwith other symbols or pictographs.• WARNING - READ OPERATOR'SMANUALRead the Operator’s Manual(s) andfollow all warnings and safetyinstructions. Failure to do so canresult in serious injury to theoperator and/or bystanders.• WEAR EYE AND HEARINGPROTECTION

WARNING: Thrown objects and

loud noise can cause severe eyeinjury and hearing loss. Wear eyeprotection meeting ANSI Z87.1-1989standards and ear protection when operating this unit. Use a full faceshield when needed.• KEEP BYSTANDERS AWAY

WARNING: Keep all bystanders,

especially children and pets, at least50 feet (15 m.) from the operating area. • UNLEADED FUELAlways use clean, fresh unleaded fuel.• THROWN OBJECTS ANDROTATING CUTTER CAN CAUSESEVERE INJURY

operate without the cuttingattachment shield in place. Keep away from the rotating cuttingattachment.

SAFETY AND INTERNATIONAL SYMBOLS

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

• ON/OFF STOP CONTROLON / START / RUN•ON/OFF STOP CONTROLOFF or STOP• HOT SURFACE WARNINGDo not touch a hot muffler orcylinder. You may get burned. Theseparts get extremely hot fromoperation. When turned off theyremain hot for a short time.

TB490BC ONLY: BRUSHCUTTERS

• REPLACE DULL BLADE Do not sharpen the cutting blade.Sharpening the blade can cause theblade tip to break off while in use. Thiscan result in severe personal injury.

objects and rotating cutter can causesevere injury. Keep bystanders,especially children and pets, at least50 feet (15 m) away from the cuttingarea. The cutting attachment shieldmust be used when using thetrimmer cutting attachment.• OILRefer to operator's manual for theproper type of oil.7

APPLICATIONS As a trimmer:

• Cutting grass and light weeds

• Decorative trimming around trees, fences, etc. As a brushcutter (TB490BC only):

• Cutting weeds and light brush of up to 1/2 inch in diameter Other optional accessories may be used with your unit. Refer to Operating the EZ-Link System for a list of add-ons. NOTE: The below illustration may differ slightly from your unit. For example, the picture shows a straight shaft. Your unit may have a curved shaft. Also, the TB475SS has a D-handle, although only a J-handle is pictured. Primer Bulb Oil Fill Plug / Dipstick Air Filter Cover Engine Feet Spark Plug Cutting Attachment Shield Fuel Cap Throttle Control Throttle Lock-Out (TB490BC only) J-Handle (TB425CS & TB475SS only) Cutting Attachment Gear Housing Shaft Grip On/Off Stop Control Shaft Housing Starter Rope Grip EZ-Link™ Blade Shield / Shield Mount (TB490BC only) Brush Blade (TB490BC only) Line Cutting Blade Spark Plug Muffler Muffler Guard Spark Arrestor Shoulder Strap Clip8 ASSEMBLY INSTRUCTIONS

The TB475SS uses a D-handle, which is pre-installed onthe unit. If you ever need to adjust it, make sure it is atleast 6 inches from the end of the shaft grip (Fig. 1).2. While holding the three pieces together, install the four(4) screws through the top clamp and into middle clamp.NOTE: The holes in the top and middle clamp will line uponly when assembled correctly.3. Place the clamps and the J-handle over the shafthousing and onto the bottom clamp.4. Hold each hex nut in the bottom clamp recess with afinger. 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 onthe decal touches the clamp assembly (Fig. 3). You mustfirst loosen the screws if the handle is pre-installed.Fig. 2Fig. 36. While holding the unit in the operating position(Fig. 27), position the J-handle to the location thatprovides you the best grip. 7. Tighten the clamp screws evenly, until the J-handleis secure.

INSTALL AND ADJUST THE J-HANDLE

1. Place the J-handle between the top and middleclamp pieces (Fig. 2).Decal

TB490BC ONLY: INSTALL THE HARNESS

1. Push the strap through the center of the buckle.2. Pull the strap over the cross bar and down throughthe slot in the buckle (Fig. 4).3. Put the harness on over head and onto shoulder.Snap it on to the support fitting (Fig. 5).4. Adjust length to fit the operator’s size. Pull tab tolengthen, pull strap to shorten (Fig 6).Support FittingFig. 4Fig. 5Fig. 6

Remove the cutting attachment shield when using the unit as a brushcutter Remove the cutting attachment shield from the shieldmount by removing the three (3) screws with a flat bladescrewdriver (Fig. 7). Store parts for future use.The cuttingattachment shieldshould NOT be installed when operating theunit with a blade. Remove the cuttingattachment shield before removing orinstalling the blade.

Always use theshoulder harnesswhen using the cutting blade to avoidserious personal injury.

(4) ScrewsTop ClampJ-Handle Middle ClampBottom Clamp Nuts ShaftHousingBottom ClampShaft GripMinimum 6 inches(15.24 cm)Fig. 19 ASSEMBLY INSTRUCTIONS Install the cutting attachment shield when using the unit as a grass trimmer Install the cutting attachment shield on the shield mountby inserting the three (3) screws into the shield mount.Tighten securely with a flat blade screwdriver (Fig. 7).

