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Operatorâs Manual Chipper Shredder Vacuum Model 204 IMPORTANT : Read safety rules and instructions carefully Warning : This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest - covered , brush - covered or grass - covered land unless the engineâs exhaust system is equipped with a spark arrester meeting applicable local or state laws ( if any ) . If a spark arrester is used , it should be maintained in effective working order by the operator . In the State of California the above is required by law ( Section 4442 of the California Public Resources Code ) . Other states may have similar laws . Federal laws apply on federal lands . A spark arrester for the muffler is available through your nearest engine authorized service dealer or contact the service department , P.O . Box 361131 Cleveland , Ohio 44136 - 0019 . TROY - BILT LLC P.O . BOX 361131 CLEVELAND , OHIO 44136 - 0019 PRINTED IN U.S.A . 769 - 00170B.fm FORM NO . ( 5 / 2003 )
TABLE OF CONTENTS Content Page Important Safe Operation Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Assembling Your Chipper Shredder Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Know Your Chipper Shredder Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Operating Your Chipper Shredder Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Adjusting Your Chipper Shredder Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Maintaining Your Chipper Shredder Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 FINDING MODEL NUMBER This Operatorâs Manual is an important part of your new chipper shredder vacuum . It will help you assemble , prepare and maintain the unit for best performance . Please read and understand what it says . Before you start assembling your new equipment , please locate the model plate on the equipment and copy the information from it in the space provided below . The information on the model plate is very important if you need help from our Customer Support Department or an authorized dealer . â¢ You can locate the model number by standing behind the unit and looking down at the frame below the engine . 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 . Copy the model number here : TROY - BILT LLC31 Copy the serial number here : P . O . BOX 3611 CLEVELAND , OH 44136 www.troybilt.com 330 - 558 - 7220 866 - 840 - 6483 ENGINE INFORMATION The engine manufacturer is responsible for all engine - related issues with regards to performance , power - rating , specifications , warranty and service . Please refer to the engine manufacturerâs Ownerâs / Operatorâs Manual packed separately with your unit for more information . CALLING CUSTOMER SUPPORT If you have difficulty assembling this product or have any questions regarding the controls , operation or maintenance of this unit , please call the Customer Support Department . Call 1 - ( 330 ) 558 - 7220 or 1 - ( 866 ) - 840 - 6483 to reach a Customer Support representative . Please have your unitâs model number and serial number ready when you call . See previous section to locate this information . You will be asked to enter the serial number in order to process your call . For more details about your unit , visit our website at www.troybilt.com 2
SECTION 1 : IMPORTANT SAFE OPERATION PRACTICES WARNING : This symbol points out important safety instructions which , if not followed , could endanger the personal safety and / or property of yourself and others . Read and follow all instructions in this manual before attempting to operate this machine . Failure to comply with these instructions may result in personal injury . When you see this symbol - heed its warning . WARNING : The Engine Exhaust from this product contains chemicals known to the State of California to cause cancer , birth defects or other reproductive harm . DANGER : This machine was built to be operated according to the rules for safe operation in this manual . As with any type of power equipment , carelessness or error on the part of the operator can result in serious injury . This machine is capable of amputating hands and feet and throwing objects . Failure to observe the following safety instructions could result in serious injury or death . bare feet or sandals . Wear leather work gloves when Training feeding material in the chipper chute . 1 . Read , understand , and follow all instructions on the 4 . Before starting , check all bolts and screws for proper machine and in the manual ( s ) before attempting to tightness to be sure the machine is in safe working assemble and operate . Keep this manual in a safe place condition . Also , visually inspect machine for any damage for future and regular reference and for ordering at frequent intervals . replacement parts . 5 . Maintain or replace safety and instructions labels , as 2 . Be familiar with all controls and their proper operation . necessary . Know how to stop the machine and disengage them 6 . To avoid personal injury or property damage use extreme quickly . care in handling gasoline . Gasoline is extremely 3 . Never allow children under 16 years old to operate this flammable and the vapors are explosive . Serious machine . Children 16 years old and over should read and personal injury can occur when gasoline is spilled on understand the operation instructions and safety rules in yourself or your clothes which can ignite . Wash your skin this manual and should be trained and supervised by a and change clothes immediately . parent . a . Use only an approved gasoline container . 4 . Never allow adults to operate this machine without b . Extinguish all cigarettes , cigars , pipes , and other proper instruction . sources of ignition . 