TROY-BILT LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019
Printed In USA
Op e r a t O r ’s Ma n u a l
Safe Operation Practices • Set-Up • Operation • Maintenance • Service • Troubleshooting • Warranty
WARNING
READ AND FOLLOW ALL SAFETY RULES AND INSTRUCTIONS IN THIS MANUAL
BEFORE ATTEMPTING TO OPERATE THIS MACHINE.
FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
Form No. 769-03931
(April 23, 2008)
Chipper Shredder Vacuum
Model 204
Customer Support
Please do NOT return the machine to the retailer or dealer without first contacting our Customer Support Department.
If you have difficulty assembling this product or have any questions regarding the controls, operation, or maintenance of
this machine, you can seek help from the experts. Choose from the options below:
Visit us on the web at www.troybilt.com◊
Call a Customer Support Representative at (800) 828-5500 or (330) 558-7220◊
Write us at Troy-Bilt LLC • P.O. Box 361131 • Cleveland, OH • 44136-0019◊
Thank you for purchasing a Chipper/Shredder Vacuum
manufactured by Troy-Bilt LLC. It was carefully engineered to
provide excellent performance when properly operated and
maintained.
Please read this entire manual prior to operating the equipment.
It instructs you how to safely and easily set up, operate and
maintain your machine. Please be sure that you, and any other
persons who will operate the machine, carefully follow the
recommended safety practices at all times. Failure to do so could
result in personal injury or property damage.
All information in this manual is relative to the most recent
product information available at the time of printing. Review
this manual frequently to familiarize yourself with the machine,
its features and operation. Please be aware that this Operator’s
Manual may cover a range of product specifications for various
models. Characteristics and features discussed and/or illustrated
in this manual may not be applicable to all models. Troy-Bilt LLC
reserves the right to change product specifications, designs and
equipment without notice and without incurring obligation.
If you have any problems or questions concerning the machine,
phone a authorized Troy-Bilt service dealer or contact us directly.
Troy-Bilt’s Customer Support telephone numbers, website
address and mailing address can be found on this page. We want
to ensure your complete satisfaction at all times.
Throughout this manual, all references to right and left side of the
machine are observed from the operating position
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 manufacturer’s
Owner’s/Operator’s Manual, packed separately with your
machine, for more information.
Thank You
Record Product Information
Before setting up and operating your new equipment, please
locate the model plate on the equipment and record the
information in the provided area to the right. You can locate the
model plate by standing at the operator’s position and looking
down at the rear of the frame. This information will be necessary,
should you seek technical support via our web site, Customer
Support Department, or with a local authorized service dealer.
MO d e l nu M b e r
se r i a l nu M b e r
To The Owner
1
2
Safe Operation Practices ........................................ 3
Assembly & Set-Up .................................................. 6
Controls & Features ................................................. 9
Operation ................................................................10
Maintenance & Adjustment..................................11
Service .....................................................................13
Troubleshooting .....................................................14
Illustrated Parts List ...............................................15
Warranty ................................................................ 20
Table of Contents
Important Safe Operation Practices
2
3
Training
Read, understand, and follow all instructions on the 1.
machine and in the manual(s) before attempting to
assemble and operate. Keep this manual in a safe place for
future and regular reference and for ordering replacement
parts.
Be familiar with all controls and their proper operation. 2.
Know how to stop the machine and disengage them
quickly.
Never allow children under 16 years of age to operate this 3.
machine. Children 16 and over should read and understand
the instructions and safe operation practices in this manual
and on the machine and be trained and supervised by an
adult.
Never allow adults to operate this machine without proper 4.
instruction.
Keep bystanders, helpers, pets, and children at least 75 feet 5.
from the machine while it is in operation. Stop machine if
anyone enters the area.
Never run an engine indoors or in a poorly ventilated area. 6.
Engine exhaust contains carbon monoxide, an odorless
and deadly gas.
Do not put hands and feet near rotating parts or in the 7.
feeding chambers and discharge opening. Contact with
the rotating impeller can amputate fingers, hands, and
feet.
Never attempt to unclog either the feed intake or discharge 8.
opening, remove or empty bag, or inspect and repair the
machine while the engine is running. Shut the engine off
and wait until all moving parts have come to a complete
stop. Disconnect the spark plug wire and ground it against
the engine.
Preparation
Thoroughly inspect the area where the equipment is to 1.
be used. Remove all rocks, bottles, cans, or other foreign
objects which could be picked up or thrown and cause
personal injury or damage to the machine.
Always wear safety glasses or safety goggles during 2.
operation and while performing an adjustment or repair,
to protect your eyes. Thrown objects which ricochet can
cause serious injury to the eyes.
Wear sturdy, rough-soled work shoes and close-fitting 3.
slacks and shirts. Loose fitting clothes or jewelry can be
caught in movable parts. Never operate this machine
in bare feet or sandals. Wear leather work gloves when
feeding material in the chipper chute.
Before starting, check all bolts and screws for proper 4.
tightness to be sure the machine is in safe working
condition. Also, visually inspect machine for any damage at
frequent intervals.
Maintain or replace safety and instructions labels, as 5.
necessary.
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!
DANGER: This machine was built to be operated according to the safe operation practices 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 fingers, hands,
toes and feet and throwing debris. Failure to observe the following safety instructions could
result in serious injury or death.
CAlIfoRNIA PRoPoSITIoN 65
WARNING: Engine Exhaust, some of its constituents, and certain vehicle components
contain or emit chemicals known to State of California to cause cancer and birth defects
or other reproductive harm.
