Troy Bilt 204 User Manual

Safety • Assembly • Operation • Maintenance • Troubleshooting • Parts Lists • Warranty  
OPERATOR’S MANUAL  
Chipper Shredder Vacuum - Model 204  
IMPORTANT  
READ SAFETY RULES AND INSTRUCTIONS CAREFULLY BEFORE OPERATION  
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 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.  
FORM NO. 769-00170F  
5/23/2007  
PRINTED IN U.S.A.  
TROY BILT LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019  
NOTES  
Use this page to make notes and write down important information.  
3
WARNING: Engine Exhaust, some of its constituents, and certain vehicle compo-  
nents contain or emit chemicals known to State of California to cause cancer and  
birth defects or other reproductive harm.  
2
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.  
Safe  
Operation Failure to observe the following safety instructions could result in serious injury or death.  
Training  
Preparation  
1. Read, understand, and follow all instructions on the ma-  
chine 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.  
2. Be familiar with all controls and their proper operation.  
Know how to stop the machine and disengage them  
quickly.  
1. Thoroughly inspect the area where the equipment is to  
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.  
2. Always wear safety glasses or safety goggles during opera-  
tion or while performing an adjustment or repair, to protect  
eyes. Thrown objects which ricochet can cause serious  
injury to the eyes.  
Practices  
3. Never allow children under 16 years old to operate this  
machine. Children 16 years old and over should read and  
understand the operation instructions and safety rules in  
this manual and should be trained and supervised by a  
parent.  
3. Wear sturdy, rough-soled work shoes and close-fitting  
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.  
WARNING  
4. Never allow adults to operate this machine without proper  
instruction.  
4. Before starting, check all bolts and screws for proper tight-  
ness to be sure the machine is in safe working condition.  
Also, visually inspect machine for any damage at frequent  
intervals.  
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  
5. Keep bystanders, helpers, pets, and children at least  
75 feet from the machine while it is in operation. Stop  
machine if anyone enters the area.  
5. Maintain or replace safety and instructions labels, as  
necessary.  
6. Never run an engine indoors or in a poorly ventilated area.  
Engine exhaust contains carbon monoxide, an odorless  
and deadly gas.  
6. 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.  
7. Do not put hands and feet near rotating parts or in the  
feeding chambers and discharge opening. Contact with  
the rotating impeller can amputate fingers, hands, and  
feet.  
8. Never attempt to unclog either the feed intake or dis-  
charge opening, remove or empty vacuum 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.  
manual before at-  
a. Use only an approved gasoline container.  
b. Extinguish all cigarettes, cigars, pipes, and other  
sources of ignition.  
tempting to operate  
this machine. Failure  
to comply with these  
instructions may result  
in personal injury. When  
you see this symbol.  
c. Never fuel machine indoors.  
d. Never remove gas cap or add fuel while the engine is hot  
or running.  
e. Allow engine to cool at least two minutes before refuel-  
ing.  
f. Never over fill fuel tank. Fill tank to no more than 1/2  
inch below bottom of filler neck to provide space for fuel  
expansion.  
HEED ITS WARNING!  
Your Responsibility  
Restrict the use  
g. Replace gasoline cap and tighten securely.  
h. If gasoline is spilled, wipe it off the engine and equip-  
ment. Move machine to another area. Wait 5 minutes  
before starting the engine.  
of this power machine  
to persons who read,  
understand  
i. Never store the machine or fuel container inside where  
there is an open flame, spark, or pilot light (e.g. furnace,  
water heater, space heater, clothes dryer, etc.).  
j. To reduce a fire hazard, keep machine free of grass,  
leaves, or other debris build-up. Clean up oil or fuel  
spillage and remove any fuel soaked debris.  
k. Allow machine to cool at least 5 minutes before storing.  
and follow the warnings  
and instructions  
in this manual  
and on the machine.  
4
Operation  
Maintenance & Storage  
1. Do not put hands and feet near rotating parts or in the  
feeding chambers and discharge opening. Contact with the  
rotating impeller can amputate fingers, hands, and feet.  
2. Before starting the machine, make sure the chipper chute,  
feed intake, and cutting chamber are empty and free of all  
debris.  
