The Handy THPK45CH User manual

OWNER
MANUAL
THPK45CH BRUSH CUTTER
GRASS TRIMMER
ISO 9001:2000
Rev. 2010/12/15
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25/02/2011

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CONTENTS
1. DESCRIPTION OF SYMBOLS
2. SAFETY RULES
3. PARTS IDENTIFICATION
4. TECHNICAL DATA
5. ACCESSORIES
6. EXPLANATION OF TERMS
7. ATTACHMENT SETUP
8. EXAMPLE OF FUEL-MIXING
9. STARTING、OPERATION、STOPPING
10. TRIMMING
11. MAINTENANCE
12. DECLARATION OF CONFORMITY
-1. DESCRIPTION OF SYMBOLS
Read and follow this operator’s manual. Failure to do so
could result in serious injury.
Wear head, eye and hearing protection during the operation
of this machine.
Wear heavy-duty gloves, preferably made of leather.
Wear steel-toed safety boots with non-slip soles.
Beware of thrown objects.
Make sure no one is within 15 metres
of the machine during operation.
The maximum speed of the cutting attachment shaft
Sound Power Level
measured in accordance with
2000/14/EC + 2005/88/EC

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2. SAFETY RULES
2-1. Notes when using the nylon-cutting head and 3 teeth blade.
1. The grass trimmer was designed to cut grass and small soft vegetation. Never use the trimmer for any other purpose.
2. Only use nylon cutting heads that meet the trimmer rotation rate requirements. Use nylon cords designated for the nylon cutting heads.
3. After starting the engine, pull the throttle lever gradually. The engine speed will increase and the nylon-cutting head or 3 teeth blade will start
rotating.
4. When the throttle lever is released, the engine goes back to idle speed automatically.
5. Operate the unit at full throttle while cutting. Best fuel efficiency is obtained by releasing the throttle when swinging back after a cut.
6. The blade rotates counterclockwise. For best performance and to avoid being struck by debris, move the blade from right to left while
working.
2-2. Notes when using the unit.
1. Wear close fitting, tough work clothing that will provide protection, such as long slacks or trousers, safety work shoes, heavy duty work gloves,
a head protector (helmet), a safety face shield, or safety goggles for eye protection and a good grade of ear plugs or other hearing protection.
2. Refuel in a safe place. Open the fuel cap slowly to release any pressure which may have formed in the fuel tank. To prevent a fire hazard,
move at least 3 metres from the fueling area before starting.
3. Comply with all fire prevention regulations. Compliance with all local laws is the user’s responsibility. Your unit comes with a spark arrester
screen in the user kit. Replacement spark arrester screen kits are available from the distributor.
4. Turn off the unit before setting it down.
5. Always hold the unit firmly with both hands, the thumb and fingers encircling the handles.
6. Keep all screws and fasteners tight. Never operate your equipment when it is improperly adjusted or not completely and securely assembled.
7. Keep the handles dry, clean and free of the fuel mixture.
8. Keep the cutting-head as close to the ground as possible. Avoid hitting small objects with the cutting-head. When cutting on a slope, stand
below the cutting-head. Never cut or trim on a hill or slope, etc. if there is the slightest chance of slipping, sliding or losing firm footing.
9. Check the area you will be trimming for debris that may be struck or thrown during operation.
10. Keep all parts of your body and clothing away from the cutting-head when starting or running the engine. Before starting the engine, make
sure the cutting-head will not come into contact with any obstacle.
11. Stop the engine before examining the cutting line.
12. Store equipment away from possible ignition sources, such as gas-powered water heaters, clothes dryers, or oil-fired furnaces, portable
heaters, etc.
13. Always keep the debris shield, cutting-head, and engine free of debris build-up.
14. Operation of equipment should always be restricted to mature and properly instructed individuals.
15. WARNING: The emission of exhaust gases is toxic.
16. Emergency Stopping Procedure. When it is necessary to stop engine immediately, move the switch to the stop position
17. This unit has a centrifugal clutch which enables the cutting attachment to stop turning once the engine is idling.