4 se c t i O n 2 — iM p O r t a n t sa f e Op e r a t i O n pr a c t i c e s
Safe Handling of Gasoline:
To avoid personal injury or property damage use extreme care
in handling gasoline. Gasoline is extremely flammable and the
vapors are explosive. Serious personal injury can occur when
gasoline is spilled on yourself or your clothes which can ignite.
Wash your skin and change clothes immediately.
Use only an approved gasoline container.1.
Never fill containers inside a vehicle or on a truck or trailer 2.
bed with a plastic liner. Always place containers on the
ground away from your vehicle before filling.
When practical, remove gas-powered equipment from 3.
the truck or trailer and refuel it on the ground. If this is not
possible, then refuel such equipment on a trailer with a
portable container, rather than from a gasoline dispenser
nozzle.
Keep the nozzle in contact with the rim of the fuel tank or 4.
container opening at all times until fueling is complete. Do
not use a nozzle lock-open device.
Extinguish all cigarettes, cigars, pipes and other sources of 5.
ignition.
Never fuel machine indoors.6.
Never remove gas cap or add fuel while the engine is hot or 7.
running. Allow engine to cool at least two minutes before
refueling.
Never over fill fuel tank. Fill tank to no more than ½ 8.
inch below bottom of filler neck to allow space for fuel
expansion.
Replace gasoline cap and tighten securely.9.
If gasoline is spilled, wipe it off the engine and equipment. 10.
Move unit to another area. Wait 5 minutes before starting
the engine.
To reduce fire hazards, keep machine free of grass, leaves, 11.
or other debris build-up. Clean up oil or fuel spillage and
remove any fuel soaked debris.
Never store the machine or fuel container inside where 12.
there is an open flame, spark or pilot light as on a water
heater, space heater, furnace, clothes dryer or other gas
appliances.
Operation
Do not put hands and feet near rotating parts or in the 1.
feeding chambers and discharge opening. Contact with
the rotating impeller can amputate fingers, hands, and
feet.
Before starting the machine, make sure the chipper chute, 2.
feed intake, and cutting chamber are empty and free of all
debris.
Thoroughly inspect all material to be shredded and remove 3.
any metal, rocks, bottles, cans, or other foreign objects
which could cause personal injury or damage to the
machine.
If the impeller strikes a foreign object or if your machine 4.
should start making an unusual noise or vibration,
immediately shut the engine off. Allow the impeller to
come to a complete stop. Disconnect the spark plug wire,
ground it against the engine and perform the following
steps:
Inspect for damage.a.
Repair or replace any damaged parts.b.
Check for any loose parts and tighten to assure c.
continued safe operation.
Do not allow an accumulation of processed material to 5.
build up in the discharge area. This can prevent proper
discharge and result in kickback of material through the
feed opening.
Do not attempt to shred or chip material larger than 6.
specified on the machine or in this manual. Personal injury
or machine damage could result.
Never attempt to unclog either the feed intake or discharge 7.
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.
Never operate without vacuum bag and discharge chute 8.
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.
Never operate without either the inlet nozzle or optional 9.
hose attachment (if applicable) properly attached to
the machine. Never attempt to attach or change either
attachment while the engine is running.
Keep all guards, deflectors and safety devices in place and 10.
operating properly.
Keep your face and body back and to the side of the 11.
chipper chute while feeding material into the machine to
avoid accidental kickback injuries.
Never operate this machine without good visibility or light. 12.
Always be sure of your footing and keep a firm hold on the
handles.
Do not operate this machine on a paved, gravel or non-13.
level surface.
Do not operate this machine while under the influence of 14.
alcohol or drugs.
Muffler and engine become hot and can cause a burn. Do 15.
not touch.
Never pick up or carry machine while the engine is running.16.
If situations occur which are not covered in this manual, use 17.
care and good judgement. Contact Customer Support for
assistance and the name of the nearest service dealer.
5se c t i O n 2 — iM p O r t a n t sa f e Op e r a t i O n pr a c t i c e s
Maintenance & Storage
Never tamper with safety devices. Check their proper 1.
operation regularly.
Check bolts and screws for proper tightness at frequent 2.
intervals to keep the machine in safe working condition.
Also, visually inspect machine for any damage and repair,
if needed.
Before cleaning, repairing, or inspecting, stop the engine 3.
and make certain the impeller and all moving parts have
stopped. Disconnect the spark plug wire and ground it
against the engine to prevent unintended starting.
Do not change the engine governor settings or overspeed 4.
the engine. The governor controls the maximum safe
operating speed of the engine.
Maintain or replace safety and instruction labels, as 5.
necessary.
Follow this manual for safe loading, unloading, 6.
transporting, and storage of this machine.
Never store the machine or fuel container inside where 7.
there is an open flame, spark or pilot light such as a water
heater, furnace, clothes dryer, etc.
Allow machine to cool at least 5 minutes before storing.8.
Always refer to the operator’s manual for proper 9.
instructions on off-season storage.
If the fuel tank has to be drained, do this outdoors.10.
Observe proper disposal laws and regulations for gas, oil, 11.
etc. to protect the environment.
Do not modify engine
To avoid serious injury or death, do not modify engine in any
way. Tampering with the governor setting can lead to a runaway
engine and cause it to operate at unsafe speeds. Never tamper
with factory setting of engine governor.