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.  
2
3. Thoroughly inspect all material to be shredded and remove  
any metal, rocks, bottles, cans, or other foreign objects  
which could cause personal injury or damage to the  
machine.  
3. Before cleaning, repairing, or inspecting, stop the engine  
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.  
4. Do not change the engine governor settings or overspeed  
the engine. The governor controls the maximum safe  
operating speed of the engine.  
Safe  
Operation  
Practices  
4. If the impeller strikes a foreign object or if your machine  
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:  
a. Inspect for damage.  
5. Maintain or replace safety and instruction labels, as  
necessary.  
6. Follow this manual for safe loading, unloading, transport-  
ing, and storage of this machine.  
b. Repair or replace any damaged parts.  
c. Check for any loose parts and tighten to assure  
continued safe operation.  
7. Never store the machine or fuel container inside where  
there is an open flame, spark or pilot light such as a water  
heater, furnace, clothes dryer, etc.  
5. Do not allow an accumulation of processed material to build  
up in the discharge area. This can prevent proper discharge 8. Always refer to the operator’s manual for proper instruc-  
and result in kickback of material through the feed opening.  
6. Do not attempt to shred or chip material larger than  
specified on the machine or in this manual. Personal injury  
or machine damage could result.  
tions on off-season storage.  
WARNING  
9. If the fuel tank has to be drained, do this outdoors.  
10. Observe proper disposal laws and regulations for gas, oil,  
etc. to protect the environment.  
This symbol points  
7. Never attempt to unclog either the feed intake or 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.  
out important safety  
instructions, which if  
not followed, could  
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.  
endanger the personal  
safety and/or property  
of yourself and others.  
Read and follow all  
8. 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.  
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 gaso-  
line, and may include the following emission control systems:  
Engine Modification (EM) and Three Way Catalyst (TWC) if so  
equipped.  
instructions in this man-  
ual before attempting to  
operate this machine.  
Failure to comply with  
these instructions may  
result in personal injury.  
When you see this  
9. 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.  
10. Keep all guards, deflectors and safety devices in place and  
operating properly.  
Your Responsibility  
11. 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.  
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.  
symbol.  
HEED IT’S WARNING!  
12. Never operate this machine without good visibility or light.  
Always be sure of your footing and keep a firm hold on the  
handles.  
Your Responsibility  
Restrict the use  
13. Do not operate this machine on a gravel surface.  
14. Do not operate this machine while under the influence of  
alcohol or drugs.  
of this power machine  
to persons who read,  
understand  
15. Muffler and engine become hot and can cause a burn. Do  
not touch.  
16. Never pick up or carry machine while the engine is running.  
and follow the warnings  
and instructions  
in this manual  
and on the machine.  
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 separate engine manual  
before operating your machine.  
3
Chipper  
Chute  
Nozzle  
Loose Parts In Carton  
1. Following is the list of loose parts shipped with your  
equipment. Compare the parts with the illustration in  
Figure 3-1 to identify these items.  
Setting  
UpYour  
Chipper  
Shredder  
Vacuum  
Bag  
a. Nozzle  
b. Bag  
c. Chipper Chute  
d. Engine Oil (May be located in bag)  
e. Safety Glasses  
f. Tamper Plug (If Equipped)  
Tamper  
Plug  
NOTE: All references in this manual to the left or right  
side of the yard vacuum is from the operating position  
only. Exceptions, if any, will be specified.  
Bottle of Oil  
Safety Glasses  
Figure 3-1  
Attaching The Nozzle  
2. a. Remove three wing nuts from the front of the  
chipper shredder vacuum. See Figure 3-2.  
b. Place nozzle in position over three studs on unit.  
c. Secure with wing nuts just removed. See Figure  
3-2.  
IMPORTANT  
This unit is shipped  
without gasoline or  
oil in the engine. Be  
certain to service  
A
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 Figure 3-2.  
engine with gasoline  
and oil as instructed  
in the separate engine  
manual before operat-  
ing your machine.  
B
Attaching The Chipper Chute  
3. Loosen, but do not remove, the two hex bolts, flat  
washers, and flange nuts which are secured to the  
support bracket. See Figure 3-3.  
