Manual

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m iwm m mmm r®

TRnV:BILT

Operator's Manual

4-Cycle Gasoline

Trimmer / Brushcutter

Model TB490BC

IMPORTANT:READ SAFETY RULES AND INSTRUCTIONS CAREFULLY

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 Iaw 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, Accessory Part 791-

180890 Spark Arrestor Screen is available by contacting the service department at Troy-Biff LLC, P.O. Box 36t 131 Cleveland, Ohio 44I 36-0019.

TROY-BILT LLC, P.O. BOX 361131, CLEVELAND, OH 44136-0019

P!N 771-10661 (11/01 rev. P00)

PRINTED IN USA

Summary of content (32 pages)

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TRnV:BILT m iwm m mmm r® Operator's Manual 4-Cycle Gasoline Trimmer / Brushcutter Model TB490BC IMPORTANT:READ SAFETY RULES AND INSTRUCTIONS NOTE: For users on U,S, Forest Land and in the states of California. Maine, Oregon and Washington.
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Content Page Calling Customer Support .................................................... 2 Rules for Safe Operation ..................................................... 3 Know Your Unit ............................................................ 7 Assembly Instructions ....................................................... 8 Oil and Fuel Information ..................................................... 11 Starting/Stepping 13 Instructions .................................................
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Thepurposeofsafetysymbolsisto attractyour attentionto possibledangers.Thesafety symbols, DANGER: Failure to obey a safety warning will result in serious injury to yourself or to others. Always follow the safety precautions to reduce the risk of fire, electric shock, and personal injury. and their explanations, deserve your careful attention and understanding. The safety warnings do not by themselves eliminate any danger.
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• 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. • To reduce fire hazard, replace faulty muffler and spark arrestor, keep the engine and muffler free from grass, leaves, excessive grease or carbon build up. WHILE OPERATING WITH CUTTING BLADE • The cutting attachment shield must always be in place while operating the unit.
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OTHER SAFETY WARNINGS • 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. • Never store the unit, with fuel in the tank, inside a building where fumes may reach an open flame or spark. • Keep these instructions. Refer to them often and use them to instruct other users.
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SYMBOL MEANING • OIL Refer to operator's manual for the proper type of oil. * THROWN OBJECTS AND ROTATING CUTTER CAN CAUSE SEVERE INJURY WARNING: Do not operate without the cutting attachment shield in place, Keep away from the rotating cutting attachment. • ON/OFF STOP CONTROL ON / START / RUN • ON/OFF STOP CONTROL OFF OR STOP • HOT SURFACE WARNING Do not touch a hot muffler, gear housing or cylinder. You may get burned. These parts get extremely hot from operation.
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Spark Arrestor •=p---Spark Plug APPLICATIONS AS a trimmer: • CuRing gross and light weeds. • Edging. • Decorative trimming around trees, fences, etc. Muffler Guard --> AS a brushcu_er; • Cutting weeds and light bush of up to 1/2 inch in diameter. Fuel Cap Starter Rope Shaft Grip Other optional accessories may be used with the TB490BC.
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INSTALLINGAND ADJUSTINGTHEJ-HANDLE 1. 6, While holding the unit in the operating position (Fig. 3), position the J-handle to the location that provides you the best grip. 7. Tighten the clamp screws evenly, until the J-handle is secure. Place the J-handle between the top and middle clamp pieces (Fig. 1). J-Handle INSTALLING (4) IA Top Clamp Middle Clamp Bottom Clamp THE HARNESS WARNING: Always the shoulder personalwhen us nginjury.the cutt use ng bade to avo dharness ser cue 1.
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REMOVING AND INSTALLING ATTACHMENT SHIELD CUTTING Output Shaft Remove the cutting attachment shield when using the unit as a brushcutter. WARNING: The cutting attachment shield should NOT be installed when operating the unit with a blade. Remove the cutting attachment shield before removing or installing the blade. I I Cutting Attachment Shield ........ OutputSh | _ Bushing _dl_m_mmm.__ Fig, 8 Screws Gear Housing 2.
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Install the Cutting Blade WARNING: To avoid serious personal injury, always wear gloves while handling or installing the blade. 6. Align the shaft bushing hole with the locking rod slot and insert the locking rod into the bushing hole (Fig. 8, Pg. 9). 7. Put the blade retainer and nut on the output shaft. Make sure that the blade is installed correctly. 4. Place the cutting blade on the output shaft bushing (Fig. 11). 8. Tighten nut counterclockwise against the blade while holding the locking rod.
