Troybilt 24A-204B063-2002 Owner’s Manual
O TRO BILT'__
OPERATOR'S MANUAL
Chipper Shredder
Vacuum
Model Number
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 engine's exhaust system is equipped with a spark attester 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 attester 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.
FORM NO. 769-00170
(6/02)
TABLEOFCONTENTS
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 ................................................................................................. 14
Parts List ............................................................................................................ 16
FINDINGMODELNUMBER
This Operator's 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.
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:
O_I_I_IIX_..T, TROY-BILT LLC
www.troybilt.com CLEVE_ND. OH_136
P. O. BOX 361131
330-558-7220
866-840-6483
Copy the serial number here:
ENGINEINFORMATION
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 unit for more information.
CALLINGCUSTOMERSUPPORT
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 unit's 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.
SECTION1: IMPORTANTSAFEOPERATIONPRACTICES
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.
2.
TRAINING
1. Read, understand, and follow all instructions on the
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.
2. Be familiar with all controls and their proper
operation. Know how to stop the machine and
disengage them quickly.
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.
4. Never allow adults to operate this machine without
proper instruction.
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.
6. Never run an engine indoors or in a poorly
ventilated area. Engine exhaust contains carbon
monoxide, an odorless and deadly gas.
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
discharge 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.
PREPARATION
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.
Always wear safety glasses or safety goggles
during operation or while performing an adjustment
or repair, to protect eyes. Thrown objects which
ricochet can cause serious injury to the eyes.
.
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.
4.
Before starting, check all bolts and screws for
proper tightness to be sure the machine is in safe
working condition. Also, visually inspect machine
for any damage at frequent intervals.
5.
Maintain or replace safety and instructions labels,
as necessary.
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.
a. Use only an approved gasoline container.
b. Extinguish all cigarettes, cigars, pipes, and
other sources of ignition.
c. Never fuel machine indoors.
d. Never remove gas cap or add while the
engine is hot or running.
e. Allow engine to cool at least two minutes
before refueling.
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.
g. Replace gasoline cap and tighten securely.
h. If gasoline is spilled, wipe it off the engine
and equipment. Move machine to another
area. Wait 5 minutes before starting the
engine.
L 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. Toreduceafirehazard,keepmachinefree
ofgrass,leaves,orotherdebrisbuild-up.
Cleanupoilorfuelspillageandremoveany
fuelsoakeddebris.
k. Allowmachinetocoolatleast5minutes
beforestoring.
OPERATION
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.
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.
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.
b. Repair or replace any damaged parts.
c. Check for any loose parts and tighten to
assure continued safe operation.
6. Do not allow an accumulation of processed
material to build up in the discharge area. This can
prevent proper discharge and result in kickback of
material through the feed opening.
7. 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.
8. 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.
9. 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.
10. 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.
11. Keep all guards, deflectors and safety devices in
place and operating properly.
12. 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.
13. Never operate this machine without good visibility
or light. Always be sure of your footing and keep a
firm hold on the handles.
14. Do not operate this machine on a gravel surface.
15. Do not operate this machine while under the
influence of alcohol or drugs.
16. Muffler and engine become hot and can cause a
burn. Do not touch.
17. Never pick up or carry machine while the engine is
running.
MAINTENANCEANDSTORAGE
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 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.
5. Maintain or replace safety and instruction labels, as
necessary.
6. Follow this manual for safe loading, unloading,
transporting, and storage of this machine.
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.
8. Always refer to the operator's manual for proper
instructions on off-season storage.
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.
understand and follow the warnings and instructions in this manual and on the machine.
WARNING: - YOUR RESPONSIBILITY: Restrict the use of this power machine to persons who read,
NOTE: Not all safety labels shown may apply to your chipper shredder vacuum.
I _O AVOLD SE_NO US _NJURY
_!_I_._................ tt
SECTION2: ASSEMBLINGYOURCHIPPERSHREDDERVACUUM
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.
NOTE: Reference to right or left hand side of the
chipper shredder vacuum is observed from the
operating position.
RemovingUnitFromCarton
• Remove staples, break glue on top flaps, or cut
tape at carton end and peel along top flap to open
carton.
• Remove loose parts if included with unit (i.e.,
operator's manual, etc.)
• Cut along corners, lay carton down flat, and remove
packing material.
• Roll or slide unit out of carton and check carton
thoroughly for loose parts.
LoosePartsInCarton(SeeFigure1)
• Nozzle
• Bag
• Chipper Chute
• Oil(Not Shown)
WARNING: Before setting up your chipper
shredder vacuum, disconnect the spark
plug wire from the spark plug and ground
against the engine.
Chipper Chute
Figure 1
AttachingTheNozzle
• Remove three wing nuts from the front of the
chipper shredder vacuum.
• Place nozzle in position over the three studs on unit
and secure with wing nuts just removed.
See Figure 2.
Wing.
Nut_ Nuts
Nozzle
Figure 2
NOTE: The metal tab on the nozzle must depress the
safety switch button attached to the front of chipper
shredder vacuum or the engine will not start.
