Troy-Bilt TB490BC, Operator'S Manual

Page 1: ...s 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 replaceme...

Page 2: ...s information is very important if you need help from our Customer Support Department or an authorized dealer You can locate the model number by looking at the side of the engine housing A sample model plate is explained below For future reference please copy the model number and the serial number of the equipment in the space below Serial Number Model Parent Part Number lllllill H r l llL LtL Cop...

Page 3: ...obey a safety warning can result in injury to yourself and others Always follow the safety precautions to reduce the risk of fire electric shock and personal injury CAUTION Failure to obey a safety warning may result in property damage or personal injury to yourself or to others Always fellow the safety precautions to reduce the risk of fire electric shock and personal injury the cutting attachmen...

Page 4: ... vegetation and other materials They may become lodged between the cutting attachment and shield 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 Read and understand all safety warnings before operating this unit Always use the shoulder harness when using the bru...

Page 5: ...d 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 i e WARNING READ OPERATOR S MANUAL Read the Operator s Manual s and follow all warnings and safety instructions Failu...

Page 6: ...ing blade CHOKE CONTROL A FULL choke position B PARTIAL choke position C RUN position BRUSHCUTTERS Replace dull blade Do not sharpen the cutting blade Sharpening the blade can cause the blade tip to break off while in use This can result in severe personal injury TRIMMER BRUSHCUTTER SAFETY WARNING Thrown objects and rotating cutter can cause severe injury Keep bystanders especially children and pe...

Page 7: ...be used with the TB490BC See list of add ons on page 14 Muffler Guard Starter Rope Shaft Grip Throt de Spark Arrestor p Spark Plug Fuel Cap On Off Stop Shoulder Strap Clip Throttle Control Blade Shield Shield Mount Brush Blade Gear Housing EZ Unk TM Shaft Housing Air Filter Cover Cutting Attachment Shield J Handle Choke Lever Spark Plug Engine Feet Oil Fill Plug Dipstick Cutting Attachment Line Cu...

Page 8: ...ndle adjustment 5 Slide the J handle in or out until the arrow white line on the decal touches the clamp assembly Fig 2 S Fig 3 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 INSTALLING THE HARNESS IA WARNING Always use the shoulder harness personalwhen us ...

Page 9: ...ling the cutting blade Fig 7 Install the cutting attachment shield when using the unit as a grass trimmer WARNING To avoid serious personal injury the cutting attachment shield SHALL be in place at all times while operating the unit as a grass trimmer Install the cutting attachment shield on the shield mount by inserting the three 3 screws into the shield mount Tighten securely with a flat blade s...

Page 10: ...335 inolb 27 28 ft Ib 37 38 Nora Without a torque wrench use a 5 8 inch closed end or socket wrench turning the nut until the blade retainer is snug against the shaft bushing Make sure that the blade is installed correctly then rotate the nut an additional 1 4 to 1 2 turn counterclockwise Fig 13 9 Remove the locking rod from the locking rod slot WARNING To avoid serious personal injury I or damage...

Page 11: ...ng the unit as a grass trimmer DANGER OVERFILLING OIL CRANKCASE MAY CAUSE SERIOUS PERSONAL INJURY The importance of checking and maintaining the proper oil level in the crank case cannot be overemphasized Check oil before each use and change as needed See Changing the Oil RECOMMENDED OIL TYPE _ Using the proper type and weight of oil in the crankcase is extremely important Check the oil before eac...

Page 12: ...hen using alcohol blended fuel Using Blended Fuels If you choose to use a blended fuel or its use is unavoidable follow recommended precautions Always use fresh unleaded gasoline Use the fuel additive STA BIL or an equivalent Drain tank and run the engine dry before storing unit Using Fuel Additives The use of fuel additives such as STA BIL Gas Stabilizer or an equivalent will inhibit corrosion an...

Page 13: ...ottle for 30 seconds WARNING Avoid accidental starting Be in I the starting position whenever pulling the J starting rope To avoid serious personal injury the operator and unit must be in a stable position while starting Starter Rope Throttle Control Fig 22 11 Release the throttle control to the idle position and begin operation NOTE If the engine does not start using these procedures repeat steps...

Page 14: ...dd on easier place the unit on the ground or on a work bench 1 Turn knob countercIockwise to loosen Fig 23 EZ Link TM Coupler Release Button Guide Recess Fig 23 2 While firmly holding the add on push it straight into the EZ Link TM coupler Fig 24 NOTE Aligning the release button with the guide recess will help instalIation Fig 23 Release Button EZ LinkTM Coupler _ _s_ Primary Hole Upper Shaft Hous...

Page 15: ...becomes more difficult as the cutting line becomes shorter NOTE Do not rest the Bump Head TM on the ground while the unit is running CAUTION Do not remove or alter the line cutting blade assembly Excessive line length I will make the clutch overheat This may lead I to serious personal in ury or damage to the unt Some line breakage will occur from Entanglement with foreign matter Normal line fatigu...

Page 16: ... stalls or binds This is more likely to occur in areas where it is difficult to see the material being cut Cut while swinging the upper part of your body from right to left Always release the throttle trigger and allow the engine to return to idle speed when not cutting When done always unsnap unit from harness before taking harness off 16 i WARNING The blade continues to spin after the engine is ...

