Troy-Bilt 494 User Manual

OPERATOR’S MANUAL

Chipper Shredder

Model 494

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 arrester meeting
applicable local or state laws (if any). If a spark arrester is used, it should be maintained in effective working order by the operator.
In the State of California the above is required by law (Section 4442 of the California Public Resources Code). Other states may have
similar laws. Federal laws apply on federal lands. A spark arrester for the muffler is available through your nearest engine authorized
service dealer or contact the service department, P.O. Box 361131 Cleveland, Ohio 44136-0019.

TROY-BILT LLC P.O. BOX 361131 CLEVELAND, OHIO 44136-0019

PRINTED IN U.S.A.

FORM NO.

769-00167A.fm
(9/2002)

TABLE OF CONTENTS

Content Page

Important Safe Operation Practices...................................................................3

Assembling Your Chipper Shredder...................................................................5

Know Your Chipper Shredder ............................................................................ 7

Operating Your Chipper Shredder ....................................................................8

Maintaining Your Chipper Shredder ..................................................................9

Troubleshooting................................................................................................. 12

Parts List............................................................................................................ 14

FINDING MODEL NUMBER

This Operator’s Manual is an important part of your new chipper shredder. 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:

www.troybilt.com

TROY-BILT LLC
P. O. BOX
CLEVELAND, OH 44136

330-558-7220
866-840-6483

361131

Copy the serial number here:

ENGINE INFORMATION

The engine manufacturer is responsible for all engine-related issues with regards to performance, power­rating, specifications, warranty and service. Please refer to the engine manufacturer’s Owner’s/Operator’s
Manual packed separately with your unit for more information.

CALLING CUSTOMER SUPPORT

If you have difficulty assembling this product or have any questions regarding the controls, operation or
maintenance of this unit, please call the Customer Support Department.

Call 1- [phone] 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.

For more details about your unit, visit our website at www.troybilt.com

2

SECTION 1: IMPORTANT SAFE OPERATION PRACTICES

WARNING: This symbol points out important safety instructions which, if not followed, could

endanger the personal safety and/or property of yourself and others. Read and follow all instructions in
this manual before attempting to operate this machine. Failure to comply with these instructions may
result in personal injury. When you see this symbol - heed its warning.

WARNING: The Engine Exhaust from this product contains chemicals known to the

State of California to cause cancer, birth defects or other reproductive harm.

DANGER: This machine was built to be operated according to the rules for safe operation in this

manual. As with any type of power equipment, carelessness or error on the part of the operator can
result in serious injury. This machine is capable of amputating hands and feet and throwing objects.
Failure to observe the following safety instructions could result in serious injury or death.

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 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.

2. 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.

3. Wear sturdy, rough-soled work shoes and close­fitting 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 fuel 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.
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.)

3

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.

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 it becomes necessary to push material through
the shredder hopper, use a small diameter stick. Do
not use your hands or feet.

5. 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 the shredder hopper,
chipper chute, or discharge chute properly attached
to the machine. Never empty or change discharge

bag while the engine is running.

10. Keep all guards, deflectors and safety devices in
place and operating properly.

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.

12. Never operate this machine without good visibility
or light.

13. Do not operate this machine on a paved, gravel or
non-level surface.

14. Do not operate this machine while under the
influence of alcohol or drugs.

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.

Maintenance And Storage

1. Never tamper with safety devices. Check their
proper operation regularly.

2. Check bolts and screws for proper tightness at
frequent intervals to keep the machine in safe
working condition. Also, visually inspect machine
for any damage and repair, if needed.

3. Before cleaning, repairing, or inspecting, stop the
engine and make certain the impeller and all
moving parts have 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.

-

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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. Not all safety labels shown may apply to your chipper shredder.

SECTION 2: ASSEMBLING YOUR CHIPPER SHREDDER

IMPORTANT:

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 is observed from the operating
position.

Removing Unit From Carton

• 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.

Loose Parts In Carton (See Figure 1)

• Hopper Assembly

• Discharge Chute

• Chipper Chute

• Bag (Not Shown)

• Tamper Plug (If Equipped)

This unit is shipped without gasoline or oil

Disconnecting Spark Plug Wire

Before setting up your chipper shredder, disconnect the
spark plug wire from the spark plug and ground against
the engine.