C
NOTE: All references  
in this manual to the  
left or right side of  
the chipper shredder  
vacuum is from the  
operating position only.  
Exceptions, if any, will  
be specified.  
Figure 3-2  
NOTE: The metal tab  
on the nozzle must  
depress the safety  
switch button attached  
to the front of the chip-  
per shredder vacuum  
or the engine will not  
start.  
Figure 3-3  
6
4. a. Remove the two flange nuts, hex bolts and saddle  
washers which secure the right side of the upper  
handle to the right side of the lower handle. See  
Figure 3-4.  
b. Remove the three hex nuts and bell washers from  
the weld studs beside the opening on the right side  
of the chipper-shredder vacuum. See Figure 3-4.  
5. a. Place the chipper chute over the weld studs keep-  
ing 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  
3-5.  
3
Setting  
UpYour  
Chipper  
Shredder  
Vacuum  
b. Align the support bracket with the holes in the right  
side of the upper and lower handles where the hex  
bolts were just removed. Push up slightly on the  
chipper chute in order to better align the holes in  
the support bracket with the holes in the handles.  
c. Replace the hex bolts, saddle washers and flange  
nuts to affix the support bracket to the handle  
assemblies. See Figure 3-5.  
Figure 3-4  
d. Follow by tightening all hardware securely first on  
the chipper chute, then on the support bracket, and  
finally on the handle.  
Attaching The Bag  
6. a. 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 3-6.  
b. Place the four straps on top of the bag over the  
upper handle, hooking them on the studs to secure  
in place. See Figure 3-6.  
B, C, & D  
A & D  
7. Squeeze the clamp on the drawstring and pull the  
drawstring tight. Release the clamp. See Figure 3-7.  
Figure 3-ꢀ  
A
B
Figure 3-ꢁ  
Figure 3-6  
KnowYour Chipper Shredder Vacuum  
Drive Control  
4
† Tamper  
Plug  
Chipper  
Chute  
Setting  
UpYour  
Chipper  
Shredder  
Vacuum  
Caster Lock  
Vacuum/  
Chipper  
Bag  
WARNING  
Nozzle Door  
Adjustment  
Lever  
Be familiar with all  
controls and their  
proper operation.  
† If Equipped  
Figure 4-1  
Know how to stop the  
machine and disen-  
gage them quickly.  
WARNING: Be familiar with all controls  
and their proper operation. Know how  
to stop the machine and disengage  
them quickly.  
Vacuum/Chipper Bag  
Collects shredded or chipped material fed through the  
chipper chute or vacuumed up through the nozzle.  
Drive Control  
The drive control is located on the upper handle assem-  
bly. 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.  
Always wear  
safety glasses during  
operation or while  
performing any ad-  
justments or repairs.  
Thrown objects  
which ricochet can  
cause serious injury  
to the eyes.  
Now that you have set up your yard vacuum for  
operation, get acquainted with its controls and features.  
These are described below and illustrated on this page.  
This knowledge will allow you to use your new equip-  
ment to its fullest potential.  
Caster Locks  
The caster locks are located on top of each front caster  
wheel. Refer to the Adjustment Section to position wheel  
locks. See Figure 4-1.  
Chipper Chute  
Allows twigs and small branches up to 3” in diameter to  
be fed into the impeller for chipping. See Figure 4-1.  
Tamper Plug (If Equipped)  
WARNING: Always wear safety glasses  
during operation or while performing  
any adjustments or repairs. Thrown  
objects which ricochet can cause  
This plug is inserted into the chipper chute to push twigs  
and small branches towards the impeller blades without  
endangering your hands.  
serious injury to the eyes.  
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 perfor-  
mance for the operating conditions. See Figure 4-1.  
Engine Controls  
See the separate engine manual for the location and  
function of the controls on the engine.  
8
Gas and Oil Fill-Up  
Service the engine with gasoline and oil as instructed in  
the engine manual. Read instructions carefully.  
StoppingThe Engine  
1. Move throttle control lever to STOP or OFF position.  
2. Disconnect spark plug wire from spark plug and  
ground against the engine.  
4
WARNING: Use extreme care when han-  
dling gasoline. Gasoline is extremely  
flammable and the vapors are explosive.  
