Page 1
Operator's Manual 4-Cycle Gasoline Trimmer/ Brushcutter Model TB490BC IMPORTANT: READ SAFETY RULES AND INSTRUCTIONS CAREFULLY P/N 769-00386 (10/02) PRINTED IN USA...
Page 2
Content Page Calling Customer Support ............ Rules for Safe Operation ............. <now Your Unit ............Assembly Instructions ..........Oil and Fuel Information ............. Starting/Stopping Instructions ..........Operating Instruct=ons ............Maintenance and Repair Instructions ........Cleaning and Storage ............Accessories and Replacement Parts ........Troubleshooting Chart ............
SYMBOL MEANING The purpose of safety symbols is to attract your attention to possible dangers. The safety symbols, DANGER: Failure to obey a Safety warning and their explanations, deserve your careful attention will result in serious injury to yourself or to and understanding.
• Wear heavy, long pants, boots and gloves. Do not • Keep the J-handle between the operator and cutting attachment or blade at all times. wear loose clothing, jewelry, short pants, sandals or go barefoot. Secure hair above shoulder level. •...
Page 5
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 SYMBOL MEANING • ON/OFF STOP CONTROL Indicates danger, warning or caution.
Page 6
Spark Arrestor .,G_ Spark Plug APPLICATIONS As a trimmer: Cutting grass and light weeds Edging Decorative trimming around trees, fences, etc. As a brushcutter: Fuel Cap Cutting weeds and light bush of up to 112 inch in Starter Rope Grip diameter Other optional accessories may be used with the Shaft Grip...
INSTALL HARNESS On some units, the J-handle may be pre-installed. In this case you must loosen screws and adjust the handle to fit the operator. Go to step 5 if the J-handle is pre-installed. WARNING: Always use the shoulder harness when using the cutting blade to INSTALL AND ADJUST THE J-HANDLE avo d serous...
Page 8
Hold the locking rod in place by grasping it next to Cutting Attachment the boom of the unit (Fig. 9). Screws Shield 3. While holding the locking rod, remove the cutting attachment by turning it clockwise off of the output shaft (Fig.
5. Makesurethatthecuttingbladeis centered onthe REMOVE THE CUTTING BLADE AND pilot stepandsittingf!atagainst t heoutputshaft INSTALL THE CUTTING ATTACHMENT bushing (Fig.12), WARNING: TO avoid serious personal I Allk l injury, always wear gloves while handling or Allk I center, the unit will vibrate and the blade I l installing the blade.
Place the unit on a flat level surface. OVERFILLING OIL CRANKCASE DANGER: Remove the oil plug / dipstick from the crankcase MAY CAUSE SERIOUS PERSONAL (Fig. 17). INJURY. Checking and maintaining proper oil level in the crank case (_annot is important and cannot be overemphasized, Check oil before each use and change as...
RECOMMENDED FUEL TYPE FUELING THE UNIT Old fuel is the primary reason for the unit not running WARNING: Gasoline is extremely flammable properly. Be sure to use fresh, clean, unleaded gasoline. and its vapors can explode if ignited. To avoid NOTE: This is a four cycle engine.
STARTING INSTRUCTIONS On/Off Stop Control Stop/Off (O) ventilated area outdoors. Carbon monoxide Throttle Lock-Out exhaust fumes can be ethan a Confined area. I wARNING: Operate this unit °nly in a well- WARNING: Avoid accidental starting. Remain in the starting position when pulling the starter rope (Fig.
Page 13
OPERATING THE EZ-LINK SYSTEM While firmly holding the add-on, push it straight into the EZ-Link coupler (Fig. 25). The EZ-Link system enables the use of these optional Add-Ons. NOTE: Aligning the release button with the guide recess Blower/Vacuum ......TBBV will help installation (Fig.
HOLDING THE TRIMMER 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. and body protection to reduce the tisk of _[WARNING: Always wear eye, hearing, foot For best results, tap the Bump Head...
DECORATIVE TRIMMING Decorative trimming is accomplished by removing all vegetation around trees, posts, fences and more. Rotate the whole unit so that the cutting attachment is at • Swing the unit in the opposite direction that the blade a 30 ° angle to the ground (Fig. 29). spins which increases the cutting action.