NOTE: To make cutting blade removal and installation easier,place the unit on the ground or on a work bench

Remove the Cutting Attachment Shield See Remove and Install the Cutting Attachment Shield. Remove the Cutting Attachment

Align the shaft bushing hole with the locking rod slot andinsert the locking rod into the shaft bushing hole (Fig. 8).(3) ScrewsCuttingAttachmentShieldShield MountGear HousingFig. 7Cutting AttachmentLocking Rod Slot Locking RodShaft Bushing HoleLocking Rod SlotOutput ShaftBushingLocking RodOutput Shaft2. Hold the locking rod in place by grasping it next tothe boom of the unit (Fig. 9).3. While holding the locking rod, remove the cuttingattachment by turning it clockwise off of the output shaft(Fig. 10). Store the cutting attachment for future use.NOTE: The blade retainer under the cutting attachmentwill be used when installing the cutting blade.Fig. 8Fig. 10Fig. 9 Install the Cutting Blade

Nut Output ShaftBushingPilot HoleFig. 11The gear housinggets hot with use. Itcan result in injury to the operator. Thehousing remains hot for a short time evenafter the unit is turned off. Do not touch thegear housing until it has cooled.

To avoid seriouspersonal injury, thecutting attachment shield MUST be in placeat all times while operating the unit as agrass trimmer.

To avoid seriouspersonal injury,always wear gloves while handling orinstalling the blade.

Remove the Cutting Blade 1. Align the shaft bushing hole with the locking rod slotand insert the locking rod into the bushing hole (Fig. 8).2. Hold the locking rod in place by grasping it next tothe boom of the unit (Fig. 14).3. While holding the locking rod, loosen the nut on theblade by turning it clockwise with a 5/8 inch closed-end or socket wrench (Fig. 14). Fig. 139. Remove the locking rod from the locking rod slot.1/4-1/2 turnCounterclockwise6. Align the shaft bushing hole with the locking rod slot and insert the locking rod into the bushing hole(Fig. 8).7. Put the blade retainer and nut on the output shaft.Make sure that the blade is installed correctly. 8. Tighten nut counterclockwise against the blade whileholding the locking rod:• If using a torque wrench and an 5/8 inch socket tightento: 325 - 335 in•lb, 27 - 28 ft.•lb, 37 - 38 N•m.•Without a torque wrench, use a 5/8 inch closed-end orsocket wrench, turning the nut until the blade retaineris snug against the shaft bushing. Make sure that theblade is installed correctly, then rotate the nut anadditional 1/4 to 1/2 turn counterclockwise (Fig. 13).Cutting AttachmentLocking RodClockwise6. Remove the locking rod.7. Install the cutting attachment shield. Refer to Removeand Install the Cutting Attachment Shield.Blade RetainerOutput ShaftBushingFig. 145. Make sure that the cutting blade is centered on thepilot step and sitting flat against the output shaftbushing (Fig. 12).4. Remove the nut, blade retainer and blade. Store thenut and blade together for future use in a secureplace. Store out of children’s reach. Install the Cutting Attachment

Align the shaft bushing hole with the locking rod slot andinsert the locking rod into the shaft bushing hole (Fig. 8).Place the blade retainer on the output shaft with the flatsurface against the output shaft bushing (Fig. 15). Screwthe cutting attachment counterclockwise onto the outputshaft. Tighten securely.NOTE: The blade retainer must be installed on the outputshaft in the position shown for the cuttingattachment to work correctly.If the cutting bladeis off-center, theunit will vibrate and the blade may fly off,causing possible serious personal injury.

To avoid seriouspersonal injury,always wear gloves while handling orinstalling the blade.

Do not sharpen thecutting blade.Sharpening the blade can cause the blade tipto break off while in use. This can result insevere personal injury. Replace the blade.

To avoid seriouspersonal injury ordamage to the unit, do not start or operate thisunit with the locking rod in the locking rod slot.

To avoid seriouspersonal injury, thecutting attachment shield MUST be in place atall times while operating the unit as a trimmer.

Using the proper type and weight of oil inthe crankcase is extremely important.Check the oil before each use and changethe oil regularly. Failure to use the correct oil, or usingdirty oil, can cause premature engine wear and failure.Use a high-quality SAE 30 weight oil of API (AmericanPetroleum Institute) service class SF, SG, SH.

ADDING OIL TO CRANKCASE: INITIAL USE

NOTE: This unit is shipped without oil. In order to avoiddamage to the unit, put oil in the crankcasebefore you attempt to start the unit.Your unit is supplied with one 3.4 fluid oz. (100 ml.) bottle of SAE 30 SF, SG, SH oil (Fig. 16).NOTE: Save the bottle of oil. It can be used to measurethe correct amount during future oil changes.See Changing the Oil.1. Unscrew the top of the bottle of oil and remove thepaper seal covering the opening. Replace the top.Next, cut the tip off the funnel spout (Fig. 16).2. Place the unit on a flat level surface (Fig. 18).3. Remove the oil plug / dipstick from the crankcase(Fig. 17). Fig. 16Fig. 18Oil FillNOTE: Never add oil to the fuel or fuel tank.5. Wipe up any oil that may have spilled and reinstallthe oil fill plug / dipstick.Check oil before each use and change as needed. Referto Changing the Oil.Oil Fill Plug/DipstickOil Fill HoleFig. 174. Pour the entire bottle of oil into the oil fill hole (Fig. 18).O-RingFunnel Spout OVERFILLING OIL CRANKCASE MAY CAUSE SERIOUS PERSONAL INJURY. Check and maintain the proper oil level in the crank case; it is important and cannot be overemphasized. Check the oil before each use and change it as needed. See Changing the Oil.