Never fuel machine indoors or while  
To Empty Bag  
1. Open the large zipper in the rear of the bag to  
empty the contents. Be certain the zipper is closed  
completely when operating the unit.  
Setting  
UpYour  
Chipper  
Shredder  
Vacuum  
the engine is hot or running. Extinguish cigarettes,  
cigars, pipes, and other sources of ignition.  
2. If bag is removed for any reason, follow instructions  
for attaching the bag in the “Setting Up Your Chipper  
Shredder Vacuum” section.  
Starting Engine  
To Engage Drive  
To engage the wheel drive, hold the drive control  
against the upper handle.  
WARNING: Keep bystanders, helpers,  
pets, and children at least 75 feet from  
the machine before starting and while  
Release the drive control to stop the rear wheels  
from driving.  
operating. Do not operate this machine  
unless the discharge chute and bag have been  
properly installed and secured to the machine.  
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.  
1. Attach spark plug wire to spark plug. Make certain  
the metal cap on the end of the spark plug is fastened Using the Chipper Shredder Vacuum  
securely over the metal tip on the spark plug.  
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.  
WARNING  
2. Make certain drive control is in the disengaged  
(released) position.  
Use extreme care when  
handling gasoline.  
Gasoline is extremely  
flammable and the  
vapors are explosive.  
Never fuel machine  
indoors or while  
the engine is hot or  
running. Extinguish  
cigarettes, cigars,  
pipes, and other  
3. Engines with choke lever:  
Move choke lever on engine to CHOKE position. (A  
warm engine may not require choking).  
After material has been shredded by the blades  
on the impeller assembly, it will be discharged into  
catcher bag.  
Engines with primer:  
Prime engine as instructed in separate engine manual.  
Branches up to three inches in diameter can be fed  
into the chipper chute.  
4. Move engine throttle control lever to FAST or START  
position.  
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.  
5. Place one foot on the left rear wheel to prevent the  
unit from skidding while starting.  
6. Grasp starter handle and pull rope out slowly until  
engine reaches start of compression cycle (rope will  
pull slightly harder at this point).  
sources of ignition.  
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.  
NOTE: A noise will be heard at the start of the compres-  
sion cycle, which will continue to be heard till the impeller  
reaches full speed.  
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.  
7. Keeping a firm grip on the starter handle, pull rope  
with a rapid, continuous, full arm stroke. Let the rope  
rewind slowly.  
8. Repeat the previous steps until engine fires. When  
engine starts, move choke control (if equipped)  
gradually to RUN position.  
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.  
NOTE: See your engine manual packed with your unit for  
more detailed instructions.  
9
under extremely dusty conditions. To service the air  
cleaner, refer to the separate engine manual packed  
with your unit.  
3. The spark plug should be cleaned and the gap reset  
once a season. Check engine manual for correct plug  
type and gap specifications.  
Nozzle Door Height Adjustment  
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 clear-  
ance, to provide best performance.  
2
Maintaining  
Your  
1
1. Push adjustment lever out away from nozzle.  
Chipper  
Shredder  
Vacuum  
2. Slide the height adjustment lever forward or backward  
for adjusting the nozzle door upwards or downwards.  
See Figure 5-1.  
3
Figure ꢀ-1  
3. Release lever towards nozzle.  
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.  
Drive Control Cable Adjustment  
Adjust the drive control if:  
a. The chipper shredder vacuum moves forward with  
the drive control disengaged.  
b. It does not self-propel with the drive control  
engaged.  
WARNING  
c. Drive belt is slipping (unit hesitates while engine  
maintains the same speed).  
Always stop engine,  
disconnect spark plug,  
and ground against  
engine before cleaning,  
lubricating or doing any  
kind of maintenance on  
your machine.  
Use the adjustment wheel located in the control housing  
to tighten or loosen the drive control cable until the above  
situation is corrected.  
Figure ꢀ-2  
In addition, the adjustment wheel may also be used to de-  
termine 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.  
WARNING: Always stop engine and  
disconnect spark plug wire before  
cleaning, lubricating or doing any kind  
of maintenance on your machine.  
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.  