MAINTENANCE SCHEDULE NOTE: Maintenance, replacement, or repair of the emission control devices and system may be performed by Perform these required maintenance procedures at the any non-road engine repair establishment, individual frequency stated in the table. I hose procedures should or authorized service dealer.
Page 17
F0_ US_ _itl_ Sp!itLi_!_ 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). Slotted Holes 10. Before winding, split the line back about 6 inches. 11.
INSTALLING A PREWOUND REEL Oil Fill Plug/Dipstick ..Hold the OLiterspool with one hand and unscrew the blimp knob clockwise {Fig. 32). Inspect the bolt inside O-Ring the bump knob to make sure it moves freely. FZeplace the bump knob if damaged. I_emove the old inner reel from the outer spool Full - [Fig.
CHANGING THE OIL 4. Wipe up any oil residue on the Linit and clean Lip any oil that may have spilled. Dispose of the oil For a new engine, change the oil after the first 10 hours of according to Federal, State and local regulations. operation.
AIR FILTER MAINTENANCE iiiiiiiiiiii iiiii i iiiiiiiiiiiiiiiTili%iLiiiiiiiiii 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 the air filter will VOID the warranty. _LLLLLLLLLLLLLLLLLLLLiiLLLLLLLLitLLLLLLLLLLLi 1.
_!_a _ Air Fi!ter ROCKER ARM CLEARANCE I his 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 Aaju ia!espeea and then every 25 hours of operation thereafter.
Page 22
3. Remove t hescrewbehind theengine cover(Fig.53). Adjusting Huts Rocker Arms "- INTAKE Screw Feeler Gauge Figi 53 Disconnect the spark plug wire. 5. Clean dirt from around the spark plug. I,Zemove the spark plug from the cylinder head by turning a 5/8 in. socket counterclockwise.
REPLACING THE SPARK PLUG SPARK ARRESTOR MAINTENANCE I;_emovethe mL_ff]ercover. See RockerArm Cfearance. Use only Champion I,ZI_)Z19H spark plug or equivalent. I he correct air gap is 0.025 in. (0.655 mm.). Remove the plug 2. With a flat blade screwdriver or Iorx 1-20 bit, after every 25 hours of operation and check its condition.
CLEANING NOTE: I,Zemove the spark plug and drain all of the oil from the cylinder before attempting to start the trimmer after storage. Change the oil referring to Chanqtng the Oil. Dispose of the old oil in accordance to Federal, State and Local regulations.
Page 25
CAUSE ACTION Fill fuel tank with new fuel Empty f'uel tank Primer bulb wasn't pressed enough Press primer bulb fully and slowly 10 times Old f'uel Drain gas tank and add fresh f'uel Fouled spark plug Replace or clean the spark plug Plugged spark arrestor Clean or replace spark arrestor When it is above 40°F outside, the Cold Start Lever is in the...
Page 27
EPA Emission Control Warranty Statement Your Warranty Rights and Obligations Ihe Environmental Protection Agency and MID SOUl HWESI INC (MID) are pleased to explain the emission control system warranty on your 2002 and later small off-road engine. New small off-road engines must be designed, built and equipped to meet stringent anti-smog standards.
Page 28
ENGINE PARTS - MODELS TB490BC 4-CYCLE GAS TRIMMER PPN - 41BDT49C063 ®...
Page 29
ENGINE PARTS - MODEL TB49OBC 4-CYCLE GAS TRIMMER PPN - 41BDT49C063 Item Part No, Descr!ption !tern Pa_ NQ, Descr!ption 753-04083 Engine Cover 781-181247 Palrrut 791-182339 Engine Cover Screws 753-1 lgg Recoil Pulley 791-181025 Valve Cover Screw 753-04286 Recoil Sprfng 791-182098 Valve Cover 781-182368 Nut Clip...
Page 30
BOOM AND TRIMMER PARTS - MODEL TB49OBC 4-CYCLE GAS TRIMMER PPN - 41BDT49C063 !tem Pa_ No, De_cdption 791-00840 _hrottle Housing and rrfgger Assembly (irlcludes 2-4) 791-00841 _hrottle Trigger Lock=OL$ 791-00842 _hrottle Trigger 791-182688 _hrottle Trigger Spring 791=182405 Swit_:fl _&_lrirlbly 791=618327 Harness Clip 753-1247 Upper Drive Shaft Housing Assembly...
Page 31
Troy-Bilt LLC During the period to be defective in material or workmanship. I his limited...