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.

3. Wipe up any gasoline that may have spilled.

4. Reinstall the fuel cap.

5. Move the unit at least 30 ft. (9.1 m) from the fueling

source and site before starting the engine. NOTE: Dispose of the old gasoline in accordance to Federal, State and Local regulations.

RECOMMENDED FUEL TYPE

Old fuel is the primary reason for improper unit performance. Be sure to use fresh, clean, unleaded gasoline. NOTE: This is a four cycle engine. In order to avoid damage to the unit, do not mix oil with gasoline. Definition of Blended Fuels Today's fuels are often a blend of gasoline and oxygenates such as ethanol, methanol or MTBE (ether). Alcohol-blended fuel absorbs water. As little as 1% water in the fuel can make fuel and oil separate or form acids when stored. Use fresh fuel (less than 60 days old), when using alcohol-blended fuel. Using Blended Fuels If you choose to use a blended fuel, or its use is unavoidable, follow recommended precautions:

• Always use fresh unleaded gasoline

• Use the fuel additive STA-BIL

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

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

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

STARTING INSTRUCTIONS STOPPING INSTRUCTIONS

1. Release your hand from the throttle control. Allow the

engine to cool down by idling.

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

Avoid accidental starting. Make sure you are in the 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.

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

Checking the Oil Level.

2. Fill the fuel tank with fresh, clean unleaded gasoline.

Refer to Fueling the Unit. NOTE: There is no need to turn the unit on. The On/Off Stop Control is in the ON (I) position at all times (Fig. 20). IF COLD... For cold weather conditions (below 40°F), flip the Cold Weather Start Lever (Fig. 23) down to the start/closed position and continue to step 3. DO NOT flip this lever down if the temperature is above 40°F.

3. Fully press and release the primer bulb 10 times,

slowly. Some amount of fuel should be visible in the primer bulb and fuel lines (Fig. 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. With the unit in the starting position, do not squeeze

the throttle control (Fig. 22). Pull the starter rope out a short distance, until you feel some resistance. This is usually around 2-4 inches. Then pull the rope smoothly and briskly. Repeat this 5 times. The engine should start IF COLD... For cold weather conditions (below 40°F), flip the Cold Weather Start Lever back up to the run/open position.

5. Squeeze the throttle control (and squeeze the throttle

lock-out if your unit is a TB490BC) to warm up the engine for 15 to 30 seconds. In cold weather, let the engine warm up for 30 to 60 seconds. IF... The engine does not start, go back to step 3. IF... The engine stops while you are squeezing the throttle, go back to step 4.14 OPERATING INSTRUCTIONS For edging (when using the line head cutting attachment with EZ-Link™ models), lock the release button of the cutting attachment into the 90° edging hole (Fig. 26).

3. While firmly holding the upper shaft housing, pull

the cutting attachment or add-on straight out of the EZ-Link™ coupler (Fig. 25). Installing the Cutting Attachment or Add-On NOTE: Place the unit on the ground or on a work bench to make add-on installation or removal easier.

2. While firmly holding the add-on, push it straight into

Fig. 25 Fig. 26 Knob Lower Shaft Housing Release Button 90˚ Edging Hole (Trimmer Only) To avoid serious personal injury and damage to the unit, shut the unit off before removing or installing add-ons.

Add-ons are to be used in the primary hole only. Using the wrong hole could lead to personal injury or damage to the unit. CAUTION: Lock the release button in the primary hole and securely tighten the knob before operating this unit. CAUTION: Before you begin using any attachment, read and understand the manual that came with the attachment. Follow all safety information contained within.

Before operating the unit, stand in the operating position (Fig. 27). Check for the following:

• The operator is wearing eye protection and proper clothing

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

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

• The unit is at waist level

• The cutting attachment is parallel to the ground and easily contacts the grass without the need to bend over After starting the unit and standing in the operating position, hook the shoulder strap to the unit (TB490BC only). Fig. 27

ADJUSTING TRIMMING LINE LENGTH

The Bump Head™ cutting attachment allows you to release trimming line without stopping the engine. To release more line, lightly tap the cutting attachment on the ground (Fig. 28) while operating the trimmer at high speed. NOTE: Always keep the trimming line fully extended. Line release becomes more difficult as the cutting line becomes shorter. Each time the head is bumped, about 1 inch (25.4 mm) of trimming line is released. A blade in the cutting attachment shield will cut the line to the proper length if excess line is released. For best results, tap the Bump Head™ on bare ground or hard soil. If line release is attempted in tall grass, the engine may stall. Always keep the trimming line fully extended. Line release becomes more difficult as the cutting line becomes shorter. NOTE: Do not rest the Bump Head™ on the ground while the unit is running. Fig. 28 Some line breakage will occur from:

• Entanglement with foreign matter

• Attempting to cut thick, stalky weeds

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

TIPS FOR BEST TRIMMING RESULTS

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

• Keep the cutting attachment parallel to the ground.