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3. PARTS IDENTIFICATION
1 Engine 2 Air cleaner 3 Fuel Tank
4 Suspension point 5 Ergonomic handle 6 Handle clamp
7 Shaft tube 8 Cutting attachment guard 9 Gear case
10 3 Teeth blade 11 Engine stopping device 12 Throttle trigger lockout
13 Throttle trigger 14 Throttle lever lock button 15 Double shoulder harness
16 Nylon-cutting head

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4. TECHNICAL DATA
Model No. X-800
Engine Type TJ45E, Air Cooled, 2 Cycle
Displacement 45.4 cm3
Carburetor Diaphragm Type
Air Cleaner Polyurethane foam
Spark plug BPMR7A, NGK
Petrol and oil mix ratio
Petrol and mineral 2 cycle oil mix ratio (25 : 1)
Petrol and semi-synthetic 2 cycle oil mix ratio (50 : 1)
Dry weight 6.9 kg
Fuel capacity 1000 cm3
Bump head Twin line bump feed
Cutting blade 3 teeth blade
Drive shaft length 1500 mm
Cutting width 254mm for blade; 465mm for bump head
Handle Bike Handle
Ignition Electronic
Drive Centrifugal Clutch
Sound Pressure Level 101 dB (A)
Sound Power Level 109 dB (A)
Guarantee Sound Power Level 112 dB (A)
Vibration level during use (Max.) ﹤9 m/s2
Vibration level for idling (Max.) ﹤5 m/s2
Maximum engine performance 1.6 kW
Engine speed (rotational frequency) at
recommended max. spindle rotational
frequency
12500 min-1
Maximum rotational frequency of the
spindle (Max.) 10000 min-1
Idle speed (Max.) 2850 min-1
Fuel consumption 544 g / kWh

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5. ACCESSORIES
The brush cutter is packed in two separate cartons: one for the engine and another for the drive shaft attachment.
The engine carton contains the following. Please check the contents.
Model X800
Engine Kawasaki TJ45E
Cutting attachment Nylon line cutter, Tap & Go, M10 x 0.25 Left handed nut
Handle Ergonomic handle type (Ø 19 mm)
Safety Guard CE Standard
Bracket spacer Double shoulder harness
Mounting screws Screw Socket M6 x 30 mm
Screw wrench 17 x 19 mm
Spanner 8 x 10 mm
Standard tools
Allen wrench 4mm-5mm
6. EXPLANATION OF TERMS
1 Brush cutter The trimmer with a blade, for cutting weeds, shrubs and bushes.
2 Grass trimmer
The trimmer with a grass trimmer head, for cutting weeds, grass and
similar soft shrubs.
3 Cutting attachment General terms for blade and grass trimmer heads.
4 Idling
Minimum stable speed with the carburetor adjusted to the manufacturers
specifications.
5 Throttle lock Locks the throttle at half revs.
6 Quick release mechanism Device to allow the operator to halt operation and disengage the trimmer in
an emergency.
7 Throttle trigger lock out Device to prevent the throttle trigger from accidental activation before it is
released manually.
7. ATTACHMENT SETUP
7-1. Attach the Engine to the shaft tube
1. Put the engine and shaft tube on the ground and then assemble as shown in Fig.1.
2. Lock the M6x30 screws tight to prevent them coming loose during operation.
Fig.1 Fig.2 Fig.3
7-2. Double- hand handles
1. Insert both handles into Handle Joint A evenly as in Fig.2.
2. Adjust the handle joint to the most comfortable position for the user.
3. Adjust the handle to a suitable angle.
4. Lock bolts tight.
7-3. Cutting attachment guard mounting
1. Join the two parts of the cutter guard by clicking them together. Lock them in position by inserting the screw provided.
2. Fit the guard assembly to the drive shaft housing using brackets, screws and nuts as in Fig 3.

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7-4. Throttle wire mounting
1. Pass the throttle wire through the adjusting screw. Fig.4
2. Move the carburetor swivel toward the attachment.
3. Fit the tip (thick portion) of the throttle wire into the hole in the swivel.
4. Fit the tip of the throttle wire from the throttle trigger into the tip of the throttle wire from the engine. Fig.5
5. Close the cover so that the arrow mark is set toward the lever by holding the joint of the 2 throttle wires.
Fig. 4 Fig. 5
7-5. Lead wire
Connect the 2 lead wires from the throttle trigger to the corresponding 2 wires from the engine. Fig.6
Fig.6 Fig.7
7-6. Wearing the double-shoulder harness
Pass your arms through the straps as if putting on a coat. Buckle the harness at the front of your body.
Set the shoulder pads properly as in Fig. 7
CAUTION
Only use the quick release mechanism in an emergency!
The double-shoulder harness has a quick release mechanism so that you can release the harness instantly in an emergency.
1. Pull the harness grip upward to separate the hook from the harness so that the harness is separated from the trimmer.
2. To re-connect the harness to the trimmer, readjust the grip by pulling it and re-setting the hook ring. Fig.8-2
Fig.8-1 Fig.8-2 Fig.8-3