Notice Regarding Emissions
Engines which are certified to comply with California and federal
EPA emission regulations for SORE (Small Off Road Equipment)
are certified to operate on regular unleaded gasoline, and
may include the following emission control systems: Engine
Modification (EM), Oxidizing Catalyst (OC), Secondary Air
Injection (SAI) and Three Way Catalyst (TWC) if so equipped.
Spark Arrestor
WARNING: This machine is equipped with an
internal combustion engine and should not be used
on or near any unimproved forest-covered,
brushcovered or grass-covered land unless the
engine’s 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.
Average Useful Life
According to the Consumer Products Safety Commission
(CPSC) and the U.S. Environmental Protection Agency (EPA),
this product has an Average Useful Life of seven (7) years, or 60
hours of operation. At the end of the Average Useful Life, buy
a new machine or have the machine inspected annually by an
authorized service dealer to ensure that all mechanical and
safety systems are working properly and not worn excessively.
Failure to do so can result in accidents, injuries or death.
WARNING: Your Responsibility—Restrict the use of this power machine to persons who read, understand and
follow the warnings and instructions in this manual and on the machine.
SAVE THESE INSTRUCTIONS!
Assembly & Set-Up
3
6
Contents of Carton
One Chipper Shredder Vacuum• One Operator’s Manual• One Engine Operator’s Manual•
One Chipper Chute• One Nozzle• One Safety Glasses•
One Bag• One Tamper (If Equipped)• One Bottle of Oil•
Assembly
NOTE: This unit is shipped without gasoline or oil in the engine.
Fill up gasoline and oil as instructed in the accompanying engine
manual BEFORE operating your chipper shredder vacuum.
Nozzle
Remove three wing nuts from the front of the chipper 1.
shredder vacuum. See Fig. 3-1.
Place nozzle in position over three studs on unit.2.
Secure with wing nuts just removed. See Fig. 3-1.3.
NOTE: The metal tab on the nozzle must depress the safety
switch button attached to the front of the chipper shredder
vacuum or engine will not start. See Fig. 3-1.
Chipper Chute
Loosen, but do not remove, the two hex bolts, flat washers, 1.
and flange nuts which are secured to the support bracket.
See Fig. 3-2.
1
2
3
Figure 3-1
Remove the two flange nuts, hex bolts and saddle washers 2.
which secure the right side of the upper handle to the right
side of the lower handle. See Fig. 3-3A.
Figure 3-2
A
B
Figure 3-3
7se c t i O n 3 — as s e M b l y & se t -up
Bag
Place bag under the upper handle assembly and slip the 1.
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 Fig. 3-5A.
Place the four straps on top of the bag over the upper 2.
handle, hooking them on the studs to secure in place. See
Fig. 3-5B.
Squeeze the clamp on the drawstring and pull the 3.
drawstring tight. Release the clamp. See Fig. 3-6.
Remove the three hex nuts and bell washers from the weld 3.
studs beside the opening on the right side of the chipper-
shredder vacuum. See Fig. 3-3B.
Place the chipper chute over the weld studs keeping the 4.
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 Fig. 3-4A.
Align the support bracket with the holes in the right side 5.
of the upper and lower handles where the hex bolts were
just removed. See Fig. 3-4B. Push up slightly on the chipper
chute in order to better align the holes in the support
bracket with the holes in the handles.
Replace the hex bolts, saddle washers and flange nuts to 6.
affix the support bracket to the handle assemblies. See Fig.
3-4C.
Follow by tightening all hardware securely first on the 7.
chipper chute, then on the support bracket, and finally on
the handle. See Fig. 3-4D.
Figure 3-4
A & D
B, C, & D
Figure 3-5
Figure 3-6
B
A
8 se c t i O n 3 — as s e M b l y & se t -up
Front Caster Wheels
This chipper shredder vacuum is equipped with front caster
wheels. The casters can be locked in a straight ahead position or
to swivel freely.
Place pins in smaller holes to allow casters to rotate freely 1.
for maneuvering around trees and flower beds. See Fig.
3-8.
Lift and place pins in the larger holes for locked or straight 2.
ahead operation and when operating on slopes.
Set-Up
Gas and Oil Fill-Up
Refer to the separate engine owner’s manual for additional
engine information.
Add oil provided before starting unit for the first time out 1.
of the box.
Service the engine with gasoline as instructed in the 2.
separate engine owner’s manual.
WARNING: Use extreme care when handling
gasoline. Gasoline is extremely flammable and the
vapors are explosive. Never fuel the machine
indoors or while the engine is hot or running.
Extinguish cigarettes, cigars, pipes and other
sources of ignition.
WARNING: Never fill fuel tank indoors with engine
running or until the engine has been allowed to cool
for at least two minutes after running.
Adjustments
Nozzle 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” to 3” ground clearance, to provide
best performance.
Push adjustment lever out away from nozzle.1.
Slide the height adjustment lever forward or backward for 2.
adjusting the nozzle door upwards or downwards. See Fig.
3 -7.
Release lever towards nozzle.3.
NOTE: Height must be adjusted equally. In general, raise
the nozzle to vacuum a thick layer of leaves and lower the
nozzle for smooth surfaces.
Figure 3-7
Figure 3-8
1
2
3
1
2
Controls and Features
4
9
WARNING: Be familiar with all controls and their
proper operation. Know how to stop the machine
and disengage them quickly.
Drive Control
The drive control is located on the upper handle assembly.