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

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

• For the TB490BC brushcutter, cut from left to right whenever possible. Cutting to the right improves the unit's cutting efficiency. Clippings are thrown away from the operator. For the other units, cut from right to left.

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

• Trim only when grass and weeds are dry.

• The life of your cutting line is dependent upon:

• Proper adherence of explained trimming techniques

• What vegetation is cut

• Where vegetation is cut For example, the line will wear faster when trimming against a foundation wall as opposed to trimming around a tree. Do not remove or alter the line cutting blade assembly. Excessive line length will make the clutch overheat. This may lead to serious personal injury or damage to the unit. CAUTION: Always wear eye, hearing, foot and body protection to reduce the risk of injury when operating this unit.

Fig. 29Fig. 30Fig. 31 DECORATIVE TRIMMING Decorative trimming is accomplished by removing allvegetation around trees, posts, fences and more.Rotate the whole unit so that the cutting attachment is ata 30° angle to the ground (Fig. 29). TB490BC ONLY: USING THE CUTTING BLADE Before operating the unit with the cutting blade, stand inthe operating position (Fig. 30). Refer to Holding theTrimmer. Cutting Blade Operating Tips To establish a rhythmic cutting procedure:• Plant feet firmly, comfortably apart.• Bring the engine to full throttle before entering thematerial to be cut. At full throttle the blade hasmaximum cutting power and is less likely to bind, stallor cause blade thrust (which can result in seriouspersonal injury to the operator or others).• Cut while swinging the upper part of your body fromleft to right.• Always release the throttle trigger and allow the engineto return to idle speed when not cutting. • When you are finished, always unsnap the unit fromthe harness before taking off the harness.• Swing the unit in the opposite direction as the bladespins, which increases the cutting action.• After the return swing, move forward to the next areato be cut plant your feet again.• The cutting blade is designed with a second cuttingedge. You can use it by removing the blade, turning itupside down, and reinstalling it.To reduce the chance of material wrapping around theblade, follow these steps:• Cut at full throttle• Swing the unit into material to be cut from your left toyour right (Fig. 31)• Avoid the material just cut as you make the return swingAlways wear eye,hearing, foot, bodyprotection and the shoulder strap to reduce therisk of injury when operating this unit.

Do not use thecutting blade foredging or as an edger. Severe personal injuryto yourself or others can result.

The blade continuesto spin after theengine is turned off. The coasting blade canseriously cut you if accidentally touched.

Do not sharpen thecutting blade.Sharpening the blade can cause the blade tipto break off while in use. This can result insevere personal injury to yourself or others.Replace the blade.

ade thrust mayoccur when thespinning blade contacts an object that it doesnot immediately cut. Blade thrust can be violentenough to cause the unit and/or operator to bepropelled in any direction, and possibly losecontrol of the unit. Blade thrust can occurwithout warning if the blade snags, stalls orbinds. This is more likely to occur in areas whereit is difficult to see the material being cut.

Do not clear awayany cut material withthe engine running or blade turning. To avoidserious personal injury, turn off the engine.Allow the blade to stop before removingmaterials wrapped around the blade shaft.

To prevent seriousinjury, never performmaintenance or repairs with unit running.Always service and repair a cool unit.Disconnect the spark plug wire to ensure thatthe unit cannot start.

MAINTENANCE SCHEDULE Perform these required maintenance procedures at thefrequency stated in the table. These procedures shouldalso be a part of any seasonal tune-up.NOTE: Some maintenance procedures may requirespecial tools or skills. If you are unsure aboutthese procedures take your unit to any non-roadengine repair establishment, individual orauthorized service dealer. NOTE: Maintenance, replacement, or repair of theemission control devices and system may beperformed by any non-road engine repairestablishment, individual or authorized service dealer.

FREQUENCY MAINTENANCE REQUIRED REFER TO

Before starting engineFill fuel tank with fresh fuelCheck oilPage 12Page 21Every 10 hours Clean and re-oil air filter Page 22First change at 10 hoursEvery 25 hours thereafterEvery 25 hoursChange oilChange oilClean spark arrestorPage 22Page 22Page 2610 hours on new engineEvery 25 hoursEvery 25 hoursCheck rocker arm to valve clearance and adjustCheck rocker arm to valve clearance and adjustCheck spark plug condition and gapPage 24Page 24Page 26 LINE INSTALLATION This section covers both SplitLine™ and standard singleline installation.Always use 0.105 in. (2.67 mm) original equipmentmanufacturer replacement line. Line other than thespecified 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 theBump Knob clockwise (Fig. 32). Inspect the bolt insidethe bump knob to make sure it moves freely. Replacethe bump knob if damaged. BUMP HEAD ( TB490BC ONLY) Never use metal-reinforced line, wire,chain or rope. These can break off andbecome dangerous projectiles.