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7-7. Cutting attachment mounting.
For the nylon line cutting attachment
1. Match the hole in the side of the cutting attachment guard with the hole in the side of the gear housing.
2. Then insert a 4mm Allen wrench into the holes to stop the clamp moving. Fig. 10
3. Undo the shaft nut by turning in a clockwise direction with the spanner provided.
4. Insert the upper clamp and lower clamp into the gear housing.
5. Rotate the nylon cutting head counterclockwise by hand to attach it to the gear housing.
6. Remove the Allen wrench.
Fig. 9 Fig. 10 Fig. 11 Fig.12
For the blade cutting attachment
1. Match the hole in the side of the cutting attachment guard with the hole in the side of the gear housing.
2. Then insert a 4mm Allen wrench into the holes to stop the clamp moving. Fig.12
3. Undo the shaft nut on the blade cutting attachment head by turning in a clockwise direction with the
spanner provided.
4. Remove the blade cutting attachment tightening nut, cup washer and lower blade mounting washer
from the gear housing.
5. Fit the cutting blade as in Fig. 11 and tighten the nut securely in an anti-clockwise direction.
6. Remove the 4mm Allen wrench.
7. When not in use store the blade in its protective cover as in Fig. 13.
Fig. 13
8. EXAMPLE OF FUEL - MIXING
8-1 Fuel mixing
Use unleaded Petrol containing 4%, 2 cycle mineral engine oil (25:1) or 2%, 2 cycle semi-synthetic engine oil (50:1).
WARNING
1. Use a container to mix Petrol with 2 cycle engine oil. Do not mix them in the fuel tank directly. Wipe off spilt fuel immediately.
2. Do not use old mixed fuel as it will deteriorate over time and adversely affect the engine.
3. Do not smoke while mixing fuels.

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9. STARTING, OPERATION, STOPPING
9-1 Before starting the engine
Check for loose screws and nuts and fill with properly mixed fuel. Place the engine on stable ground with the engine stand (fuel tank) and
the guard resting on the ground.
9-2 To start a cold engine
Fig.14 Fig.15 Fig.16
1. Push the priming pump 5 times. Fig.14
2. Fully close the choke lever. Fig.15
3. Set the switch to the Iposition. Fig. 16
4. Hold the trimmer shaft near the engine firmly and as in Fig. 17 pull the starter strongly.
5. When ignition is heard, reset the choke and pull the starter.
6. Warm up the engine for about 3 minutes.
7. When the engine has started at the initial ignition open the choke lever gradually.
9-3 When the engine has been warmed up
1. Fully open the choke lever.
2. Push the priming pump 5 times. Fig.14.
3. Hold the handle and depress the throttle trigger. Release the throttle trigger while
pushing the throttle lock button on the handle. Fig. 17
4. Set the switch to the Iposition. Fig. 16
5. Hold the trimmer shaft near the engine firmly and as in Fig. 17 pull the starter strongly.
6. If the engine does not start, repeat 9-2, the procedure for starting a cold engine.
CAUTION
1. After starting the engine, accelerate and decelerate the engine several times by opening and
closing the throttle trigger.
2. Air in the carburetor causes poor acceleration or engine stoppage.
3. Re-fuel before the fuel is used up, starting the engine after using all of the fuel is very difficult.
9-4 Operation
After starting the engine, warm it up for about 3 minutes and gradually increase the speed.
9-5 Stopping
Do not suddenly stop the engine when operating at high speeds. Fig. 18
Gradually return the throttle trigger and idle the engine before setting the switch to STOP. Fig.18
CAUTION
Do not operate the engine at high speeds with no load on the cutting attachment,
Especially when the engine is new. When operated at high speeds with no load,
it will accelerate to an excessively high speed that might harm the engine.
9-6 When the engine does not start
If the engine does not start or flames flow back through the muffler even though you have pulled the starter many times, remove and check the
spark plugs.
1. If the spark plugs are dry, no fuel has been fed into the cylinder. Check the fuel pipe and carburetor.
2. Clean or replace the spark plugs if they are wet or dirty.
3. If fuel has overflowed into the crank case, remove the spark plugs, open the throttle and pull the starter 2 or 3 times to remove excess fuel
from the crank case.