Lubrication  
1. Wheels: Lubricate the rear wheels with light oil once  
a season.  
2. Nozzle Door Adjustment Levers: Lubricate each  
adjustment lever once a season with light oil.  
1. Lift and place pins in the larger holes for locked or  
straight ahead operation and when operating on  
slopes. See Figure 5-2.  
3. Front Caster Wheels: Grease fittings are located on  
the front caster wheels to provide easy lubrication of  
the swivel pins.  
2. Place pins in smaller holes to allow casters to rotate  
freely for maneuvering around trees and flower beds.  
Engine Maintenance  
Refer to the separate engine manual for all engine  
maintenance instructions.  
Cleaning The Flail Screen  
If the discharge area becomes clogged, remove the flail  
screen and clean area as follows.  
1. Check engine oil level before each use as in-  
structed in the separate engine manual packed with  
your unit. Read and follow instructions carefully.  
1. Stop the engine. Make certain the chipper/shredder  
vacuum has come to a complete stop.  
2. Disconnect spark plug wire from spark plug and  
ground against the engine.  
2. Clean air cleaner every 25 hours under normal  
conditions or once a season. Clean every few hours  
10  
3. Remove and set aside the vacuum bag.  
4. a. Remove the four self-tapping screws from the  
bottom of the discharge chute. See Figure 5-3.  
b. Remove the hex bolt, saddle washer and hex  
nut from the top and remove the discharge chute  
assembly. See Figure 5-3.  
Chipper  
Shredder  
Vacuum  
B
5. a. Remove the two hex bolts and hex nuts which  
extend through the impeller housing.  
A
b. Lift the flail screen from inside the housing. See  
Figure 5-4.  
Maintaining  
Your  
6. Clean the flail screen by scraping and/or washing with  
water, and reinstall the screen.  
A
NOTE: Be certain to reassemble the flail screen with the  
curved side down.  
7. Reattach the discharge chute assembly with the  
hardware previously removed and attach the bag to  
the unit.  
Figure ꢀ-3  
Sharpening Or Replacing Chipper  
Blades  
B
NOTE: When tipping the unit, empty the fuel tank and  
keep engine spark plug side up.  
1. Disconnect spark plug wire and ground it against  
engine.  
WARNING  
2. Remove flail screen as instructed in previous section.  
Use caution when re-  
placing the blades. Wear  
heavy gloves to avoid  
injury while handling the  
weld bolts, housing or  
the blades.  
3. a. Remove plastic belt cover from front of the engine  
by removing the two self-tapping screws. See  
Figure 5-5 on next page.  
A
b. Remove the access plate by removing two hex lock  
nuts.  
c. Locate one of the chipper blades in the access  
opening by rotating the impeller assembly by hand.  
Remove the chipper blade using a 3/16” allen  
wrench and a 1/2” wrench. See Figure 5-5.  
4. Remove other blade in the same manner to replace or  
sharpen.  
Figure ꢀ-4  
WARNING: Use caution when replacing  
the blades. Wear heavy gloves to avoid  
injury while handling the weld bolts,  
housing or the blades.  
NOTE: Be certain to  
reassemble the flail  
screen with the curved  
side down.  
A
C
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.  
NOTE: When sharpen-  
ing blades, follow the  
original angle of grind.  
Also, make sure to re-  
move 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.  
B
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 ꢀ-ꢀ  
11  
Problem  
Cause  
Remedy  
1. Throttle lever not in correct starting  
position.  
1. Move throttle lever to FAST or  
START position.  
Engine fails to start  
6
2. Spark plug wire disconnected.  
2. Connect wire to spark plug.  
3. Choke not in CHOKE position (if  
equipped).  
3. Move choke lever to CHOKE  
position.  
Trouble  
Shooting  
4. Fuel tank empty or stale fuel.  
4. Fill tank with clean, fresh gasoline.  
5. Engine not primed (if equipped).  
5. Prime engine as instructed in  
Engine Manual.  
6. Clean, adjust gap, or replace.  
6. Faulty spark plug.  
7. Engine flooded.  
7. Wait a few minutes to restart, but  
do not prime.  
1. Spark plug wire loose.  
1. Connect and tighten spark  
plug wire.  