Page 17: ...ng This section covers both SpIitLine TM and standard single line installation Always use geniune Troy Bilt TM 0 105 in 2 667 mm replacement line Line other than specified may make the engine overheat or fail I WARNING Never use metal reinforced line I wire chain or rope etc These can break off r and become dangerous projectiles There are two methods to replace the trimming line Wind the inner ree...

Page 18: ...ection indicated wilt cause the cutting attachment to operate incorrectly 12 Insert the ends of the line into the two holding slots Fig 38 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 39 Push the inner reel and outer spool together While holding the inner reel and outer spool grasp the ends and pull firmly to rele...

Page 19: ...7 Hold the inner reel in place and installthe bump knob by turning counterclockwise Tighten securely Fig 41 NOTE Make sure the O ring is in place on the oil fill Replacement Parts plug dipstick when checking and changing the See Accessories Replacement Parts oil Fig 42 CHECKING THE OIL LEVEL I _I_ DANGER OVERFILLING OIL CRANKCASE I_k MAY CAUSE SERIOUS PERSONAL INJURY I_k CAUTION To prevent extensi...

Page 20: ... Allow ample time for complete drainage 4 Wipe up any oil residue on the unit and clean up any oil that may have spilled Dispose of the oil according to Federal State and local regulations 5 Refill the crankcase with 3 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 3 4 ounce 100 mt is approximately to the top of the la...

Page 21: ...er to spread and remove excess oil Fig 48 Air Filter Air Filter Cover Tab Choke Lever Fig 48 6 Replace the filter Fig 49 NOTE If the unit is operated without the air filter you will VOID the warranty Back Plate Fig 45 3 Wash the filter in detergent and water Fig 46 Rinse the filter thoroughly and allow it to dry Fig 46 4 Apply enough clean SAE 30 motor oil to lightly coat the filter Fig 47 Slots B...

Page 22: ... 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 e turn at a time as needed to reduce idle speed idle Adjustment Screw Checking the fuel cleaning the air filter and adjusti...

Page 23: ... in 076 0 152 mm Use a standard automotive 005 in 0 127 mm feeler gauge The fee_er gauge should sl de between the rocker arm and valve stem with a slight amount of resistance without binding Fig 56 Rocker Arms Nuts Feeler Gauge Gasket Fig 55 Adjustinl 003 006 in 076 0 152 ram J Rooker Arm Valve Stem Fig 56 10 If the clearance is not within specification a Turn the adjusting nut using a 5 16 inch 8...

Page 24: ...n the engine could damage the cylinder 4 install a correctly gaped spark plug in the cylinder head Tighten by turning the 5 8 inch deep socket clockwise until snug If using a torque wrench torque to 110 120 in olb 12 3 13 5 N m Do not over tighten Slot Tab Screw Spark Arrestor Cover Fig 58 3 Pull the tab on the spark arrestor cover out of the muffler Remove the spark arrestor cover 4 Remove the sp...

Page 25: ...ilBbe stored for an extended time 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 with 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 pl...

Page 26: ...ealer for carburetor adjustment Stop the engine and clean the cutting attachment Clean or replace the air filter Clean or Replace See Pg 24 CAUSE Old Gasoline improper carburetor adjustment Clogged Spark Arrestor Screen CAUSE Cutting head bound with grass Cutting head out of line Inner reel bound up Cutting head dirty Line welded Line twisted when refilled Not enough line is exposed ACTION Drain f...

Page 27: ...sition Starter Auto Rewind Muffler Baffled with Guard Throttle Manual Spring Return Fuel Tank Capacity 20 oz 591 ml Fuel Tank HD Polyethylene Drive Shaft Housing Aluminum Tube EZ Link TM Throttle Control Finger Tip Trigger Unit Weight No Fuel with J handle Cutting attachment shield and Cutting attachment 13 5 Ibs 6 13 kg Cutting Mechanism 4 Tooth Cutting Blade Dual String Cutting Head Line Spool B...

Page 28: ...ENGINE PARTS MODEL TB490BC 4 CYCLE GAS TRIMMER ppn 41ADT49C063 Serial Number 011 and greater Part Numbers On Following Page 22B 28 Reissued12 01 ...

Page 29: ... Arrestor Screen Screen Cover Screw Muffler Shield Muffler Mounting Screw Muffler Cover Switch Wire Assembly IJ _m _ t _L_ 47 791 18t247 Painut 48 753 1199 Recoil Pulley 49 791 613102 Recoil Spring 50 791 182366 Nut Clip 51 791 181079 Pull Handle 52 791 611061 Rope Guide 53 791 613103 Rope 54 791 181020 Starter Housing Screw 55 753 1237 Starter Housing Assembly includes 49 56 55 791 182368 Clutch ...

Page 30: ...le Bracket Assembly includes 12 7 Screw Upper Handle Clamp Middle Handle Clamp Lower Handle Clamp Nut Anti Rotation Screw Click Link Coupler includes 18 22 Screw Bott Adjustment Knob Knob Retaining Nut Lower Drive Shaft Housing Assembly Lower Flexible Drive Shaft Shield Mount Screw Assembly 2 piece Gearbox Assembly includes 25 97 28 Gearbox Screw Anti Rotation Screw Blade Shield Shield Mount Blade...

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Page 32: ... through Troy Bilt s authorized channels of export distribution Trey 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 No implied warranty including any implied warranty of merchantability or fitness for a particular purpose applies after the applicable period of express written warrant...