5 . Keep bystanders , helpers , pets , and children at least 75 c . Never fuel machine indoors . feet from the machine while it is in operation . Stop d . Never remove gas cap or add while the engine is machine if anyone enters the area . hot or running . 6 . Never run an engine indoors or in a poorly ventilated e . Allow engine to cool at least two minutes before area . Engine exhaust contains carbon monoxide , an refueling . odorless and deadly gas . f . Never over fill fuel tank . Fill tank to no more than 7 . Do not put hands and feet near rotating parts or in the 1 / 2 inch below bottom of filler neck to provide feeding chambers and discharge opening . Contact with space for fuel expansion . the rotating impeller can amputate fingers , hands , and g . Replace gasoline cap and tighten securely . feet . h . If gasoline is spilled , wipe it off the engine and 8 . Never attempt to unclog either the feed intake or equipment . Move machine to another area . Wait 5 discharge opening , remove or empty vacuum bag , or minutes before starting engine . inspect and repair the machine while the engine is i . Never store the machine or fuel container inside running . Shut the engine off and wait until all moving where there is an open flame , spark , or pilot light parts have come to a complete stop . Disconnect the ( e.g . furnace , water heater , space heater , clothes spark plug wire and ground it against the engine . dryer , etc . ) Preparation j . To reduce a fire hazard , keep machine free of 1 . Thoroughly inspect the area where the equipment is to grass , leaves , or other debris build - up . Clean up be used . Remove all rocks , bottles , cans , or other foreign oil or fuel spillage and remove any fuel soaked objects which could be picked up or thrown and cause debris . personal injury or damage to the machine . k . Allow machine to cool at least 5 minutes before 2 . Always wear safety glasses or safety goggles during storing . operation or while performing an adjustment or repair , to Operation protect eyes . Thrown objects which ricochet can cause 1 . Do not put hands and feet near rotating parts or in the serious injury to the eyes . feeding chambers and discharge opening . Contact with 3 . Wear sturdy , rough - soled work shoes and close - fitting the rotating impeller can amputate fingers , hands , and slacks and shirts . Loose fitting clothes or jewelry can be feet . caught in movable parts . Never operate this machine in 3
2 . Before starting the machine , make sure the chipper stopped . Disconnect the spark plug wire and ground it chute , feed intake , and cutting chamber are empty and against the engine to prevent unintended starting . free of all debris . 4 . Do not change the engine governor settings or 3 . Thoroughly inspect all material to be shredded and overspeed the engine . The governor controls the remove any metal , rocks , bottles , cans , or other foreign maximum safe operating speed of the engine . objects which could cause personal injury or damage to 5 . Maintain or replace safety and instruction labels , as the machine . necessary . 4 . If the impeller strikes a foreign object or and / or if your 6 . Follow this manual for safe loading , unloading , machine should make an unusual noise or vibration , shut transporting , and storage of this machine . the engine off immediately . Allow the impeller to stop ; 7 . Never store the machine or fuel container inside where disconnect the spark plug wire , ground it against the there is an open flame , spark or pilot light such as a water engine and perform the following steps : heater , furnace , clothes dryer , etc . a . Inspect for damage . 8 . Always refer to the operatorâs manual for proper b . Repair or replace any damaged parts . instructions on off - season storage . c . Check for any loose parts and tighten to assure 9 . If the fuel tank has to be drained , do this outdoors . continued safe operation . 10 . Observe proper disposal laws and regulations for gas , 4 . Do not allow an accumulation of processed material to oil , etc . to protect the environment . build up in the discharge area . This can prevent proper Your Responsibility discharge and result in kickback of material through the Restrict the use of this power machine to persons who feed opening . read , understand and follow the warnings and 5 . Do not attempt to shred or chip material larger than instructions in this manual and on the machine . specified on the machine or in this manual . Personal injury or machine damage could result . NOTE : Not all safety labels shown may apply to your 6 . Never attempt to unclog either the feed intake or chipper shredder vacuum . discharge opening while the engine is running . Shut the engine off , wait until all moving parts have stopped , disconnect the spark plug wire and ground it against the engine before clearing debris . 7 . Never operate without vacuum bag and discharge chute properly attached to the machine . Never empty or change vacuum bag while the engine is running . Zippered end of vacuum bag must be kept closed at all times during operation . 8 . Never operate without either the inlet nozzle or optional hose attachment properly attached to the machine . Never attempt to attach or change either attachment while the engine is running . 9 . Keep all guards , deflectors and safety devices in place and operating properly . 10 . Keep your face and body back and to the side of the chipper chute while feeding material into the machine to avoid accidental kickback injuries . 11 . Never operate this machine without good visibility or light . Always be sure of your footing and keep a firm hold on the handles . 12 . Do not operate this machine on a gravel surface . 13 . Do not operate this machine while under the influence of alcohol or drugs . 14 . Muffler and engine become hot and can cause a burn . Do not touch . 15 . Never pick up or carry machine while the engine is running . Maintenance & Storage 1 . Never tamper with safety devices . Check their proper operation regularly . 2 . Check bolts and screws for proper tightness at frequent intervals to keep the machine in safe working condition . Also , visually inspect machine for any damage and repair , if needed . 3 . Before cleaning , repairing , or inspecting , stop the engine and make certain the impeller and all moving parts have 4