Engine runs erratic  
2. Unit running on CHOKE (if equipped).  
3. Blocked fuel line or stale fuel.  
2. Move choke lever to OFF position.  
3. Clean fuel line; fill tank with clean,  
fresh gasoline.  
4. Low engine RPM.  
4. Always run engine at full throttle.  
For repairs beyond  
the minor adjustments  
listed here, contact  
an authorized service  
dealer.  
5. Water or dirt in fuel system.  
5. Drain fuel tank. Refill with  
fresh fuel.  
6. Dirty air cleaner.  
6. Refer to engine manual.  
7. Carburetor out of adjustment.  
7. See authorized service dealer.  
1. Engine oil level low.  
1. Fill crankcase with proper oil.  
2. Refer to engine manual.  
Engine overheats  
2. Dirty air cleaner.  
3. Carburetor not adjusted properly.  
3. See authorized service dealer.  
1. Spark plug gap too close.  
1. Remove spark plug and adjust gap.  
2. See authorized service dealer.  
Occasional skips  
(hesitates) at  
high speed  
2. Carburetor idle mixture adjustment  
improperly set.  
Excessive  
Vibration  
1. Loose parts or damaged impeller.  
1. Discharge area clogged.  
1. See authorized service dealer.  
1. Stop engine immediately and  
disconnect spark plug wire. Clean  
flail screen and inside of discharge  
opening.  
Unit does not  
discharge  
2. Foreign object lodged in impeller.  
2. Stop engine and disconnect spark  
plug wire. Remove lodged object.  
3. Low engine RPM.  
4. Vacuum bag is full.  
1. Low engine RPM.  
2. Chipper blade dull.  
3. Always run engine at full throttle.  
4. Empty bag.  
1. Always run engine at full throttle.  
Rate of discharge  
slows considerably  
or composition of  
discharged material  
changes  
2. Replace chipper blade or see your  
authorized service dealer.  
12  
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.  
StoringYourYard Vacuum  
1. Clean the equipment thoroughly.  
2. Wipe equipment with an oiled rag to prevent rust.  
3. Refer to engine manual for correct engine storage  
instructions.  
4. Store unit in a clean, dry area. Do not store next to  
corrosive materials such as fertilizer.  
Off  
Season  
Storage  
& Safety  
Labels  
DANGER  
ROTATING CUTTING BLADES.  
KEEP HANDS AND FEET OUT  
OF OPENINGS WHILE MACHINE  
IS RUNNING.  
WARNING  
ROTATING BLADES INSIDE. KEEP HANDS AWAY FROM ALL OPENINGS. DO NOT  
REMOVE OR ATTACH NOZZLE OR OPTIONAL HOSE KIT WHEN ENGINE IS RUNNING!  
DANGER  
TO AVOID SERIOUS INJURY  
WARNING  
• Read operator's manual.  
Keep hands out of inlet and discharge openings while  
machine is running.There are rotatingblades inside.  
Turn engine off and allow to come to a complete stop before  
clearing clogs, removing or attaching bag, vac nozzle or optional  
hose kit.  
• Do not operate without bag and vac nozzle or optional hose kit in plaec.  
Keep bystanders away.  
• Wear approved safety glasses and gloves. Avoid loose fitting clothes.  
• Muffler gets hot. Do not touch or allow debris to collect on it.  
• Shut engine off and allow to coolfor at least 2 min.before refueling.  
DO NOT remove safety  
(or any) labels from  
chipper shredder  
vacuum for any reason.  
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.  
13  
Model 204  
2
1
3
18  
19  
5
17  
20  
4
C
39  
38  
18  
19  
41  
63  
64  
21  
62  
61  
40  
20  
23  
22  
C
39  
41  
30  
37  
44  
24  
45  
42  
43  
38  
47  
46  
52  
60  
25  
34  
25  
35  
26  
27  
36  
48  
49  
A
55  
54  
58  
51  
57  
50  
56  
31  
29  
32  
6
A
7
9
30  
33  
10  
11  
53  
65  
65  
69  
12  
15  
71  
8
66  
67  
28  
70  
16  
68  
59  
14  
13  
14  
1.  