Squeezing the drive control against the upper handle engages
the rear wheels. Release the drive control to slow down or stop
wheel drive. See Figure 4-1.
Chipper Chute
Allows twigs and small branches up to 3” in diameter to be fed
into the impeller for chipping.
Nozzle Door Adjustment Levers
The nozzle adjustment levers are located on each side of the
nozzle door. They are used to adjust nozzle door for ground
clearance that will provide the best performance for the
operating conditions. See Fig. 4-1.
Figure 4-1
Vacuum/Chipper Bag
Collects shredded or chipped material fed through the chipper
chute or vacuumed up through the nozzle.
Caster Locks
The caster locks are located on top of each front caster wheel.
Refer to the Assembly & Set-Up Section to position wheel locks.
WARNING: Always wear safety glasses during
operation or while performing any adjustments or
repairs. Thrown objects which ricochet can cause
serious injury to the eyes.
Engine Controls
See the separate engine manual for the location and function of
the controls on the engine.
Nozzle Door
Adjustment Lever
Chipper Chute
Caster Lock
Drive Control
Vacuum/
Chipper
Bag
Operation
5
10
Starting Engine
WARNING: Keep bystanders, helpers, pets, and
children at least 75 feet from the machine before
starting and while operating. Do not operate this
machine unless the discharge chute and bag have
been properly installed and secured to the machine.
Attach spark plug wire to spark plug. Make certain the 1.
metal cap on the end of the spark plug is fastened securely
over the metal tip on the spark plug.
Make certain drive control is in the disengaged (released) 2.
position.
Engines with choke lever: 3.
Move choke lever on engine to CHOKE position. (A warm
engine may not require choking).
Engines with primer:
Prime engine as instructed in separate engine manual.
Move engine throttle control lever to FAST or START 4.
position. See Fig. 5-1.
Place one foot on the left rear wheel to prevent the unit 5.
from skidding while starting.
Grasp starter handle and pull rope out slowly until engine 6.
reaches start of compression cycle (rope will pull slightly
harder at this point).
NOTE: A noise will be heard at the start of the compression
cycle, which will continue to be heard till the impeller
reaches full speed.
Keeping a firm grip on the starter handle, pull rope with 7.
a rapid, continuous, full arm stroke. Let the rope rewind
slowly.
Repeat the previous steps until engine fires. When engine 8.
starts, move choke control (if equipped) gradually to RUN
position.
NOTE: See your engine manual packed with your unit for
more detailed instructions.
Stopping The Engine
Move throttle control lever to STOP or OFF position.1.
Disconnect spark plug wire from spark plug and ground 2.
against the engine.
To Empty Bag
Open the large zipper in the rear of the bag to empty the 1.
contents. Be certain the zipper is closed completely when
operating the unit.
If bag is removed for any reason, follow instructions for 2.
attaching the bag in the Assembly & Set-Up section.
To Engage Drive
To engage the wheel drive, hold the drive control against •
the upper handle.
Release the drive control to stop the rear wheels from •
driving.
Release the drive control to slow down when negotiating •
an obstacle, making a turn, or stopping.
Engage control slowly to prevent the front wheels from •
lifting up.
Using the Chipper Shredder Vacuum
Place both hands on top of the upper handle and hold the •
drive control against the upper handle to propel the unit
over yard. Yard waste such as leaves and pine needles can
be vacuumed up through the nozzle for shredding.
After material has been shredded by the blades on the •
impeller assembly, it will be discharged into catcher bag.
Branches up to three inches in diameter can be fed into the •
chipper chute.
IMPORTANT: Do not attempt to shred or chip any material
other than vegetation found in a normal yard (i.e. branches,
leaves, twigs, etc.) Avoid fibrous plants such as tomato
vines until they are thoroughly dried out. Materials such as
stalks or heavy branches up to 3” in diameter may be fed
into the chipper chute.
WARNING: Do not attempt to shred, chip, or
vacuum any material larger than specified on the
machine or in this manual. Personal injury or
damage to the machine could result.
IMPORTANT: The flail screen is located inside the housing
in the discharge area. If the flail screen becomes clogged,
remove and clean as instructed in the Maintenance section.
For best performance, it is also important to keep the
chipper blade sharp.
Figure 5-1
S
T
O
P
Throttle
Control
Choke
Control
Maintenance & Adjustments
6
11
Engine Care
Refer to the separate engine manual for all engine •
maintenance instructions.
Check engine oil level before each use as instructed in the •
separate engine manual packed with your unit. Read and
follow instructions carefully.
Clean air cleaner every 25 hours under normal conditions •
or once a season. Clean every few hours under extremely
dusty conditions. To service the air cleaner, refer to the
separate engine manual packed with your unit.
The spark plug should be cleaned and the gap reset once •
a season. Check engine manual for correct plug type and
gap specifications.
Cleaning The Flail Screen
If the discharge area becomes clogged, remove the flail screen
and clean area as follows:
Stop the engine. Make certain the chipper/shredder 1.
vacuum has come to a complete stop.
Disconnect spark plug wire from spark plug and ground 2.
against the engine.
Remove and set aside the vacuum bag.3.
Remove the four self-tapping screws from the bottom of 4.
the discharge chute. See Fig. 6-1A.
Remove the hex bolt, saddle washer and hex nut from the 5.
top and remove the discharge chute assembly. See Fig.
6-1B.
Maintenance
General Recommendations
Always observe safety rules when performing any •
maintenance.