SECTION 2 : ASSEMBLING YOUR CHIPPER SHREDDER VACUUM Unpacking Attaching The Nozzle â¢ Remove staples , break glue on top flaps , or cut â¢ Remove three wing nuts from the front of the tape at carton end and peel along top flap to open chipper shredder vacuum . carton . â¢ Place nozzle in position over the three studs on unit â¢ Remove loose parts if included with unit ( i.e . , and secure with wing nuts just removed . operatorâs manual , etc . ) See Figure 2 . Wing â¢ Cut along corners , lay carton down flat , and remove Nuts packing material . Wing â¢ Roll or slide unit out of carton and check carton Nut thoroughly for loose parts . Loose Parts In Carton Following is the list of loose parts shipped with your Nozzle equipment . Compare the parts with the illustration in Figure 1 to identify these items . 1 . Nozzle 2 . Bag 3 . Chipper Chute 4 . Tamper Plug Figure 2 5 . Oil ( Not Shown ) NOTE : The metal tab on the nozzle must depress the safety switch button attached to the front of the chipper shredder vacuum or the engine will not start . Bag Attaching the Chipper Chute â¢ Loosen , but do not remove , the two hex bolts , flat Nozzle washers , and flange nuts which are secured to the support bracket . See Figure 3 . Chipper Hex Bolts Chute Chipper Chute Tamper Plug Figure 1 Flat Before Assembly Washers IMPORTANT : This unit is shipped without gasoline or oil in the engine . Be certain to service engine with gasoline and oil as instructed in the accompanying engine Flange manual before operating your machine . Nuts Support Bracket NOTE : Reference to right or left side of the equipment is observed from the operating position , unless Figure 3 otherwise stated . â¢ Remove the two flange nuts , hex bolts and saddle â¢ Before starting assembly , disconnect the spark washers which secure the right side of the upper plug wire from the spark plug on the chipper handle to the right side of the lower handle . shredder vacuum and ground against the engine . See Figure 4 . 5
â¢ Align the support bracket with the holes in the right â¢ Remove the three hex nuts and bell washers from side of the upper and lower handles where the hex the weld studs beside the opening on the right side bolts were just removed . Push up slightly on the of the chipper - shredder vacuum . See Figure 4 . chipper chute in order to better align the holes in the support bracket with the holes in the handles . â¢ Replace the hex bolts , saddle washers and flange nuts to affix the support bracket to the handle assemblies . See Figure 5 . Flange Nuts â¢ Follow by tightening all hardware securely first on the chipper chute , then on the support bracket , and finally on the handle . Attaching The Bag Weld Studs â¢ Place bag under the upper handle assembly and slip the front opening on the bag over the discharge chute , making certain it is over the rim on the discharge chute . Follow direction of the arrows in Figure 6 . Hex Nuts & Upper Hex Bolts & Bell Washers Strap Handle Saddle Washers Strap Figure 4 Discharge Chute â¢ Place the chipper chute over the weld studs keeping the slotted side towards the bottom . Loosely secure with the three hex nuts and bell washers that were removed earlier . Do not fully tighten the hex nuts at this point in the assembly . See Figure 5 . Strap Chipper Chute Bag Support Bracket Figure 6 Flange Nuts â¢ Place the four straps on top of the bag over the upper handle , hooking them on the studs to secure in place . See Figure 6 . Squeeze the clamp on the drawstring and pull the drawstring tight . Release the clamp . Hex Nuts & Bell Washers Slot Hex Bolts & Saddle Washers Figure 5 6
SECTION 3 : KNOW YOUR CHIPPER SHREDDER VACUUM m WARNING : Be familiar with all controls and their proper operation . Know how to stop the machine and disengage them quickly . Drive Clutch Control Tamper Plug Chipper Chute Nozzle Bag Nozzle Door Adjustment Lever Caster Locks Figure 7 Vacuum / Chipper Bag Nozzle Collects shredded or chipped material fed through the Yard waste such as leaves and pine needles can be chipper chute or vacuumed up through the nozzle . vacuumed up through the nozzle for shredding . See Figure 7 . Drive Clutch Control Chipper Chute The drive clutch control is located on the upper handle assembly . Squeezing the drive clutch control against Allow twigs and small branches up to 3 â in diameter to the upper handle engages the rear wheels . Release the be fed into the impeller for chipping . See Figure 7 . drive clutch control to slow down or stop the wheel Tamper Plug drive . See Figure 7 . This plug is inserted into the chipper chute to push Throttle Control Lever twigs and small branches towards the impeller blades without endangering your hands . The throttle control lever is located on the engine . It controls the engineâs speed and stops the engine . Caster Locks Refer to the engine manual for further details . The caster locks are located on top of each front caster Engine Controls wheel . Refer to the Adjustment Section to position wheel locks . See Figure 7 . Refer to the engine manual for the location and function of these controls . Nozzle Door Adjustment Levers The nozzle adjustment levers are located on each side Stopping the Engine of the nozzle door . They are used to adjust the nozzle door for ground clearance that will provide the best â¢ Move throttle control lever to STOP or OFF performance for the operating conditions . See Figure 7 . position . â¢ Disconnect spark plug wire from spark plug and ground against the engine . 7