Fig. 36 Fig. 37 Fig. 38 Fig. 39 Fig. 40 Fig. 35 NOTE: SplitLine™ can only be used with the inner reel with the slotted holes. Single line can be used on either type of inner reel. Use Figure 35 to identify the inner reel you have. NOTE: Always use the correct line length when installing trimming line on the unit. The line may not release properly if the line is too long. Single Line Installation Go To Step 8 for SplitLine™ Installation

6. Take approximately 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. 36). 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. 37). Wind the line in the direction indicated on the inner reel. Place your index finger between the two lines to stop the lines from overlapping. Do not overlap the ends of the line. Proceed to step 11. Spring SplitLine™ Installation

8. Take approximately 9 feet (3 m) of new trimming line.

Insert one end of the line through one of the two holes in the inner reel (Fig. 38). 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. 38).

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

11. Wind the line in tight even layers in the direction

indicated on the inner reel. NOTE: Failure to wind the line in the direction indicated will cause the cutting attachment to operate incorrectly. Loop Slotted Holes For Use with SplitLine™ or Single Line For Use with Single Line ONLY Loop Holding Slots NOTE: The spring must be assembled on the inner reel before reassembling the cutting attachment.

14. Hold the inner reel in place and install the bump knob

by turning counterclockwise. Tighten securely.

12. Insert the ends of the line into the two holding slots

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. 40). Push the inner reel and outer spool together. While holding the inner reel and outer spool, grasp the ends and pull firmly to release the line from the holding slots in the reel.19

MAINTENANCE AND REPAIR INSTRUCTIONS

LINE INSTALLATION Always use original equipment manufacturer 0.095 inch(2.41 mm) replacement line. Lines other than thosespecified may make the engine overheat or fail.There are two methods to replace the SpeedSpool trimming line:• Wind the inner reel with new line• Install a pre-wound inner reel Winding the Inner Reel With New Line NOTE: It Is unnecessary to remove the bump knob toinstall a new trimming line.1. Cut two pieces of 0.095 inch (2.41 mm) trimmingline, 10 feet (3 m) long.2. Hold the outer spool and turn the inner reelcounterclockwise to line up the arrows on the outerspool and inner reel (Fig. 41).Top View Of The SpeedSpool Outer SpoolInner ReelFig. 41Bump KnobArrows SPEEDSPOOL

Always use thecorrect line lengthwhen installing trimming line on the unit.The line may not release properly if the lineis too long.

Line Locking HoleTrimming LineLine Loading HoleEyelet5. Insert the line into the locking hole (Fig. 43). Do notpush the line more than a 1/2 inch (12.7 mm) into theline locking hole. The line will form a small loop(Fig. 43) when it is inserted correctly.3. Pull old line out of the line loading and line lockingholes (Fig. 42 and 43).4. Insert a piece of trimming line straight into one of thetwo eyelets in the outer spool. Push it up through theline loading hole in the inner reel (Fig. 42). Do notbend the line when inserting it into the eyelet.Fig. 42Fig. 43

INSTALLING A PREWOUND REEL

1. Hold the outer spool with one hand and unscrew thebump knob clockwise (Fig. 32). Inspect the bolt insidethe bump knob to make sure it moves freely. Replacethe bump knob if damaged.2. Remove the old inner reel from the outer spool (Fig. 32). 3. Remove the spring from the old inner reel (Fig. 32).4. Place the spring in the new inner reel. NOTE:The spring must be assembled on the inner reelbefore reassembling the cutting attachment.5. Insert the ends of the line through the eyelets in theouter spool (Fig. 40). 6. Place the new inner reel inside the outer spool. Push theinner reel and outer spool together. While holding theinner reel and outer spool, grasp the ends and pull firmlyto release the line from the holding slots in the spool.7. Hold the inner reel in place and install the bump knobby turning counterclockwise. Tighten securely.20

MAINTENANCE AND REPAIR INSTRUCTIONS

6. Pull the line from the outer spool until the line is tight

9. If winding the line becomes difficult or if the line

jams, pull the ends of the line from the spool (Fig. 46). Continue winding the inner reel counterclockwise until approximately 6 inches of line is left. Fig. 45 Fig. 46

7. Repeat procedures 4-6 with the second piece of line.

8. Hold the outer spool. Wind the inner reel

counterclockwise until approximately four (4) inches (102 mm) of line remain (Fig. 45). NOTE: Do not wind the inner reel before installing the second piece of line. Bump Knob Foam Seal Spring Inner Reel Fig. 47

4. Hold the inner reel in place and install the bump

knob, spring and foam seal (Fig. 47). Press down and turn the bump knob clockwise. Grasp the ends and pull firmly to release the line from the holding slots in the inner reel. Releasing the Inner Reel If the SpeedSpool

does not release line correctly, pull the ends of the line firmly from the spool (Fig. 46). If this does not the release line, follow the Cleaning the SpeedSpool

2. Pull the old inner reel with existing line from the outer

3. Insert the ends of the prewound inner reel line into

the outer spool eyelets (Fig. 48). Push the new inner reel, arrow side up, into the outer spool. Fig. 48

CLEANING THE SPEEDSPOOL

Cleaning the SpeedSpool

• A jammed or excessive line must be removed

becomes difficult to wind or does not operate correctly when bumping the head on the ground

1. Hold the outer spool, and unscrew the bump knob

counterclockwise (Fig. 49).