Attachingthe ChipperChute
• Loosen, but do NOT remove, the two hex bolts, flat
washers, and flange nuts which are secured to the
support bracket. See Figure 3.
e Nuts
Weld
Hex Bolts & Bell Washers
Saddle Washers
Figure 4
• 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.
SuppOrth _ J Chipper
Bracket II | / Chute
Flange
_" Nuts
Hex Bolts
Washers
Flange
Nuts
Bracket
Figure 3
• 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 4.
• Next, remove the three hex nuts and bell washers
from the weld studs found beside the opening on
the right side of the chipper-shredder vacuum.
Bell Washers
Figure 5
• Align the support bracket with the holes in the right
side ofthe 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.
• Replace the hex bolts, saddle washers and flange
nuts to affix the support bracket to the handle
assemblies. See Figure 5.
• Follow by tightening all hardware securely first on
the chipper chute, then on the support bracket,
and finally on the handle.
AttachingTheBag
• Place bag under of 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. See Figure 6.
Discharge Bag Opening
Chute
pull the drawstring tight. Release the clamp.
See Figure 7.
Bag
Figure 6
in place. Squeeze the clamp on the drawstring and
Place the four straps on the top ofthe bag over
upper handle, hooking them on the studs to secure
Figure 7
SECTION3: KNOWYOURCHIPPERSHREDDERVACUUM
Control
Straps
Chipper
Chute
WARNING: Be familiar with all controls
and their proper operation. Know how to
stop the machine and disengage them
quickly.
Bag
Collects shredded or chipped material fed through the
chipper chute or vacuumed up through the nozzle.
See Figure 8.
ChipperChute
Allow twigs and small branches up to 3" in diameter to
be fed into the impeller for chipping. See Figure 8.
Nozzle
Nozzle Door
ustment Lever
Figure 8
CasterLocks
The caster locks are located on top of each front caster
wheel. Refer to the Adjustment Section to position
wheel locks. See Figure 8.
NozzleDoorAdjustmentLevers
The nozzle adjustment levers are located on each side
of the nozzle door. They are used to adjust the nozzle
door for ground clearance that wilt provide the best
performance for the operating conditions. See Figure 8.
Nozzle
Yard waste such as leaves and pine needles can be
vacuumed up through the nozzle for shredding.
DriveClutchControl
The drive clutch control is located on the upper handle
assembly. Squeezing the drive clutch control against
the upper handle engages the rear wheels. Release the
drive clutch control to slow down or stop the wheel
drive. See Figure 8.
ThrottleControlLever(Not Shown)
The throttle control lever is located on the engine. It
controls the engine's speed and stops the engine. See
separate engine manual packed with unit for details.
EngineControls
See the separate engine manual for the location and
function of the controls on the engine.
StoppingEngine
• Move throttle control lever to STOP or OFF
position.
• Disconnect spark plug wire from spark plug and
ground against the engine.
SECTION4: OPERATINGYOURCHIPPERSHREDDERVACUUM
• Grasp starter handle and pull rope out slowly until
all instructions and warnings on the
WARNING: Read, understand, and follow
machine and in this manual before
operating.
with this machine during operation or
Always wear the safety glasses provided
while performing any adjustments or
repairs. Thrown objects which ricochet
can cause serious injury to the eyes.
GasAndOilFill-Up
Service the engine with gasoline and oil as instructed in
the separate engine manual packed with your chipper
shredder vacuum. Read instructions carefully.
_1= WARNING: 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
sources of ignition.
StartingEngine
• Attach spark plug wire to spark plug. Make certain
the metal cap on the end of the spark plug is
fastened securely over the metal tip on the spark
plug.
• Make certain drive clutch control is in the
disengaged (released) position.
• Engines with choke lever:
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.
• The throttle control lever is located on the engine.
Move engine throttle control lever to FAST or
START position.
• Place one foot on the left rear wheel to prevent the
unit from skidding while starting.
engine reaches start of compression cycle (rope
will pull slightly harder at this point).
NOTE: A noise will be heard when at the start of the
compression cycle. This noise should be expected until
the impeller reaches full speed.
• Pull rope with a rapid, continuous, full arm stroke.
Keep a firm grip on starter handle. Let rope rewind
slowly.
• Repeat the previous steps until engine fires. When
engine starts, move choke control (if equipped)
gradually to RUN position.
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.
ToEmptyBag
The bag is designed to be emptied without being
removed from unit. Open the large zipper in the rear of
the bag to empty the contents. If bag is removed for any
reason, follow the instructionsfor attaching the bag in
the ASSEMBLY section. Be certain the zipper is closed
completely when operating the unit.
ToEngageDrive
To engage the wheel drive, hold the drive clutch control
against the upper handle. Releasing the drive clutch
control stops the rear wheels from driving. Release the
drive clutch control to slow down when negotiating an
obstacle, making a turn, or stopping. Engage control
slowly to prevent the front wheels from lifting up.
Usingthe ChipperShredderVacuum
Place both hands on top of upper handle to push unit
over yard waste. Yard waste such as leaves and pine
needles can be vacuumed up through the nozzle for
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