SECTION 4 : OPERATING YOUR CHIPPER SHREDDER VACUUM â¢ Repeat until engine cranks . When engine starts , â¢ Read , understand , and follow all instructions and move choke control ( if equipped ) gradually to RUN warnings on the machine and in this manual before position . operating . A pair of safety glasses has been provided with this equipment . To Empty Bag WARNING : Always wear safety glasses â¢ Open the large zipper in the rear of the bag to during operation or while performing any empty the contents . Be certain the zipper is closed adjustments or repairs . Thrown objects which completely when operating the unit . ricochet can cause serious injury to the eyes . â¢ If bag is removed for any reason , follow instructions for attaching the bag in the ASSEMBLY section . Gas & Oil Fill - Up Service the engine with gasoline and oil as instructed in To Engage Drive the engine manual . Read instructions carefully . â¢ To engage the wheel drive , hold the drive clutch control against the upper handle . WARNING : Use extreme care when â¢ Release the drive clutch control to stop the rear handling gasoline . Gasoline is extremely wheels from driving . flammable and the vapors are explosive . Never â¢ Release the drive clutch control to slow down when fuel machine indoors or while the engine is hot negotiating an obstacle , making a turn , or stopping . or running . Extinguish cigarettes , cigars , pipes , â¢ Engage control slowly to prevent the front wheels and other sources of ignition . from lifting up . Starting Engine Using the Chipper Shredder Vacuum WARNING : Keep bystanders , helpers , pets , â¢ Place both hands on top of upper handle to push and children at least 75 feet from the machine unit over yard waste . Yard waste such as leaves before starting and while operating . Do not and pine needles can be vacuumed up through the operate this machine unless the discharge nozzle for shredding . chute and bag have been properly installed â¢ After material has been shredded by the blades on and secured to the machine . the impeller assembly , it will be discharged into catcher bag . Do not attempt to shred or chip any â¢ Attach spark plug wire to spark plug . Make certain material other than vegetation found in a normal the metal cap on the end of the spark plug is yard ( i.e . branches , leaves , twigs , etc . ) Avoid fastened securely over metal tip on the spark plug . fibrous plants such as tomato vines until they are â¢ Make certain drive clutch control is in the thoroughly dried out . Materials such as stalks or disengaged ( released ) position . heavy branches up to 3 â in diameter may be fed â¢ Engines with choke lever : Move choke lever on into the chipper chute . engine to CHOKE position . ( A warm engine may not require choking ) . WARNING : Do not attempt to shred , chip , or â¢ Engines with primer : Prime engine as instructed vacuum any material larger than specified on in the engine manual . the machine or in this manual . Personal injury â¢ Move engine throttle control lever to FAST or or damage to the machine could result . START position . IMPORTANT : The flail screen is located inside the â¢ Place one foot on the left rear wheel to prevent the housing in the discharge area . If the flail screen unit from skidding while starting . becomes clogged , remove and clean as instructed in â¢ Grasp starter handle and pull rope out slowly until the maintenance section . For best performance , it is engine reaches start of compression cycle ( rope also important to keep the chipper blade sharp . will pull slightly harder at this point ) . NOTE : A noise will be heard at the start of the Tire Pressure ( Pneumatic tires only ) compression cycle , which will continue to be heard till Maximum tire pressure under any circumstance is 30 the impeller reaches full speed . psi . Equal tire pressure should be maintained at all â¢ Keeping a firm grip on the starter handle , pull rope times . with a rapid , continuous , full arm stroke . Let the rope rewind slowly . 8
SECTION 5 : ADJUSTING YOUR CHIPPER SHREDDER VACUUM â¢ Slide the height adjustment lever forward or WARNING : Do not at any time make any backward for adjusting the nozzle door upwards or downwards . Height must be adjusted equally . In adjustments without first stopping engine , general , raise the nozzle to vacuum a thick layer of disconnecting spark plug wire , and grounding it leaves and lower the nozzle for smooth surfaces . against the engine . See Figure 9 . Front Caster Wheels Drive Clutch Cable This chipper shredder vacuum is equipped with front caster wheels . The casters can be locked in a straight Adjust the drive clutch control if : ahead position or to swivel freely . a . the chipper shredder vacuum moves forward â¢ Lift and place pins in the larger holes for locked or with the drive clutch control disengaged , straight ahead operation . See Figure 8 . b . it does not self - propel with the drive clutch a . Place pins in smaller holes to allow casters to control engaged , or rotate freely . c . drive belt is slipping ( unit hesitates while b . Lock wheels in straight position when engine maintains the same speed ) . operating on slopes . â¢ Use the adjustment wheel located in the clutch control housing to tighten or loosen the clutch cable . Smaller Hole â¢ In addition , the adjustment wheel may also be used ( Rotate Freely ) to determine the position in which the drive clutch control is engaged . If it is more comfortable to have the drive engaged with the lever further away from the handle , tighten the clutch cable . See Figure 10 . Larger Hole ( Locked ) Tighten Adjustment Figure 8 Wheel Nozzle Door Height The nozzle adjustment levers are located on each side of the nozzle door . The nozzle door can be adjusted to one of five positions , ranging from 1 / 2 â to 3 â ground Loosen clearance , to provide best performance . Figure 10 Nozzle Door Adjustment Lever Figure 9 9