2. Pull out the bump knob, spring and foam seal (Fig. 47).21

4. Remove any existing line from the inner reel before

cleaning. Remove any debris or grass from the knob, spring, inner reel and foam seal. Wash the inner reel with warm soapy water (Fig. 50). ShaftPlunger NOTE: The inner reel must be totally dry before reinstalling it into the outer spool. Do not lubricate the inner reel or outer spool assembly.

6. Place the inner reel into the outer spool.

7. Place the bump knob, spring and foam seal into the

inner reel (Fig. 47).

8. Press the bump knob down and tighten clockwise.

9. Install new line as described in Line Installation for

5. Clean the shaft and the inner surface of the outer

MAINTENANCE AND REPAIR INSTRUCTIONS

CHECKING THE OIL LEVEL

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

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

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

3. Keep dirt, grass clippings and other debris out of the

engine. Clean the area around the oil fill plug/dipstick before removing it.

4. Remove the oil fill plug/dipstick and wipe off oil.

Reinsert it all the way back in.

5. Remove the oil fill plug/dipstick and check the oil level.

Oil should be up to the top of the dipstick (Fig. 52).

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

fill hole and recheck (Fig. 53). Repeat this procedure until the oil level reaches the top of the dipstick. NOTE: Do not overfill the unit. Top of DipstickO-RingOil Fill Plug/DipstickFig. 52Fig. 53 NOTE: Make sure the O-ring is in place on the oil fill plug/dipstick when checking and changing the oil (Fig. 53). Oil Fill Plug/DipstickOil Fill HoleO-Ring Full Add 1.4-1.5 Oz.(41-44 ml) To prevent extensive engine wear and damage to the unit, always maintain the proper oil level in the crankcase. Never operate the unit with the oil level below the bottom of the dipstick. CAUTION: Fig. 49

3. Pull the inner reel with existing line from the outer

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

1. Unplug spark plug boot to prevent accidental starting.

2. Remove the oil fill plug/dipstick.

3. Pour the oil out of the oil fill hole and into a container

by tipping the unit to a vertical position (Fig. 54). Allow ample time for complete drainage. Fig. 54

6. Replace the oil fill plug/dipstick.

7. Reconnect the spark plug boot.

4. Wipe up any oil residue on the unit and clean up any

oil that may have spilled. Dispose of the oil according to Federal, State and local regulations.

5. Refill the crankcase with 3.4 fluid ounce (100 ml) of

SAE 30 SF, SG, SH oil. NOTE: Use the bottle and spout saved from initial use to measure the correct amount of oil. The top of the label on the bottle measures approximately 3.4 ounces (100 ml) (Fig. 55). Check the level with the dipstick. If the level is low, add a small amount of oil and recheck. Do not overfill (Fig. 55). Fill LevelFig. 55 Wear gloves to prevent injury when handling the unit. CAUTION:

AIR FILTER MAINTENANCE

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

1. Open the air filter cover. Push the tab on the right

side of the cover inward. Then pull the air filter cover out and to the left (Fig. 56). NOTE: It may be necessary to remove the fuel cap to completely remove the air filter cover.

2. Remove the air filter (Fig. 56).

Air FilterAir Filter Cover Tab Fig. 56 To avoid serious personal injury, always turn the unit off and allow it to cool before you clean or service it.

3. Wash the filter in detergent and water (Fig. 57). Rinse

the filter thoroughly and allow it to dry.

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

the filter (Fig. 58). Fig. 57

5. Squeeze the filter to spread and remove excess oil

NOTE: If the unit is operated without the air filter, you will VOID the warranty.

7. Reinstall the air filter cover. Position the hooks on

the left side of the air filter cover into the slots at the left side of the back plate (Fig. 60). NOTE: It may be necessary to remove the fuel cap to reinstall the air filter cover.

8. Swing the cover to the right until the tab on the air

filter cover snaps into place in the slot on the back plate (Fig. 60).

9. Replace the fuel cap if it was removed.

Back Plate CARBURETOR ADJUSTMENT The idle speed of the engine is adjustable. An idle adjustment screw is reached though a hole in the top of the engine cover (Fig. 61). NOTE: Careless adjustments can seriously damage your unit. An authorized service dealer should make carburetor adjustments. Check Fuel Old fuel is usually the reason for improper unit performance. Drain and refill the tank with fresh fuel prior to making any adjustments. Refer to Oil and Fuel Information. Fig. 59 Fig. 58

MAINTENANCE AND REPAIR INSTRUCTIONS24

Idle Adjustment Screw Clean Air Filter The condition of the air filter is important to the operation of the unit. A dirty air filter will restrict air flow. This is often mistaken for an out of adjustment carburetor. Check the condition of the air filter before adjusting the idle speed screw. Refer to Air Filter Maintenance. Adjust Idle Speed Screw If, after checking the fuel and cleaning the air filter, the engine still will not idle, adjust the idle speed screw as follows:

1. Start the engine and let it run at a high idle for a minute

to warm up. Refer to Starting/Stopping Instructions.