781-0633 Chute Flap Strip  
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  
2. 735-0249 Chute Flap  
3. 728-0175 Pop Rivet  
4. 731-1838A Discharge Chute  
5. 764-04001 Bag  
8
6. 631-0086 Nozzle Assembly  
Parts List  
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  
50. 710-0896 TT Screw 1/4-14 x 0.625”  
51. 726-0272 Clamp  
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  
52. 710-0382 Hex Cap Screw 1/2-13 x 5.0  
53. 712-0421 Knob 5/16-18  
To order replacement  
parts, contact  
17. 731-1574A Chipper Chute  
54. 725-3166 Switch  
1-800-828-5500,  
1-330-558-7220  
or visit  
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  
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. 731-1617† Tamper Plug  
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  
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  
27. 712-0266A Jam Lock Nut, 3/8-16  
28. 734-1984 Hub Cap  
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  
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. 742-0544A Chipper Blade  
68. 10622B  
Plastic Spring Ratchet  
69. 748-0405 Wheel Ratchet 1.62 OD x.5 serr  
70. 714-0104 Cotter Pin  
33. 712-0411  
Hex Lock Nut 5/16-24  
34. 736-0247 Flat Washer.406 x 1/1/4  
35. 736-0217 Lock Washer 3/8  
71. 748-0188B Pawl LH.345 ID  
748-0381 Pawl RH.345 ID  
36. 710-1273  
Hex Cap Screw 3/8-24 x 2.75  
725-0157 Cable Tie (Not Shown)  
37. 723-0438 Rubber Seal  
723-0400 Safety Glasses (Not Shown)  
† If Equipped  
1ꢀ  
Model 204  
56  
60  
57  
74  
58  
62  
61  
65  
76  
75  
66  
63  
B
67  
59  
68  
70  
64  
71  
80  
67  
68  
88  
72  
89  
77  
72  
73  
80  
67  
53  
69  
79  
78  
68  
B
85  
81  
83  
15  
68  
84  
13  
11  
8
17  
18  
2
82  
A
86  
5
19  
4
83  
87  
74  
14  
6
6
A
1
16  
7
8
12  
78  
10  
4
5
79  
9
3
10  
41  
21  
46  
20  
38  
36  
33  
37  
27  
35  
39  
34  
32  
37  
42  
31  
45  
55  
28  
40  
51  
24  
27  
49  
52  
26  
29  
25  
44  
23  
22  
48  
30  
47  
34  
54  
50  
43  
16  
1.  
2.  
3.  
4.  
5.  
6.  
7.  
781-0677 Chain Case LH  
781-0676 Chain Case RH  
754-0457 V-Belt  
45. 736-0270 Bell Washer.265 ID x.75 OD  
46. 736-0329 Lock Washer 1/4  
47. 736-0425 Bell Washer.325 ID x.930 OD  
48. 738-0440 Shoulder Spacer.375 ID x.165 OD  
49. 738-0826 Shoulder Bolt 1/4-28 x.375  
50. 756-0656 Flat Pulley 5.06 Dia  
51. 782-7569 Belt Keeper  
748-0313 Spacer  
8
741-0413  
Hex Flange Bearing  
736-0336 Flat Washer  
Parts List  
713-0422 Chain  
8.  
9.  
710-0896 TT Screw 1/4-14 x 0.625”  
710-0603 Hex Washer Screw 5/16  
52. 682-0054 Idler Bracket  
53. 714-0104 Cotter Pin  
10. 618-0256 Chipper Shredder Trans. Ass’y.  