SECTION 6 : MAINTAINING YOUR CHIPPER SHREDDER VACUUM â¢ Reattach the discharge chute assembly with the WARNING : Before performing any hardware previously removed and attach the bag to the unit . maintenance or repairs , stop the engine , wait until the machine comes to a complete stop , Hex Bolts disconnect the spark plug wire and ground Hex Nuts against the engine to prevent unintended Flail Screen starting . Lubrication â¢ Wheels : Lubricate the rear wheels with light oil once a season . â¢ Nozzle Door Adjustment Levers : Lubricate each adjustment lever once a season with light oil . â¢ Front Caster Wheels : Grease fittings are located on the front caster wheels to provide easy lubrication of the swivel pins . Cleaning the Flail Screen Figure 12 If the discharge area becomes clogged , remove the flail screen and clean area as follows : Servicing the Blades â¢ Stop the engine and make certain the chipper shredder vacuum has come to a complete stop . NOTE : When tipping the unit , empty the fuel tank and â¢ Disconnect spark plug wire from spark plug and keep the spark plug side up . ground against the engine . â¢ Remove the vacuum bag and tamper plug from the â¢ Disconnect the spark plug wire and ground it equipment and save . against the engine . â¢ Remove the four self - tapping screws from the â¢ Remove the flail screen as instructed in the bottom of the discharge chute , and the hex bolt , flat previous section . washer and hex nut from the top . Remove the â¢ Remove plastic belt cover from front of the engine discharge chute assembly . See Figure 11 . by removing the two self - tapping screws . See Figure 13 . Hex Bolt â¢ Remove the access plate by removing two hex lock Flat Washer nuts . See Figure 13 . Hex Nut â¢ Locate one of the chipper blades in the access opening by rotating the impeller assembly by hand . Discharge Remove the chipper blade using a 3 / 16 â allen Chute wrench and a 1 / 2 â wrench . â¢ Remove other blade in the same manner to replace or sharpen . Access Plate Self - Tapping Screws Self - Tapping Screws Lock Nuts Figure 11 â¢ Remove the two hex bolts and hex nuts which extend through the impeller housing . Lift the flail screen from inside the housing . See Figure 12 . â¢ Clean the flail screen by scraping and / or washing with water , and reinstall the screen . Belt Cover NOTE : Be certain to reassemble the flail screen with the curved side down . Figure 13 10
â¢ Remove the two hex bolts and hex lock nuts which WARNING : Use caution when replacing the extend through the housing . Lift the flail screen out of the housing . Refer to Figure 11 . blades . Wear heavy gloves to avoid injury while â¢ Remove the outer housing and housing blades by handling the weld bolts , housing or the blades . removing the fourteen self - tapping screws . â¢ When sharpening blades , follow the original angle â¢ Remove the hex bolt , lock washer , and flat washer of grind . Also , make sure to remove an equal that secures the impeller assembly to the amount from each blade and torque hardware to crankshaft . See Figure 15 . 250 - 300 in.lb . Hex Bolt Impeller Lock Washer NOTE : Make sure that blades are reassembled with the Assembly Flat Washer sharp edge facing upward . Inner Housing Replacing the Belt NOTE : Because the engine on this equipment has a tapered crankshaft , a special impeller removal tool ( part number 753 - 0900 ) is required to remove the impeller assembly . Contact your local service dealer for this . â¢ Disconnect the spark plug wire and ground it away from the spark plug . â¢ Drain the gasoline and oil from the chipper Housing shredder vacuum . Blades â¢ Remove the three wing nuts that secure the nozzle Figure 15 to the outer housing and remove the nozzle . Refer to Figure 2 . â¢ Thread the special impeller tool into the crankshaft . â¢ Remove the vacuum bag from the unit . Stop when the impeller assembly can move on the â¢ Remove the discharge chute as instructed in crankshaft . â Cleaning The Flail Screen . â â¢ If the old belt is still on the unit , cut belt to remove â¢ Remove the plastic belt cover from front of the from unit . engine by removing two self - tapping screws . Refer â¢ Remove impeller assembly from the crankshaft and to Figure 13 . unthread the impeller tool from the impeller . â¢ Tip the unit backward so that it rests on the handles . â¢ Remove the lower belt guard by removing the two Hex Bolts self - tapping screws . See Figure 14 . â¢ Remove the safety switch from front of the outer housing by removing the two self - tapping screws . See Figure 14 . Safety Switch Self - Tapping Screw Hex Bolts Lower Belt Guard Figure 16 â¢ Remove the inner housing and mounting adapter by removing the five hex bolts and two hex nuts . See Figure 16 . â¢ Insert new belt between the frame and the Self - Tapping transmission pulley . See Figure 17 . ( You may have Screws to slightly pry the frame away from the pulley with a screwdriver for this . ) Figure 14 11