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3. While holding the locking rod, loosen the nut on the blade by turning it clockwise with a 5/8 inch closed-end or socket wrench (Fig. 14). 4. Cutting Attachment Remove the nut, blade retainer, and blade. Store the nut and blade together for future use in a secure place. Store out of reach of children. Install the Cutting Attachment 5. Align the shaft bushing hole with the locking rod slot and insert the locking rod into the shaft bushing hole. (Fig. 8, Pg. 9).
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4. Pour the entire bottle of oil into the oil fill hole (Fig, 18), FUELING I4_ 1. UNIT and its vapors can explode if ignited. To avoid serious personal injury, always stop the engine and allow it to cool before filling the fuel tank. Do not smoke while filling the tank. ARNING: extremely Keep sparks Gasoline and openis flames awayflammable from the area. Remove fuel cap (Fig. 19). J _ Oil F WARNING: Remove fuel cap slowly to avoid njury from gaso ne spray. LJ ...... Fig. 18 ..........
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STARTING INSTRUCTIONS 9. Cold Start - First Start of the Day or Engine Ran Out of Fuel WARNING: Operate this unit only in a well ventilated area outdoors. Carbon monoxide exhaust fumes can be lethal in a confined area. 10. Move the choke lever to the RUN (C) I{ I position and run at full throttle for 30 seconds. WARNING: Avoid accidental starting. Be in the starting position whenever pulling the starting rope.
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STOPPINGINSTRUCTIONS 1. 2. To stop the engine, put the Start!Stop Engine Control in the STOP [O] position (Fig. 20). Release your hand from the throttle control (Fig. 22). Allow the engine to idle. OPERATING THE EZ-LINK TM SYSTEM 2. The EZ-LInk TM system enables the use of these optional add-ons. Blower/Vacuum .......................... Cultivator ............................... BV720r GC720r Edger .................................. Hedge Trimmer .......................... Snow Thrower ...........
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HOLDING THE TRIMMER WARNING: Always wear eye, hearing, foot, body protection and strap to reduce the risk of injury when operating this unit. Before operating the unit, stand in the operating position (Fig. 26), Check for the following: • The operator is wearing eye protection and proper clothing. • The right arm is slightly bent, and the hand is holding the shaft grip. • The left arm is straight, and the hand is holding the J-handle, • The unit is at waist level.
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DECORATIVE i TRIMMING WARNING: The blade continues to spin after! the engine is turned off. The coasting blade can seriously cut you if accidentally touched. Decorative trimming is accomplished by removing all vegetation around trees, posts, fences, etc. Rotate the whole unit so that the cutting attachment is at a 30 ° angle to the ground (Fig. 28). • Swing the unit in the same direction as the blade spins, which increases the cutting action.
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NOTE: Some maintenance procedures may require special tools or skills. If you are unsure about these procedures take your unit to an authorized service dealer. MAINTENANCE WARNING: To prevent serious injury, never do maintenance or repairs with unit running. Always do maintenance and repairs on a cool unit. Disconnect spark plug wire to ensure the unit will not start. SCHEDULE These required maintenance procedures should be performed at the frequency stated in the table.
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ForUsewithSingle LineONLY ForUsewithSplitLine TM or Single Line Slotted Holes _ Loop Fig. 37 Fig. 34 10. Before winding, split the line back about 6 inches. Single Line Installation Go To Step 8 for SplitLine 6. TM 11. Wind the line in tight even layers in the direction indicated on the inner reel. Installation Take approximately 30 feet (9.14 m/ of new trimming line, loop it into two equal lengths, Insert each end of the line through one of the two holes in the inner reel (Fig. 35).
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INSTALLING A PREWOUND REEL 5, 1. Hold the outer spool with one hand and unscrew the bump knob clockwise (Fig. 15, Pg. 11). Inspect the bolt inside the bump knob to make sure it moves freely. Replace the bump knob if damaged. Remove the oil fill plug/dipstick and check oil level, Oil should be up to the top of the dipstick (Fig. 40). 6. If the level is low, add a small amount of oil to the oil fill hole and recheck (Fig, 41), Repeat until the oil level reaches the top of the dipstick. 2.