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CAUTION
1. Before starting trimming, check that all the safety devices are attached. The nylon cutting head is fixed securely, the Allen
wrench has been removed and the nylon cord is the appropriate length.
2. When using the trimmer, be sure to wear goggles, hearing protection and gloves.
10. TRIMMING
1. Wear the harness and hold the brush cutter handle to start operation. Fig. 19
2. Move the brush cutter attachment from right to left. Be careful of thrown objects. Never use the right side of a nylon cutting head to cut grass!
Fig. 20
3. If you have to slant the nylon cutting attachment or blade cutting attachment downward make sure to tilt it towards the cutting side.
Take care not to drag the head on the ground.
Fig.19 Fig.20
11. MAINTENANCE
11-1. Cleaning the air cleaner
A dirty air cleaner will choke the engine, therefore causing the engine
to stop.
Wash the air cleaner as required.
Replace the cleaner when it becomes dirty.
1. Detach the cleaner mounting screws and remove the cleaner cover.
2. Remove the element.
3. Follow the same procedure as in Fig.21.
Fig.21
11-2. Lubricating the gear housing with grease
The gear housing has a greasing port. Remove the greasing ports screw and feed grease into port. Grease the port after every 20 hours of
operation. Fig.22
Fig.22 Fig.23
11-3. Checking the gear housing mounting screws
Loose gear housing fixing screws are very dangerous even though they have covers to prevent them from coming off. Be sure to check them
before operating the trimmer. Tighten the screws securely with the Allen wrench provided with the trimmer.
11-4. Spark plug
The spark plugs have a standard electrode-to-electrode distance of 0.6 to 0.7mm Fig.23
The spark plug electrodes are dry and brown under optimum operating conditions. Clean as necessary.
Use spark plugs designated for the engine.
11-5. Fuel strainer cleaning
The fuel hose has a felt strainer at its end (in the fuel tank) to prevent foreign matter such as sand from entering the carburetor. Clean the strainer
as required because the pump cannot suck up fuel if the strainer is clogged, which would cause the engine to stop. Replace the felt strainer if it is
clogged or damaged.
CAUTION
The trimmer was designed to cut weeds, grass and similar soft vegetation.
Never use the trimmer for any other applications!

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Do not store in an enclosure where fuel fumes may accumulate or reach an open flame or spark. Serious
personal injury may result.
11-6. Adjusting the throttle cable
Adjust the throttle cable length with the adjusting nut. If the Nylon cutting head rotates even after you have released your hand from the throttle
trigger to idle the engine, adjust the throttle cable length. Loosen the lock nut and turn the adjusting nut to adjust the cable length. Turn the
adjusting nut clockwise to lengthen the throttle and counterclockwise to shorten it. Tighten the lock nut after adjustment.
11-7. Carburetor
11-8.Storing
When shutting down your trimmer for a prolonged period of time (30 days or longer), store it properly, so that it will operate normally when you
need it. The Trimmer may not start smoothly if stored improperly.
1. Store the unit in a dry dust free place, out of the reach of children.
2. Place the stop switch in the “OFF” position.
3. Remove any accumulation of grease, oil, dirt and debris from the exterior of the unit.
4. Perform all periodic lubrication and services that are required.
11-9. Storage for engine
1. Drain the fuel tank completely and pull the recoil starter handle several times to remove fuel from the carburetor.
2. Remove the spark plug and pour 7cc (1/4 oz) of fresh, clean, two–stroke engine oil into the cylinder through the spark plug hole.
A. Place a clean cloth over the spark plug hole.
B. Pull the recoil starter handle 2-3 times to distribute the oil inside the engine.
C. Observe the piston location through the spark plug hole. Pull the recoil starter handle slowly until the piston reaches the top of its
travel and leave it there.
3. Install the spark plug (do not connect spark plug cable).
4. Attach the cover to the cutting blades during storage.
CAUTION
The engine has been adjusted before shipment. In the case of engine trouble, Contact your service
dealer because the engine trouble is not caused by a faulty carburetor alone.An engine that is not
adjusted properly will damage not only the carburetor but also the engine itself.
IMPORTANT
Some tree sap and resins are corrosive. Thoroughly wash the blades after each use, then coat metal parts with light oil.