Outer Belt Guard Housing Mounting Spring Adapter Idler Idler Bracket Frame Transmission Pulley Holes for Screwdrivers Figure 17 â¢ Press down on the belt guard spring by the idler Figure 18 pulley , and release the spring from the slot on the idler bracket . Engine â¢ Place the belt on the idler pulley and place belt A few general recommendations are given below . guard spring back into the slot on the idler bracket . However , refer to the accompanying engine manual for See Figure 17 . further details . â¢ Place the mounting adapter against the engine and â¢ Check engine oil level before each use as make sure the hole in the mounting adapter is instructed in the engine manual . Read and follow facing up . instructions carefully . â¢ Place the inner housing against the mounting â¢ Clean air cleaner every 25 hours under normal adapter and the frame . Secure with five hex bolts conditions or once a season . Clean every few hours and two hex nuts previously removed . Refer to under extremely dusty conditions . To service the air Figure 16 . cleaner , refer to the engine manual . â¢ Slide the impeller assembly onto the crankshaft â¢ The spark plug should be cleaned and the gap and place a screwdriver under the belt . Turn the reset once a season . Check engine manual for impeller assembly counterclockwise to place the correct plug type and gap specifications . belt into the slot on the impeller . Make sure the belt is routed inside all belt guards . â¢ Secure impeller assembly to crankshaft using hex Storing Your Chipper Shredder Vacuum bolt , lock washer , and flat washer previously â¢ Clean the equipment thoroughly . removed . Torque bolt between 550 - 700 in . lb . â¢ Wipe equipment with an oiled rag to prevent rust . â¢ Place the housing blades against the inner â¢ Refer to engine manual for correct engine storage housing . Refer to Figure 15 . instructions â¢ Place the outer housing against the inner housing . â¢ Store unit in a clean , dry area . Do not store next to See Figure 18 . Insert two screwdrivers into the corrosive materials such as fertilizer . holes to hold the blades in place while attaching the outer housing . WARNING : Never store the machine or fuel â¢ Secure with the 14 self - tapping screws , previously container indoors where there is an open removed . Insert all screws first before tightening . flame , spark , or pilot light such as on a water â¢ Reassemble the flail screen , discharge chute , heater , furnace , clothes dryer , or other gas nozzle and the bag . ( For reassembly , follow appliance . instructions on previous page in reverse order . ) 12
SECTION 7 : TROUBLESHOOTING Problem Cause Remedy 1 . Connect wire to spark plug . Engine fails to start 1 . Spark plug wire disconnected . 2 . Fill tank with clean , fresh gasoline . 2 . Fuel tank empty or stale fuel . 3 . Move throttle lever to FAST position . 3 . Throttle control lever not in correct starting position . ( If Equipped ) 4 . Move choke to CHOKE position . 4 . Choke not in CHOKE position . ( If Equipped ) 5 . Clean fuel line . 5 . Blocked fuel line . 6 . Clean , adjust gap , or replace . 6 . Faulty spark plug . 1 . Connect and tighten spark plug wire . Engine runs erratic 1 . Spark plug wire loose . 2 . Move choke lever to OFF position . 2 . Unit running on CHOKE . ( If Equipped ) 3 . Clean fuel line ; fill tank with clean , fresh 3 . Blocked fuel line or stale fuel . gasoline 4 . Drain fuel tank . Refill with fresh fuel . 4 . Water or dirt in fuel system . 5 . Clean or replace air cleaner . 5 . Dirty air cleaner . 6 . See authorized service dealer . 6 . Carburetor out of adjustment . Too much vibration 1 . Loose parts or damaged impeller . 1 . See authorized service dealer . Engine overheats 1 . Engine oil level low . 1 . Fill crankcase with proper oil . 2 . Dirty air cleaner . 2 . Clean or replace air cleaner . 3 . Carburetor not adjusted properly . 3 . See authorized service dealer . Occasional skip ( hesitates ) 1 . Spark plug gap too close . 1 . Adjust gap to . 030 â . at high speed Unit does not discharge 1 . Discharge chute clogged . 1 . Stop engine immediately and disconnect spark plug wire . Clean flail screen and inside of discharge opening . 2 . Stop engine and disconnect spark plug 2 . Foreign object lodged in impeller . wire . Remove lodged object . 3 . Always run engine at full throttle . 3 . Low engine RPM 4 . Empty bag . 4 . Vacuum bag is full . 1 . Low engine RPM . 1 . Always run engine at full throttle . Rate of discharge slows 2 . Chipper blade dull . 2 . Replace chipper blade or see your considerably or authorized service dealer . composition of discharged material changes . NOTE : For repairs beyond the minor adjustments listed above , contact your nearest authorized service dealer . 13
SECTION 8 : PARTS LIST FOR MODEL 204 Ref . Part No . Description No . 1 . 781 - 0633 Chute Flap Strip 2 . 735 - 0249 Chute Flap 3 . 728 - 0175 Pop Rivet 23 4 . 731 - 1838A Discharge Chute 5 . 764 - 04001 Bag 6 . 631 - 0086 Nozzle Assembly 7 . 731 - 1831 Nozzle Flap 3 1 8 . 710 - 0969 Screw 9 . 720 - 0190 Height Adjustment Knob 2 10 . 732 - 0754 Spring Lever 17 11 . 781 - 0702 Index Bracket RH 12 . 781 - 0703 Index Bracket LH 13 . 738 - 0913 Shoulder Screw 18 14 . 736 - 3084 Flat Washer . 510 x 1.12 x . 060 19 20 15 . 712 - 0431 Hex Flange Lock Nut 3 / 8 - 16 16 . 631 - 0049 Door Assembly 19 17 . 731 - 1574A Chipper Chute 20 21 18 . 710 - 0751 Hex Cap Screw 1 / 4 - 20 x . 620 19 . 736 - 0173 Flat Washer . 28 ID x . 74 OD 22 18 20 . 712 - 3027 Hex Lock Nut 1 / 4 - 20 21 . 781 - 0780 Support Bracket 22 . 681 - 0068A Chipper Chute Assembly 23 . 731 - 1617 Tamper Plug 777D06245 Label - TroyBilt Chipper Shredder 4 777D06513 Label - 6.5 Eng 777D06541 Label - Chipper Shredder Vac 777I20071 Label - Chipper Shredder SP 5 777I20123 Label - Castor Wheel Lock 777S30041 Label - Warning / Avoid Injury 777S30131 Label - Caution Do Not Operate 9 777S30181 Label - C / S / V Top Chute Danger 10 8 777S30183 Label - Flail Housing Warning 6 7 11 12 13 15 9 14 10 8 14 16 13 14