The warranty on this chipper/shredder vacuum does not •
cover items that have been subjected to operator abuse or
negligence. To receive full value from warranty, operator
must maintain the equipment as instructed here.
Changing of engine-governed speed will void engine •
warranty.
All adjustments should be checked at least once each •
season.
Periodically check all fasteners and make sure these are •
tight.
WARNING: Always stop engine and disconnect
spark plug wire before cleaning, lubricating or doing
any kind of maintenance on your machine.
Lubrication
Lubricate the rear wheels with light oil once a season.1.
Lubricate each nozzle door adjustment lever once a season 2.
with light oil.
Grease fittings are located on the front caster wheels to 3.
provide easy lubrication of the swivel pins.
Equipment Care
Clean the chipper/shredder vacuum thoroughly after each •
use.
Wash bag periodically with water. Allow to dry thoroughly •
in shade.
If the flail screen becomes clogged, remove and clean as •
instructed below.
NOTE: Cleaning with a forceful spray of water is not
recommended as it could contaminate the fuel system.
Figure 6-1
A
A
B
12 se c t i O n 6— Ma i n t e n a n c e & ad j u s t M e n t s
Adjustments
Drive Control Cable
Periodic adjustment of the drive control cable may be required if:
The chipper shredder vacuum moves forward with the •
drive control disengaged.
It does not self-propel with the drive control engaged.•
Drive belt is slipping (unit hesitates while engine maintains •
the same speed).
Use the adjustment wheel located in the control housing to
tighten or loosen the drive control cable until the above situation
is corrected. See Fig. 6-3.
In addition, the adjustment wheel may also be used to determine
the position in which the drive control is engaged. If it is more
comfortable to have the drive engaged with the lever further
away from the handle, tighten the cable.
Remove the two hex bolts and hex nuts which extend 6.
through the impeller housing. See Fig. 6-2A.
Lift the flail screen from inside the housing. See Fig. 6-2B.7.
Clean the flail screen by scraping and/or washing with 8.
water, and reinstall the screen.
NOTE: Be certain to reassemble the flail screen with the
curved side down.
Reattach the discharge chute assembly with the hardware 9.
previously removed and attach the bag to the unit.
Tire Pressure (Pneumatic tires only)
Maximum tire pressure under any circumstance is 30 psi. Equal
tire pressure should be maintained at all times assembly.
Figure 6-3
Loosen
Tighten
A
B
Figure 6-2
Service
7
13
Remove other blade in the same manner to replace or 6.
sharpen.
WARNING: Use caution when replacing the blades.
Wear heavy gloves to avoid injury while handling
the weld bolts, housing or the blades.
NOTE: When sharpening blades, follow the original angle
of grind. Also, make sure to remove an equal amount from
each blade and torque hardware to 250 - 300 in.lb.
IMPORTANT: Make sure that blades are reassembled with
the sharp edge facing upward.
Belt Care
NOTE: Several components must be removed and a special tool
is required in order to change the chipper/shredder vacuum’s
belt. See an authorized Service Dealer to have your belt replaced.
Off-Season Storage
When storing the chipper/shredder vacuum in an •
unventilated or metal storage shed, care should be taken
to rustproof the non-painted surfaces. Using a light oil
or silicone, coat the equipment, especially any springs,
bearings, and cables.
Remove all dirt from exterior of engine and equipment.•
Follow lubrication recommendations.•
Refer to engine manual for correct engine storage •
instructions.
Store equipment in a clean, dry area. Do not store in an •
area where equipment is present that may use a pilot light
or has a component that can create a spark.
WARNING: Never store the machine or fuel
container indoors where there is an open flame,
spark, or pilot light such as on a water heater,
furnace, clothes dryer, or other gas appliance.
Blade Care
WARNING: Before performing any type of
maintenance on the machine, wait for all parts to
stop moving and disconnect the spark plug wire.
Failure to follow this instruction could result in
personal injury or property damage.
NOTE: When tipping the unit, empty the fuel tank and keep
engine spark plug side up.
Disconnect spark plug wire and ground it against engine.1.
Remove flail screen as instructed in previous section.2.
Remove plastic belt cover from front of the engine by 3.
removing the two self-tapping screws. See Fig. 7-1A.
Remove the access plate by removing two hex lock nuts. 4.
See Fig. 7-1B.
Locate one of the chipper blades in the access opening 5.
by rotating the impeller assembly by hand. Remove
the chipper blade using a 3/16” allen wrench and a 1/2”
wrench. See Fig. 7-1C.
Figure 7-1
A
B
C
Troubleshooting
8
14
Problem Cause Remedy
Engine Fails to start Throttle lever not in correct starting position. 1.
Spark plug wire disconnected.2.
Choke not in CHOKE position (if equipped).3.
Fuel tank empty or stale fuel.4.
Engine not primed (if equipped).5.
Faulty spark plug.6.
Engine flooded.7.
Move throttle lever to FAST or START 1.
position.
Connect wire to spark plug.2.
Move choke lever to CHOKE position.3.
Fill tank with clean, fresh gasoline.4.
Prime engine as instructed in Engine Manual.5.
Clean, adjust gap, or replace.6.
Wait a few minutes to restart, but do not 7.
prime.
Engine runs erratic Spark plug boot loose.1.
Unit running on CHOKE (if equipped).2.
Blocked fuel line or stale fuel. 3.
Low engine RPM.4.
Water or dirt in fuel system.5.
Dirty air cleaner.6.
Carburetor out of adjustment.7.
Connect and tighten spark plug boot.1.