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CHANGING THE OIL 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. 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. _k when handling thegloves unit. to prevent injury AUTION: Wear 1. Unplug spark plug boot to eliminate starting 2. Remove the oil fill plug/dipstick. 3.
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AIR FILTER MAINTENANCE Cleaning the Air Filter WARNING: To avoid serious personal injury, t always turn your trimmer off and allow it to I cool before you clean or do any maintenance on it, Clean and re-oil the air filter every 10 hours of operation, It is an important item to maintain, Not maintaining the air filter will VOID the warranty, 1. Open the air filter cover. Push the tab on the right side of the cover in, pull the air filter cover out and to the left (Fig.
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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 50). NOTE: Careless adjustments can seriously damage your unit. An authorized service dealer should make carburetor adjustments. Check Fuel Old fuel is usually the main reason for the unit not running properly. Drain and refill the tank with clean, fresh unleaded fuel prior to doing any adjustments. Refer to Oil and Fuel Information.
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3. Rocker Arms Remove the screw on back of the engine cover (Fig. 53). Feeler Gauge 4. Fig. 53 Clean dirt from around the spark plug. Remove the spark plug from the cylinder head by turning a 5/8 in. socket counterclockwise. 5. Disconnect the spark plug wire. 6. 7. Remove the engine cover. Clean dirt from around the rocker arm cover. Remove the screw holding the rocker arm cover with a large flat blade screwdriver or Torx T25 bit (Fig. 54). Remove the rocker arm cover and gasket.
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REPLACING THE SPARK PLUG Use only Champion RDZ19H spark plug or equivelent. 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 coo]. 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 counterclockwise using a 5/8 inch deep socket. 3. Replace cracked, fouled or dirty spark plug.
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CLEANING WARNING: To avoid serious personal injury, always turn your trimmer off and allow it to cool before you clean or do any maintenance on it. 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 such as kerosene, can damage plastic housing or handle. Wipe off any moisture with a soft cloth. STORAGE • Never store the unit with gasoline in the tank where fumes may reach an open flame or spark.
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CAUSE Ignitionswitchis OFF Turn switch to ON Empty fuel tank Fill fueI tank Primer bulb wasn't pressed enough Press primer bulb fully and slowly 5-7 times Engine flooded Use starting procedure with choke lever in the RUN position, Pg+ 13 Old Gasoline Drain fuel tank/Add Fouled spark plug Replace or clean the spark plug ACTION fresh Gasoline ACTION CAUSE Air Filter is Plugged Replace or clean the air filter Old Gasoline Drain fuel tank / Add fresh Gasoline improper carburetor adjustment A
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Engine Type ................................................................. Displacement ................................................................. Clutch Type ......................................................................... Operating RPM (Trimmer) ......................................................... Operating RPM (Brushcutter) ...................................................... Idle Speed RPM ................................................................. Ignition Type .........
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ENGINE PARTS 4-CYCLE GAS TRIMMER (ppn - 41ADT49C063) - MODEL TB490BC (Serial Number 011 ......
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ENGINE PARTS - MODEL TB490BC 4-CYCLE (ppn - 41ADT49C063) !_m Part_Lo_ 1 2 3 4 5 8 7 8 9 10 11 12 13 14 15 79!-182338 791-182339 791-!8!925 791-!82098 791-182099 791-182340 791-182101 791-182100 791-!82341 791-182103 791-181038 791-182102 791-181033 791-182700 791-182344 16 17 18 19 20 21 22A 22B 23 24 791-182345 791-182749 791-181034 791-182347 791-182348 791-182732 791-182654 753-1225 791-181751 753-1227 25 26 27 28 29 30 31 32 33 34 35 36A 36B 37 38 39 40 41 42 43 44 45 46 791-182097 791-181750
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BOOM AND TB490BC 4-CYCLE TRIMMER PARTS - MODEL GAS TRIMMER ®( 1 791-00040 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 791-00041 791-00042 791-182690 791-182673 791-6!0327 753-1247 79!-!81099 791-612831 79t-612021 791-683296 791-181811 791-181812 791-181813 791-181814 791-181815 791-145569 753_1190 791-182057 791-181617 791-181981 791-181886 791-182541 791-613300 791-182200 791-182193 27 28 29 30 31 32 33 34 35 36 791-182195 791-145569 791-147492 791-182196 791-683304 753-119
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MANUFACTURER'S O LIMITED WARRANTY FOR: TRO RILT _ +glIIIIIIL _ 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.