Model 204 1 2 3 4 7 2 6 13 14 3 15 13 18 14 16 5 17 8 10 25 21 11 9 26 12 22 5 3 2 15 17 14 19 30 23 31 24 30 27 34 36 28 35 32 29 33 Ref . Ref . Part No . Description Part No . Description No . No . 1 . 681 - 0108 Impeller Assembly : Complete 19 . 781 - 0599 Upper Shredder Blade 2 . 719 - 0329 Flail Blade 21 . 736 - 0119 Lock Washer 5 / 16 3 . 715 - 0166 Spiral Pin 22 . 710 - 0772 Hex Cap Screw 5 / 16 - 18 x 2 4 . 681 - 0107 Impeller Assembly 23 . 781 - 0653 Flail Housing Blade 5 . 711 - 0833B Clevis Pin 24 . 710 - 3008 Hex Cap Screw 5 / 16 - 18 x . 75 6 . 736 - 0119 Lock Washer 5 / 16 25 . 719 - 0326 Discharge Screen 7 . 710 - 1054 Cap Screw 5 / 16 - 24 x 1.0 26 . 681 - 0060 Housing Assembly : Outer Flail 8 . 781 - 0490 Chipper Blade 27 . 629 - 0241A Wire Harness 9 . 712 - 0411 Hex Lock Nut 5 / 16 - 24 28 . 710 - 1652 TT Screw 1 / 4 - 20 x 0.625 â 10 . 736 - 0247 Flat Washer . 406 x 1 / 1 / 4 29 . 726 - 0272 Clamp 11 . 736 - 0217 Lock Washer 3 / 8 30 . 710 - 0382 Hex Cap Screw 1 / 2 - 13 x 5.0 12 . 710 - 1273 Hex Cap Screw 3 / 8 - 24 x 2.75 31 . 712 - 0421 Knob 5 / 16 - 18 13 . 723 - 0438 Rubber Seal 32 . 725 - 3166 Switch 14 . 710 - 0604A Hex Washer Screw 5 / 16 - 18 33 . 731 - 1613 Safety Switch Mounting Cover 15 . 712 - 0384 Hex Lock Nut 1 / 2 - 13 34 . 710 - 1268 Hex Washer Screw 16 . 781 - 0627 Chipper Blade Cover 35 . 725 - 1700 Switch Cover 17 . 712 - 3004A Hex Flange Lock Nut 5 / 16 - 18 36 . 710 - 1260A LD Screw 5 / 16 - 18 x 0.75 â 18 . 681 - 0098 Housing Assembly : Inner Flail 15
Model 204 9 11 2 5 6 4 10 6 5 1 13 17 8 3 7 4 16 15 8 17 14 18 19 12 44 49 30 24 27 27 29 25 34 40 45 55 35 36 33 48 32 42 23 41 37 38 22 28 54 51 26 50 52 39 31 47 43 50 53 46 16
Model 204 Ref . Ref . Part No . Description Part No . Description No . No . 1 . 781 - 0677 Chain Case LH 29 . 741 - 0414 Flange Bearing . 629 ID 2 . 781 - 0676 Chain Case RH 30 . 741 - 0415 Flange Bearing . 566 ID 3 . 754 - 0457 V - Belt 31 . 719 - 0325 Lower Housing 4 . 748 - 0313 Spacer 32 . 748 - 0373 Flange Bearing . 503 ID 5 . 741 - 0413 Hex Flange Bearing 33 . 719 - 0324A Upper Housing 6 . 736 - 0336 Flat Washer 34 . 748 - 0208A Flange Bearing . 378 ID 7 . 713 - 0422 Chain 35 . 710 - 0589 Hex Washer Screw # 10 - 16 x . 75 8 . 710 - 1652 TT Screw 1 / 4 - 20 x 0.625 â 36 . 717 - 1433 Pinion Shaft 10T 9 . 710 - 0603 Hex Washer Screw 5 / 16 37 . 721 - 0329 Oil Seal 10 . 618 - 0256 Transmission Assembly 38 . 736 - 0314 Thrust Washer . 382 ID x . 684 OD 11 . 611 - 0063 Axle Assembly 39 . 736 - 0520 Flat Washer . 504 ID x . 70 OD 12 . 10622B Plastic Spring Ratchet 40 . 741 - 0479 Thrust Bearing . 375 ID x . 812 OD 13 . 634 - 0244 Wheel Complete 10 x 4 x 4 41 . 656 - 0008 Pulley Assembly : Idler w / Bearing 14 . 712 - 0456 Hex Nut 1 / 4 - 20 42 . 741 - 0556 Needle Bearing . 375 ID x . 375 OD 15 . 712 - 3027 Hex Flanged Lock Nut 1 / 4 - 20 43 . 710 - 0589 Hex Screw # 10 - 16 x . 75 16 . 714 - 0104 Cotter Pin 44 . 710 - 1062 Hex Cap Screw 1 / 4 - 20 x 1.25 17 . 736 - 0366 Flat Washer 5 / 8 ID x 1.0 OD 45 . 712 - 0138 Hex Nut 1 / 4 - 28 18 . 748 - 0188B Pawl LH . 345 ID 46 . 712 - 3045 Hex Jam Nut 5 / 16 - 24 LH Thd 748 - 0381 Pawl RH . 345 ID 47 . 732 - 0357A Extension Spring 1.12 Lg 19 . 748 - 0405 Wheel Ratchet 1.62 OD x . 5 serr 48 . 736 - 0270 Bell Washer . 265 ID x . 75 OD 21 . 618 - 0255 Transmission Assembly : Complete 49 . 736 - 0329 Lock Washer 1 / 4 22 . 16500A Hex Bearing Cup 50 . 736 - 0425 Bell Washer . 325 ID x . 930 OD 23 . 711 - 1118 Output Shaft 6T Sprocket 51 . 738 - 0440 Shoulder Spacer . 375 ID x . 165 OD 24 . 717 - 1432 Helical 34T Gear 52 . 738 - 0826 Shoulder Bolt 1 / 4 - 28 x . 375 25 . 721 - 0213 Oil Seal 53 . 756 - 0656 Flat Pulley 5.06 Dia 26 . 736 - 0187 Flat Washer . 64 ID x 1.24 OD 54 . 782 - 7569 Belt Keeper 27 . 736 - 0336 Flat Washer 5 / 8 x 1.0 55 . 682 - 0054 Idler Bracket 28 . 741 - 0413 Hex Flange Bearing . 631 ID IMPORTANT : For a properly working machine , use factory approved replacement parts only . IMPORTANT : V - belts are specially designed to engage and disengage safely . A substitute ( non - OEM ) V - belt part can be dangerous by not disengaging completely . 17
Model 204 5 1 6 2 4 3 7 8 3 9 20 11 12 10 8 2 22 26 13 15 21 17 14 13 13 12 16 19 26 24 18 23 12 18 29 26 25 12 13 28 30 25 26 31 27 12 18 32 30 34 36 35 13 29 37 38 32 29 34 36 35 13 39 33 37 20 40 38 41 42 38 43 45 37 44 29 38 46 47 37 44 48 46 45 47 48 18
Model 204 Ref . Ref . Part No . Description Part No . Description No . No . 1 . 749 - 1095 Upper Handle 26 . 710 - 3103 Hex Cap Screw 5 / 16 - 18 x 1.75 2 . 1539 - 019 Push Nut 27 . 749 - 1094 Lower Push Handle 3 . 711 - 0737 Stud Pin . 250 x 1.75 28 . 710 - 0502A Screw 3 / 8 - 16 x 1.25 4 . 746 - 0714 Clutch Cable 56 " 29 . 710 - 0604A Hex Washer Screw 5 / 16 - 18 x . 625 5 . 731 - 1735 Upper Clutch Cover 30 . 741 - 0413 Hex Flange Bearing . 631 x . 720 6 . 731 - 0620 Drive Lever 31 . 681 - 0097A Frame Assembly 7 . 731 - 1736 Lower Clutch Cover 32 . 781 - 0700 Axle Bracket 8 . 710 - 0841 Screw # 10 - 12 x . 750 33 . 781 - 0697 Transmission Cover 9 . 731 - 1059 Mounting Cable Cap 34 . 747 - 0924 Lock Pin 10 . 710 - 1331 Screw # 10 - 16 x 1.25 35 . 732 - 0306 Compression Spring 11 . 710 - 0805 Hex Cap Screw 5 / 16 - 18 x 1.50 36 . 726 - 0214 Push Cap 12 . 736 - 0451 Shoulder Washer . 320 ID x . 93 OD 37 . 736 - 0366 Flat Washer 5 / 8 ID x 1.0 OD 13 . 712 - 3004A Hex Flange Lock Nut 5 / 16 - 18 38 . 741 - 0487A Flange Bearing . 632 ID 14 . 725 - 0157 Cable Tie 39 . 736 - 0264 Flat Washer . 330 ID x . 630 OD 15 . 712 - 0138 Hex Nut 1 / 4 - 28 40 . 714 - 0104 Cotter Pin 16 . 736 - 0329 Lock Washer 1 / 4 41 . 681 - 0087 Bracket Assembly 17 . 781 - 0647 Discharge Chute Bracket 42 . 737 - 3000 Grease Fitting 3 / 16 18 . 710 - 3008 Hex Cap Screw 5 / 16 - 18 x . 75 43 . 736 - 0931 Flat Washer . 203 ID x . 403 OD 19 . 747 - 0815 Eye Bolt 44 . 681 - 0088 Bracket Assembly 20 . 710 - 0896 Hex Washer Screw 1 / 4 - 14 x . 625 45 . 710 - 0521 Hex Cap Screw 3 / 8 - 16 x 3.0 21 . 731 - 1646 Belt Cover 46 . 712 - 0431 Flange Lock Nut 3 / 8 - 16 22 . 719 - 0359 Engine Mounting Adapter 47 . 750 - 1042 Spacer 23 . 747 - 0929A Belt Keeper 48 . 734 - 1804 Wheel 6.0 x 2.0 24 . 736 - 3008 Flat Washer . 344 x . 75 x . 12 â 734 - 1984 Hubcap ( not shown ) 25 . 710 - 0157 Hex Cap Screw 5 / 16 - 24 x . 75 19