Move choke lever to OFF position.2.
Clean fuel line; fill tank with clean, fresh 3.
gasoline.
Always run engine at full throttle.4.
Drain fuel tank. Refill with fresh fuel.5.
Refer to engine manual.6.
See authorized service dealer.7.
Engine overheats Engine oil level low.1.
Dirty air cleaner.2.
Fill crankcase with proper oil.1.
Refer to engine manual.2.
Occasional skips
(hesitates) at
high speed
Spark plug gap too close.1.
Carburetor idle mixture adjustment 2.
improperly set.
Remove spark plug and adjust gap to .030”.1.
See authorized service dealer.2.
Excessive Vibration Loose parts or damaged impeller.1. See authorized service dealer.2.
Unit does not discharge Discharge area clogged. 1.
Foreign object lodged in impeller. 2.
Low engine RPM.3.
Vacuum bag is full.4.
Stop engine immediately and disconnect 1.
spark plug wire. Clean flail screen and inside
of discharge opening.
Stop engine and disconnect spark plug wire. 2.
Remove lodged object.
Always run engine at full throttle.3.
Empty bag.4.
Rate of discharge slows
considerably or composition
of discharged material
changes
Low engine RPM.1.
Chipper blade dull.2.
Always run engine at full throttle.1.
Replace chipper blade or see your authorized 2.
service dealer.
Unit fails to propel itself
or slips when drive
control is engaged
Drive control cable out of adjustment. 1.
Drive belt worn or damaged.2.
Follow adjustment procedure in 1.
Maintenance & Adjustments section of
manual.
See authorized service dealer.2.
15
Model 204
Ref
No.
Part Number Description
1 741-0415 Flange Bearing.566 ID
2 618-0255 Shredder Transmission Assembly
3 16500A Hex Bearing Cup
4 711-1118 Output Shaft 6T Sprocket
5 717-1432 Helical 34T Gear
6 721-0213 Oil Seal
7 736-0187 Flat Washer, .64 ID x 1.24 OD
8 736-0336 Flat Washer, 5/8 x 1.0
9 741- 0413 Hex Flange Bearing, .631 ID
10 741- 0414 Flange Bearing, .629 ID
11 719-0325 Lower Housing
12 748-0373 Flange Bearing, .503 ID
13 719-0324A Upper Housing
14 748- 0208A Flange Bearing, .378 ID
15 710-0589 Hex Washer Screw, #10-16 x.75
16 717-1433 Pinion Shaft 10T
17 721-0329 Oil Seal
18 736-0314 Thrust Washer, .382 ID x.684 OD
19 736-0520 Flat Washer, .504 ID x.70 OD
Ref
No.
Part Number Description
20 741-0479 Thrust Bearing, .375 ID x.812 OD
21 656-0008 Idler Pulley Assembly W/ Bearing
756-0558 Idler Pulley Only
741-0556 Needle Bearing Only
22 710-1062 Hex Cap Screw, 1/4-20 x 1.25
23 712-0138 Hex Nut, 1/4-28
24 712-3045 Hex Jam Nut, 5/16-24 LH Thd
25 732- 0357A Extension Spring, 1.12 Lg
26 736-0270 Bell Washer, .265 ID x.75 OD
27 736-0329 Lock Washer, 1/4
28 736-0425 Bell Washer, .325 ID x.930 OD
29 738-0440 Shoulder Spacer, .375 ID x.165 OD
30 738-0826 Shoulder Bolt, 1/4-28 x.375
31 756-0656 Flat Pulley 5.06 Dia
32 782-7569 Belt Keeper
33 682-0054 Idler Bracket
34 618-0132 Lower Housing Assembly
35 618- 0133A Upper Housing Assembly
2
23
17
12
16
20
15
18
18
14
13
27
22
19
26
21
32
33
1
8
30
31
29
15
25
11
28
24
35
34
5
8
6
10
3
9
7
4
16
Model 204
65
33
30
29
32
27
25
31
46
25
48
58
64
37
38
52
36
35
34
55
54
57
56
6
7
43
44
63
20
17
21
20
22
23
24
4
62
61
47
30
42
41
39
40
41
5
66
67
68
60
59
28
70
69
65
26
49
9
10
11
16
14
13
8
12
53
15
51
A
50
38
39
C
C
A
45
18
3
18
19
19
1
2
17
Model 204
Ref
No.
Part Number Description
1. 781-0633 Chute Flap Strip
2. 735-0249 Chute Flap
3. 728- 0175 Pop Rivet
4. 731-1838A Discharge Chute
5. 764-04001 Bag
6. 631-0086 Nozzle Assembly
7. 731-1831 Nozzle Flap
8. 710-0969 Screw
9. 720-0426 Height Adjustment Knob
10. 732-0754 Spring Lever
11. 781-0702 Index Bracket RH
12. 781-0703 Index Bracket LH
13. 738-0913 Shoulder Screw
14. 736-3084 Flat Washer, .510 x 1.12 x.060
15. 712- 0431 Hex Flange Lock Nut, 3/8-16
16. 631-0049 Door Assembly
17. 731-1574A Chipper Chute
18. 710-0751 Hex Cap Screw, 1/4-20 x.620
19. 736-0173 Flat Washer, .28 ID x.74 OD
20. 712-3027 Hex Lock Nut, 1/4-20
21. 781-0780 Support Bracket
22. 681-0068A Chipper Chute Assembly
23. 712-3010 Hex Nut, 5/16-18
24. 736-0242 Belleville Washer, .340ID x.872OD
25. 681-04091 Impeller Assembly: Complete
26. 719- 04308 Flail Blade
27. 712-0266A Jam Lock Nut, 3/8-16
28. 734-1984 Hub Cap
29. 738-04286 Shoulder Pin, .5 x 2.625
30. 736 - 0119 Lock Washer, 5/16
31. 710-1054 Cap Screw 5/16-24 x 1.0
32. 742- 0544 Chipper Blade
33. 712 - 0 411 Hex Lock Nut 5/16-24
34. 736-0247 Flat Washer, .406 x 1/1/4
35. 736 -0217 Lock Washer, 3/8
36. 710 -1273 Hex Cap Screw, 3/8-24 x 2.75
Ref
No.