11. 611-0063 Axle Assembly  
54. 618-0132 Lower Housing Assembly  
55. 618-0133A Upper Housing Assembly  
56. 749-1095 Upper Handle  
12. 734-1804A Wheel 6.0 x 2.0  
13. 750-1042 Spacer  
57. 1539-019 Push Nut  
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  
58. 711-0737  
59. 746-0714 Clutch Cable 56”  
60. 731-1735 Upper Clutch Cover  
61. 731-0620A Drive Lever  
Stud Pin.250 x 1.75  
To order replacement  
parts, contact  
1-800-828-5500,  
1-330-558-7220  
or visit  
62. 731-1736  
Lower Clutch Cover  
63. 710-0841 Screw #10-12 x.750  
20. 741-0415  
Flange Bearing.566 ID  
64. 731-1059  
65. 710-1331  
Mounting Cable Cap  
Screw #10-16 x 1.25  
21. 618-0255 Shredder Transmission Assembly  
22. 16500A  
23. 711-1118  
24. 717-1432  
Hex Bearing Cup  
66. 710-0805 Hex Cap Screw 5/16-18 x 1.50  
67. 736-0451 Shoulder Washer.320 ID x.93 OD  
68. 712-3004A Hex Flange Lock Nut 5/16-18  
69. 726-0214 Push Cap  
Output Shaft 6T Sprocket  
Helical 34T Gear  
25. 721-0213 Oil Seal  
26. 736-0187 Flat Washer.64 ID x 1.24 OD  
27. 736-0336 Flat Washer 5/8 x 1.0  
70. 712-0380 Hex Nut 1/4-28  
71. 781-0647 Discharge Chute Bracket  
72. 710-3008 Hex Cap Screw 5/16-18 x.75  
28. 741-0413  
29. 741-0414  
Hex Flange Bearing.631 ID  
Flange Bearing.629 ID  
73. 747-0815  
74. 710-0896 Hex Washer Screw 1/4-14 x.625  
75. 731-1646 Belt Cover  
Eye Bolt  
30. 719-0325 Lower Housing  
31. 748-0373 Flange Bearing.503 ID  
32. 719-0324A Upper Housing  
76. 719-0359 Engine Mounting Adapter  
77. 736-0264 Flat Washer.330 ID x.630 OD  
78. 741-0487C Flange Bearing.632 ID  
79. 736-0366 Flat Washer 5/8 ID x 1.0 OD  
80. 710-3103 Hex Cap Screw 5/16-18 x 1.75  
81. 749-1094 Lower Push Handle  
33. 748-0208A Flange Bearing.378 ID  
34. 710-0589 Hex Washer Screw #10-16 x.75  
35. 717-1433  
Pinion Shaft 10T  
36. 721-0329 Oil Seal  
37. 736-0314 Thrust Washer.382 ID x.684 OD  
38. 736-0520 Flat Washer.504 ID x.70 OD  
82. 710-0502A Screw 3/8-16 x 1.25  
39. 741-0479  
Thrust Bearing.375 ID x.812 OD  
83. 710-0604A Hex Washer Screw 5/16-18 x.625  
40. 656-0008 Idler Pulley Assembly W/ Bearing  
84. 741-0413  
Hex Flange Bearing.631 x.720  
756-0558 Idler Pulley Only  
85. 681-0097A Frame Assembly  
86. 781-0700 Axle Bracket  
741-0556 Needle Bearing Only  
41. 710-1062 Hex Cap Screw 1/4-20 x 1.25  
42. 712-0138 Hex Nut 1/4-28  
87. 781-0697 Transmission Cover  
88. 747-0924  
Lock Pin  
43. 712-3045 Hex Jam Nut 5/16-24 LH Thd  
44. 732-0357A Extension Spring 1.12 Lg  
89. 732-0306 Compression Spring  
1ꢁ  
NOTES  
Use this page to take notes and write down important information.  
18  
NOTES  
Use this page to take notes and write down important information.  
19  
MANUFACTURER’S LIMITED WARRANTY FOR  
The limited warranty set forth below is given by Troy-Bilt LLC with  
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.  
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”).  
d. Service completed by someone other than an authorized service  
dealer.  
“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.  
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.  
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.  
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.  
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.  
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.  
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 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.  
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,  
In Canada  
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.  
Contact MTD Products Limited, Kitchener, ON N2G 4J1, or call 1-800-  
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.  
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.  
IMPORTANT: Owner must present Original Proof of Purchase to  
obtain warranty coverage.  
b. Log splitter pumps, valves, and cylinders have a separate one-  
year warranty.  
Troy-Bilt LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019; Phone: 1-866-840-6483, 1-330-ꢀꢀ8-ꢁ220  
MTD Canada Limited - KITCHENER, ON N2G 4J1; Phone 1-800-668-1238  
GDOC-100020 REV. A  

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