MANUFACTURERâS LIMITED WARRANTY FOR : The limited warranty set forth below is given by Troy - Bilt deck adjustments , and normal deterioration LLC with respect to new merchandise purchased and of the exterior finish due to use or exposure . used in the United States , its possessions and d . Troy - Bilt LLC does not extend any warranty territories . for products sold or exported outside of the United States , its possesions and territories , Troy - Bilt LLC warrants this product against defects for a except those sold through Troy - Bilt LLCâs period of two ( 2 ) years commencing on the date of authorized channels of export distribution . original purchase and will , at its option , repair or replace , e . Parts that are not genuine Troy - Bilt parts are free of charge , any part found to be defective in not covered by this warranty . materials or workmanship . This limited warranty shall f . Service completed by someone other than an only apply if this product has been operated and authorized service dealer is not covered by maintained in accordance with the Operatorâs Manual this warranty . furnished with the product , and has not been subject to g . Transportation charges and service calls are misuse , abuse , commercial use , neglect , accident , not covered . improper maintenance , alteration , vandalism , theft , fire , No implied warranty , including any implied warranty of water , or damage because of other peril or natural merchantability of fitness for a particular purpose , disaster . Damage resulting from the installation or use applies after the applicable period of express written of any accessory or attachment not approved by Troy - warranty above as to the parts as identified . No other Bilt LLC for use with the product ( s ) covered by this express warranty , whether written or oral , except as manual will void your warranty to any resulting damage . mentioned above , given by any person or entity , Normal wear parts or components thereof are subject to including a dealer or retailer , with respect to any product , separate terms as follows : All normal wear parts or shall bind Troy - Bilt LLC . During the period of the component failures will be covered on the product for a warranty , the exclusive remedy is repair or replacement period of 90 days regardless of cause . After 90 days , of the product as set forth above . but within the two year period , normal wear part failures The provisions as set forth in this warranty provide the will be covered ONLY IF caused by defects in materials sole and exclusive remedy arising from the sale . Troy - or workmanship of OTHER component parts . Normal Bilt LLC shall not be liable for incidental or consequential wear parts and components include , but are not limited loss or damage including , without limitation , expenses to : batteries , belts , blades , blade adapters , grass bags , incurred for substitute or replacement lawn care rider deck wheels , seats , snow thrower skid shoes , services or for rental expenses to temporarily replace a shave plates , auger spiral rubber , and tires . warranted product . HOW TO OBTAIN SERVICE : Warranty service is Some states do not allow the exclusion or limitation of available , WITH PROOF OF PURCHASE , through your incidental or consequential damages , or limitations on local authorized service dealer . To locate the dealer in how long an implied warranty lasts , so the above your area , check your Yellow Pages , or contact Troy - Bilt exclusions or limitations may not apply to you . LLC at P.O . Box 361131 , Cleveland , Ohio 44136 - 0019 , or call 1 - 866 - 840 - 6483 or 1 - 330 - 558 - 7220 , or log on to In no event shall recovery of any kind be greater than the our Web site at www.troybilt.com . amount of the purchase price of the product sold . Alteration of safety features of the product shall This limited warranty does not provide coverage in the void this warranty . You assume the risk and liability for following cases : loss , damage , or injury to you and your property and / or a . The engine or component parts thereof . to others and their property arising out of the misuse or These items inability to use the product . carry a separate manufacturerâs warranty . This limited warranty shall not extend to anyone other Refer to applicable manufacturerâs warranty than the original purchaser or to the person for whom it for terms and conditions . was purchased as a gift . b . Log splitter pumps , valves , and cylinders have a separate one year warranty . HOW STATE LAW RELATES TO THIS WARRANTY : c . Routine maintenance items such as This limited warranty gives you specific legal rights , and lubricants , filters , blade sharpening , tune - you may also have other rights which vary from state to ups , brake adjustments , clutch adjustments , state . Troy - Bilt LLC , P.O . BOX 361131 CLEVELAND , OHIO 44136 - 0019 ; Phone : 1 - 866 - 840 - 6483 , 1 - 330 - 558 - 7220