Part Number Description
37. 723-0438 Rubber Seal
38. 710-0604A Hex Washer Screw, 5/16-18
39. 712-0384 Hex Lock Nut, 1/2-13
40. 781-0627 Chipper Blade Cover
41. 712-3004A Hex Flange Lock Nut 5/16-18
42. 681-0098 Housing Assembly: Inner Flail
43. 781-0599 Upper Shredder Blade
44. 710-0772 Hex Cap Screw, 5/16-18 x 2
45. 781-0653 Flail Housing Blade
46. 710-3008 Hex Cap Screw, 5/16-18 x.75
47. 719- 0326 Discharge Screen
48. 681-0060 Housing Assembly: Outer Flail
49. 629-0241A Wire Harness
50. 710-0896 TT Screw, 1/4-14 x 0.625”
51. 726-0272 Clamp
52. 710-0382 Hex Cap Screw, 1/2-13 x 5.0
53. 712-0421 Knob, 5/16-18
54. 725-3166 Switch
55. 731-1613 Safety Switch Mounting Cover
56. 710 -1268 Hex Washer Screw
57. 725 -1700 Switch Cover
58. 710 -1260A LD Screw, 5/16-18 x 0.75”
59. 712-3027 Hex Flanged Lock Nut, 1/4-20
60. 748-0188B Pawl, .345 ID -LH
748-0381 Pawl, .345 ID - RH
61. 710 -0157 Hex Cap Screw, 5/16-24 x.75
62. 736-3008 Flat Washer, .344 x.75 x.12
63. 747-0929A Belt Keeper
64. 629-0923 Adapter Harness Assembly
65. 736-0366 Flat Washer, 5/8 ID x 1.0 OD
66. 634-0244 Wheel Complete 10 x 4 x 4
67. 712-0456 Hex Nut, 1/4-20
68. 10622B Plastic Spring Ratchet
69. 748- 0405 Wheel Ratchet 1.62 OD x.5 serr
70. 714-0104 Cotter Pin
18
Model 204
45
41
40
22
35
33
33
37
38
33
51
9
3
39
52
48
46
55
21
23
31
45
48
47
33
14
19
17
18
43
12
13
15
16
49
11
2
1
8
5
4
7
8
6
32
B
A
A
36
24
27
30
28
29
25
26
32
39
B
32
37
50
53
54
42
34
20
44
43
44
10
19
Ref
No.
Part Number Description
1. 781-0677 Chain Case - LH
2. 781-0676 Chain Case - RH
3. 754-0457 V-Belt
4. 748- 0313 Spacer
5. 741- 0413 Hex Flange Bearing
6. 736-0336 Flat Washer
7. 713-0422 Chain
8. 710-0896 TT Screw, 1/4-14 x 0.625”
9. 710-0603 Hex Washer Screw, 5/16
10. 618-0256† Chipper Shredder Trans. Ass’y.
11. 611- 0 0 63 Axle Assembly
12. 734-1804A Wheel, 6.0 x 2.0
13. 750-1042 Spacer
14. 712- 0431 Flange Lock Nut, 3/8-16
15. 710-0521 Hex Cap Screw, 3/8-16 x 3.0
16. 681-0088 Bracket Assembly
17. 736-0931 Flat Washer, .203 ID x.403 OD
18. 737-3000 Grease Fitting, 3/16
19. 681-0087 Bracket Assembly
20. 714-0104 Cotter Pin
21. 749 -1095 Upper Handle
22. 1539 -019 Push Nut
23. 711- 0737 Stud Pin, .250 x 1.75
24. 746-0714 Clutch Cable - 56”
25. 731-1735 Upper Clutch Cover
26. 731-0620A Drive Lever
27. 731-1736 Lower Clutch Cover
28. 710- 0841 Screw, #10-12 x.750
Ref
No.