2. Release the throttle trigger and let the engine idle. If the

engine stops, insert a small phillips or flat blade screwdriver into the hole in the air filter/muffler cover (Fig. 61). Turn the idle speed screw in, clockwise, 1/8 of a turn at a time (as needed) until the engine idles smoothly. NOTE: The cutting attachment should not rotate when the engine idles.

3. If the cutting attachment rotates when the engine idles,

turn the idle speed screw counterclockwise 1/8 of a turn at a time (as needed), to reduce idle speed. Checking the fuel, cleaning the air filter, and adjusting the idle speed should solve most engine problems. If not and all of the following are true:

• the engine will not idle

• the engine hesitates or stalls on acceleration

• there is a loss of engine power Have the carburetor adjusted by an authorized service dealer. Fig. 61RemoveScrewsFig. 62Engine Cover

2. Remove the two (2) screws on top of the engine cover

with a Flat-head or T-25 Torx screwdriver (Fig. 63). Fig. 63Engine CoverMuffler

ROCKER ARM CLEARANCE

This requires disassembly of the engine. If you feel unsure or unqualified to perform this, take the unit to an authorized service center. NOTE: Inspect the valve to rocker arm clearance with a feeler gauge after the first 10 hours of operation and then every 25 hours of operation thereafter.

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

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

1. Remove the muffler cover by pressing down on it,

separating it from the engine cover. Using a flat blade screwdriver, disengage the middle and front tabs and slots first. The cover will hinge off from the rear tab (Fig. 62). Top View Of The EngineFront SlotFront TabMiddle TabMiddle SlotRear Slotand Tab

MAINTENANCE AND REPAIR INSTRUCTIONS

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

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

5. Clean dirt from around the spark plug. Remove the

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

6. Remove the engine cover (Fig. 63).

7. Clean dirt from around the rocker arm cover.

Remove the screw holding the rocker arm cover with a large flat blade screwdriver or Torx T-25 bit (Fig. 65). Remove the rocker arm cover and gasket.

3. Remove the screw behind the engine cover (Fig. 64).

Rocker Arm Cover Screw Fig. 64 Fig. 65 Spark Plug Hole

8. Pull the starter rope slowly to bring the piston to the top

of its travel, (known as top dead center). Check that:

• The piston is at the top of its travel while looking in the spark plug hole (Fig. 65)

• Both rocker arms move freely, and both valves are closed If these statements are not true, repeat this step.

9. Slide the feeler gauge between the rocker arm and

the valve return spring. Measure the clearance between the valve stem and rocker arm (Fig. 66). Measure both the intake and exhaust valves. Adjusting Nuts Feeler Gauge Rocker Arms Fig. 66 Fig. 67 The recommended clearance for the intake is .003 – .006 in. (.076 – 0.152 mm). The recommended clearance for the exhaust is .013 – .016 in. (.330 – 0.406 mm). Use a standard automotive feeler gauge at .005 and .015 in. (0.127 and 0.381 mm). The feeler gauge should slide between the rocker arm and valve stem with a slight amount of resistance, without binding. Figure 66 shows how to measure the intake clearance, while Figure 67 shows the exhaust clearance. Feeler Gauge Exhaust Adjusting Nut Exhaust Rocker Arm Exhaust Clearance: .013–.016 in. (.330–0.406 mm) Exhaust Valve Stem

10. If the clearance is not within specification:

a. Turn the adjusting nut using a 5/16 inch (8 mm) wrench or nut driver (Fig. 67).

• To increase clearance, turn the adjusting nut counterclockwise.

• To decrease clearance, turn the adjusting nut clockwise. b. Recheck both clearances, and adjust as necessary.

11. Reinstall the rocker arm cover using a new gasket.

Torque the screw to 20–30 in

12. Reinstall the engine cover. Check alignment of the

cover before tightening the screws. Tighten screws.

13. Reinstall the muffler cover. Slip the rear tab on the

muffler cover into the engine cover rear slot. Then slide the remaining slots into the tabs until they snap into place (Fig. 62).

INTAKE EXHAUST Intake Valve Stem Intake Clearance: .003–.006 in. (.076–0.152 mm)26 CLEANING Use a small brush to clean off the outside of the unit. Do not use strong detergents. Household cleaners that contain aromatic oils such as pine and lemon, and solvents such as kerosene, can damage plastic housing or handle. Wipe off any moisture with a soft cloth. STORAGE

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

• Allow the engine to cool before storing.

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

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

• Store the unit out of the reach of children. NOTE: Remove the spark plug and drain all of the oil from the cylinder before attempting to start the trimmer after storage.

4. Change the oil, referring to Changing the Oil.

Dispose of the old oil in accordance to Federal, State and Local regulations.

5. Thoroughly clean the unit and inspect for any loose

or damaged parts. Repair or replace damaged parts and tighten loose screws, nuts or bolts. The unit is ready for storage. TRANSPORTING

• Allow the engine to cool before transporting.