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MAINTENANCE RECORD

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12. PARTS DIAGRAM AND LISTS

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No. Part No. Description QTY No. Part No. Description QTY
1 TH171-1 Gear Case Assembly
Incl. 2-23 1 37 TH171-37 Hex Bolt M6x28 1
2 TH171-2 Gear Case 1 38 TH171-38 Hex BoltM5x10 1
3 TH171-3 Bevel Pinion 1 39 TH171-39 Hex Bolt M6x30 4
4 TH171-4 Bevel Gear 1 40 TH171-40 Clamp 1
5 TH171-5 Spline Shaft 1 41 TH171-41 - -
6 TH171-6 - - 42 TH171-42 - -
7 TH171-7 Inner Washer 1 43 TH171-43 - -
8 TH171-8 Outer Washer 1 44 TH170-44 Cowhorn Handle
Assembly 1
9 TH171-9 Bearing 6001 1 45 TH170-45 Top Handle Clamp 1
10 TH171-10 Bearing 6001Z 1 46 TH170-46 Middle Handle Clamp 1
11 TH171-11 Bearing 6000 1 47 TH170-47 Rubber Clamp 2
12 TH171-12 Bearing 6002UU 1 48 TH170-48 Bottom Handle Clamp 1
13 TH171-13 - - 49 TH170-49 Bolt M6x25 2
14 TH171-14 Circlip S12 1 50 TH170-50 Bolt M6x25 4
15 TH171-15 Circlip R28 1 51 TH170-51 Handle Grip 1
16 TH171-16 Circlip R32 1 52 TH170-52 Handle Bar Left 1
17 TH171-17 Hex Bolt M8x8 1 53 TH170-53 Handle Bar Right 1
18 TH171-18 Hex Bolt M6x25 1 54 TH170-54 Throttle Assembly 1
19 TH171-19 Hex Bolt M5x12 1 55 TH171-55 - -
20 TH171-20 Cover 1 56 TH171-56 - -
21 TH171-21 Cupped Washer 1 57 TH170-57 Shoulder Harness 1
22 TH171-22 Left Hand Thread Nut 1 58 TH171-58 Clip 2
23 TH171-23 Bolt M5x15 1 59 TH171-59 - -
24 TH171-24 - - 60 TH171-60 Blade 1
25 TH171-25 Main Shaft 1 61 TH171-61 Guard Assembly 1
26 TH171-26 Driveshaft 1 62 TH170-62 Tool Set 1
27 TH171-27 Clutch Assembly 1 63 TH171-63 Pipe Clamp 1
28 TH171-28 Boss 1 64 TH171-64 Hex Bolt M5x12 1
29 TH171-29 Circlip R45 1 65 TH171-65 Safety Cover 1
30 TH171-30 Rubber Damper 1 66 TH171-66 Cutter 1
31 TH171-31 Circlip IRTW30 1 67 TH171-67 Hex Nut M5 7
32 TH171-32 Clutch Housing 1 68 TH171-68 Guard 1
33 TH171-33 Circlip S15 1 69 TH171-69 Clamp Bracket 1
34 TH171-34 Bearing 6202ZZ 1 70 TH171-70 Hex Bolt M6x25 2
35 TH171-35 Circlip R35 1 71 TH171-71 Screw M4x12 1
36 TH171-36 Clutch Drum 1 72 TH171-72 Nylon Head 1

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EC Declaration of Conformity
We，Importer
Handy Distribution
SN3 4NS
Declare that the product
Designation: 45cc BRUSH CUTTER
Model: THPK45CH
Complies with the following directives:
2006/42/EC- Machinery Directive
2004/108/EC- Electromagnetic Compatibility Directive
2000/14/EC amended by 2005/88/EC- Noise Emission in the Environment by Equipment for
Use Outdoors Directive.
The conformity assessment procedure followed was in according with Annex V of the
Directive 2000/14/EC.
Name of the Notified Body: TÜV Rheinland LGA Products GmbH
Address:. Tillystrasse 2, 90431 Nurnberg, GERMANY
- Measured Sound Pressure Level: 102 dB (A)
- Guaranteed Sound Power Level: 112 dB (A)
Standards and technical specifications referred to:
EN ISO 11806:2008
EN ISO 14982:1998
EN ISO 3744:1995
ISO 11094:1991
Authorised signatory and technical file holder
Date: 22/2/2011
Signature:
Name / title: Mr. Simon Belcher / Managing Director
Hobley Drive, Stratton St Margaret, Swindon, Wiltshire, SN3 4NS.

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To order spare parts and see the complete range of garden machinery
and garden equipment from Handy, visit:
www.thehandy.co.uk
Spares & Support: 01793 333212