Part Number Description
29. 731-1059 Mounting Cable Cap
30. 710-1331 Screw, #10-16 x 1.25
31. 710-0805 Hex Cap Screw, 5/16-18 x 1.50
32. 736-0451 Shoulder Washer, .320 ID x.93 OD
33. 712-3004A Hex Flange Lock Nut, 5/16-18
34. 726- 0214 Push Cap
35. 712-0380 Hex Nut, 1/4-28
36. 781-0647 Discharge Chute Bracket
37. 710-3008 Hex Cap Screw, 5/16-18 x.75
38. 747-0815 Eye Bolt
39. 710-0896 Hex Washer Screw, 1/4-14 x.625
40. 731-1646 Belt Cover
41. 719- 0359 Engine Mounting Adapter
42. 736-0264 Flat Washer, .330 ID x.630 OD
43. 741-0487C Flange Bearing, .632 ID
44. 736-0366 Flat Washer, 5/8 ID x 1.0 OD
45. 710-3103 Hex Cap Screw, 5/16-18 x 1.75
46. 749-1094 Lower Push Handle
47. 710-0502A Screw, 3/8-16 x 1.25
48. 710-0604A Hex Washer Screw, 5/16-18 x.625
49. 741-0413 Hex Flange Bearing, .631 x.720
50. 681-0097A Frame Assembly
51. 781-0700 Axle Bracket
52. 781-0697 Transmission Cover
53 747-0924 Lock Pin
54 732-0306 Compression Spring
55 725-0157 Cable Tie
— 723-0400 Safety Glasses (Not Shown)
Model 204
† See Page 15 for transmission breakout
MANUFACTURER’S LIMITED WARRANTY FOR
GDOC-100020 REV. A
The limited warranty set forth below is given by Troy-Bilt LLC with
respect to new merchandise purchased and used in the United States
and/or its territories and possessions, and by MTD Products Limited
with respect to new merchandise purchased and used in Canada
and/or its territories and possessions (either entity respectively,
“Troy-Bilt” ).
“Troy-Bilt” warrants this product (excluding its Normal Wear Parts
and Attachments as described below) 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 materials or workmanship.
This limited warranty shall only apply if this product has been
operated and maintained in accordance with the Operator’s Manual
furnished with the product, and has not been subject to misuse,
abuse, commercial use, neglect, accident, improper maintenance,
alteration, vandalism, theft, fire, water, or damage because of other
peril or natural disaster. Damage resulting from the installation or
use of any part, accessory or attachment not approved by Troy-Bilt
for use with the product(s) covered by this manual will void your
warranty as to any resulting damage.
Normal Wear Parts are warranted to be free from defects in material
and workmanship for a period of thirty (30) days from the date of
purchase. Normal wear parts include, but are not limited to items
such as: batteries, belts, blades, blade adapters, tines, grass bags,
wheels, rider deck wheels, seats, snow thrower skid shoes, friction
wheels, shave plates, auger spiral rubber and tires.
Attachments — Troy-Bilt warrants attachments for this product
against defects in material and workmanship for a period of one (1)
year, commencing on the date of the attachment’s original purchase
or lease. Attachments include, but are not limited to items such as:
grass collectors and mulch kits.
HOW TO OBTAIN SERVICE: Warranty service is available, WITH
PROOF OF PURCHASE, through your local authorized service dealer.
To locate the dealer in your area:
In the U.S.A.
Check your Yellow Pages, or contact Troy-Bilt LLC at P.O. Box 361131,
Cleveland, Ohio 44136-0019, or call 1-866-840-6483,
1-330-558-7220 or log on to our Web site at www.troybilt.com.
In Canada
Contact MTD Products Limited, Kitchener, ON N2G 4J1, or call 1-800-
668-1238 or log on to our Web site at www.mtdcanada.com.
This limited warranty does not provide coverage in the following
cases:
a. The engine or component parts thereof. These items may carry a
separate manufacturer’s warranty. Refer to applicable manufactur-
er’s warranty for terms and conditions.
b. Log splitter pumps, valves, and cylinders have a separate one-
year warranty.
c. Routine maintenance items such as lubricants, filters, blade
sharpening, tune-ups, brake adjustments, clutch adjustments,
deck adjustments, and normal deterioration of the exterior finish
due to use or exposure.
d. Service completed by someone other than an authorized service
dealer.
e. Troy-Bilt does not extend any warranty for products sold or
exported outside of the United States and/or Canada, and their
respective possessions and territories, except those sold through
Troy-Bilt’s authorized channels of export distribution.
f. Replacement parts that are not genuine Troy-Bilt parts.
g. Transportation charges and service calls.
h. Troy-Bilt does not warrant this product for commercial use.
No implied warranty, including any implied warranty of
merchantability of fitness for a particular purpose, applies after
the applicable period of express written warranty above as to the
parts as identified. No other express warranty, whether written or
oral, except as mentioned above, given by any person or entity,
including a dealer or retailer, with respect to any product, shall
bind Troy-Bilt. During the period of the warranty, the exclusive
remedy is repair or replacement of the product as set forth above.
The provisions as set forth in this warranty provide the sole and
exclusive remedy arising from the sale. Troy-Bilt shall not be liable
for incidental or consequential loss or damage including, without
limitation, expenses incurred for substitute or replacement lawn
care services or for rental expenses to temporarily replace a
warranted product.
Some states do not allow the exclusion or limitation of incidental
or consequential damages, or limitations on how long an implied
warranty lasts, so the above exclusions or limitations may not apply
to you.
In no event shall recovery of any kind be greater than the amount of
the purchase price of the product sold. Alteration of safety features of
the product shall void this warranty. You assume the risk and liability
for loss, damage, or injury to you and your property and/or to others
and their property arising out of the misuse or inability to use the
product.
This limited warranty shall not extend to anyone other than the
original purchaser or to the person for whom it was purchased as a
gift.
HOW STATE LAW RELATES TO THIS WARRANTY: This limited
warranty gives you specific legal rights, and you may also have other
rights which vary from state to state.
IMPORTANT: Owner must present Original Proof of Purchase to
obtain warranty coverage.
Troy-Bilt LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019; Phone: 1-866-840-6483, 1-330-558-7220
MTD Canada Limited - KITCHENER, ON N2G 4J1; Phone 1-800-668-1238