• Secure the unit while transporting.

• Drain the gas tank before transporting.

• Tighten gas cap before transporting.

1. Drain all gasoline from the gas tank into a container.

Do not use gas that has been stored for more than 60 days. Dispose of the old gasoline in accordance to Federal, State, and Local regulations.

2. Start the engine and allow it to run until it stalls. This

ensures that all gasoline has been drained from the carburetor.

3. Allow the engine to cool. Remove the spark plug and

put 1 oz. (30 ml) of high quality motor oil into the cylinder. Pull the starter rope slowly to distribute the oil. Reinstall the spark plug. To avoid serious personal injury, always turn your unit off and allow it to cool before you clean or service it.

Use a replacement part number 180890 spark plug. The correct air gap is 0.025 in. (0.655 mm.). Remove the plug after every 25 hours of operation and check its condition.

1. Stop the engine and allow it to cool. Grasp the plug

wire firmly and pull the cap from the spark plug.

2. Clean dirt from around the spark plug. Remove the

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

3. Replace cracked, fouled or dirty spark plug. Set the air

gap at 0.025 in. (0.655 mm.) using a feeler gauge (Fig. 68). Fig. 68

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

head. Turn the 5/8 in. socket clockwise until snug. If using a torque wrench torque to: 110-120 in.•lb. (12.3-13.5 N•m) Do not over tighten. Fig. 69MufflerSpark Arrestor ScreenSpark Arrestor CoverScrew Tab Slot

SPARK ARRESTOR MAINTENANCE

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

2. With a flat blade screwdriver or Torx T-20 bit,

remove the screw attaching the spark arrestor cover to the muffler (Fig. 69).

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

muffler. Remove the spark arrestor cover.

4. Remove the spark arrestor screen from the spark

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

6. Reinstall the spark arrestor screen, spark arrestor

cover and screw. Do not sand blast, scrape or clean electrodes. Grit in the engine could damage the cylinder.

TROUBLESHOOTING If further assistance is required, contact your authorized service dealer. CAUSE ACTION Cutting attachment bound with grass Stop the engine and clean cutting attachment Cutting attachment out of line Refill with new line Inner reel bound up Replace the inner reel Cutting head dirty Clean inner reel and outer spool Line welded Disassemble, remove the welded section and rewind Line twisted when refilled Disassemble and rewind the line Not enough line is exposed Push the bump knob and pull out line until 4 inches (102 mm) of line is outside of the cutting attachment CAUSE ACTION Old fuel Drain gas tank and add fresh fuel Improper carburetor adjustment Take to an authorized service dealer for adjustment Fouled spark plug Replace or clean the spark plug Plugged spark arrestor Clean or replace spark arrestor CAUSE ACTION Empty fuel tank Fill fuel tank with new fuel Primer bulb wasn't pressed enough Press primer bulb fully and slowly 10 times Old fuel Drain gas tank and add fresh fuel Fouled spark plug Replace or clean the spark plug Plugged spark arrestor Clean or replace spark arrestor

ENGINE WILL NOT ACCELERATE

ENGINE LACKS POWER OR STALLS WHEN CUTTING CAUSE ACTION Air filter is plugged Replace or clean the air filter Old fuel Drain gas tank and add fresh fuel Improper carburetor adjustment Adjust carburetor CAUSE ACTION Old fuel Drain gas tank and add fresh fuel Improper carburetor adjustment Take to an authorized service dealer for adjustment Cutting attachment bound with grass Stop the engine and clean the cutting attachment Dirty air filter Clean or replace the air filter Plugged spark arrestor Clean or replace spark arrestor

CUTTING ATTACHMENT WILL NOT ADVANCE LINE

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

CUTTING LINE ADVANCES UNCONTROLLABLY

When it is above 40°F outside & the Cold Weather Start Lever is in the CLOSED / START position When it is below 40°F outside & the Cold Weather Start Lever is in the RUN / OPEN position Flip the Cold Weather Start Lever to RUN / OPEN Flip the Cold Weather Start Lever to CLOSED / START and follow the Starting Instructions28 SPECIFICATIONS ENGINE*

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

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

• You are responsible for presenting your small off-road engine to a Troy-Bilt Authorized Service Center as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days. If you have any questions regarding your warranty rights and responsibilities, you should call 1-800-520-5520. Manufacturer’s Warranty Coverage

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

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

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

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

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

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

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

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

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

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

• The following components are included in the emission related warranty of the engine, air filter, carburetor, primer, fuel lines, fuel pick up/ fuel filter, ignition module, spark plug and muffler.MANUFACTURER’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 two (2) years commencing on the date of original purchase and will, at its option, repair or replace, free of charge, any part found to be defective in material or workmanship. This limited warranty shall only apply if this product has been operated and maintained in accordance with the Operator’s Manual furnished with the product, and has not been subject to misuse, abuse, commercial use, neglect, accident, improper maintenance, alteration, vandalism, theft, fire, water or damage because of other peril or natural disaster. Damage resulting from the installation or use of any accessory or attachment not approved by Troy-Bilt 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-

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