Chipper
Chute

Hopper
Assembly

Tamper
Plug

Figure 1

Discharge
Chute

5

Attaching the Hopper Assembly

• Remove the 8-3/8” long hex bolt and the hex nut
from the bottom of the inlet guide opening. See
Figure 2.

• Place the hopper assembly on the ground and hold
it in the position.

• Holding the hopper, push hopper pivot door down
inside the hopper.

• Slide the hopper assembly towards the chipper­shredder housing so that the upper guide on the
hopper assembly slides under the stop washer on
each side of the inlet guide.

• Align the two holes (one on each side) of the lower
hopper with the two holes (one on each side) of the
inlet guide.

• Insert the hex bolt (that you earlier removed) from
the left through the hole on the hopper and the inlet
guide. Insert the hex nut onto the bolt from the other
side.

• Tighten the bolt till the lock nut is engaged. Make
sure to remove any side play from the bolt, but the
hopper should be able to pivot.

other end of the rod has to be attached to the stop
washer on the inlet guide.

• Raise the hopper till it clicks into position.

• Unscrew the shoulder bolt from the stop washer on

the inlet guide. See Figure 3.

• Align the loose end of the flap control rod with the
stop washer on the inlet guide. See Figure 3.

• Slide the shoulder bolt through the opening in the
flap control rod. See Figure 3. Secure tightly.

WARNING: This flap control rod is a safety
device to hold the flap in place inside the
hopper while shredding branches. Do not
operate the chipper-shredder without
properly attaching this flap control rod to
the unit.

Bolt

Hex Nut*

Stop Washer*

Hopper

Inlet Guide Opening

Hex Bolt

Hopper Pivot Door

Stop Washer

Inlet
Guide

Hopper

Hopper

Hole

Hex Nut

Figure 2

• To raise the hopper, hold the hopper by the hand­hold and lift it up till it clicks into position.

• To lower the hopper, hold the hopper by the hand­hold and pull the release bar. The hopper should
drop down.

• The flap control rod is already attached to the
hopper at the top, as indicated in Figure 3. The

Flap Control Rod

NOTE:

already assembled.

* Do not remove this hardware from the inlet guide

assembly while attaching the flap control rod.

This part is

Figure 3

Attaching the Discharge Chute

• Remove the wing knobs from each side of the
discharge opening on the chipper shredder.
See Figure 4.

• Using two 7/16" wrenches, remove hex lock nut,
two spacers, and hex bolt from top of the housing
assembly. For easy assembly, do not remove the
second spacer from the hex bolt.

• Place the discharge chute in position on the
discharge opening. Insert hex bolt and spacer
through hinge on discharge chute and housing
(spacer fits inside of hinge).

• Place second spacer over hex bolt inside the other
part of the hinge. Secure with hex lock nut and
tighten securely. See Figure 4.

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• Secure both sides of discharge chute to housing
using wing knobs that you earlier removed. Tighten
wing knobs.

Hex Lock Nut

Spacer

Hex Bolt

• Align the holes towards the front opening of the
chute with the holes on the brace. See Figure 5.

• Insert one each of the hex bolts, lock nuts, and flat
washers (that you earlier removed) through each
hole in the chute and the brace. Tighten these bolts
to secure brace to the chute.

• Tighten bolts securing the brace to the lower frame.
These bolts had been removed earlier.

• Tighten the three nuts on the weld studs.

Wing Knob

Discharge Chute

Figure 4

Attaching the Chipper Chute

• Your unit is shipped with one end of the brace
already secured to the lower frame. Loosen the
bolts securing the brace to the frame.

• Remove the three cupped washers and hex nuts
from the weld studs beside the opening on the left
side of the housing. See Figure 5.

• Remove the two sets of hex bolt, lock nut, and flat
washer from the two holes on the upper end of the
brace.

• Place the chipper chute over the weld studs so the
slot on the chute is towards the bottom. Align the
three holes at the bottom of the chute with the three
weld studs.

• Secure with the three pairs of cupped washers and
hex nuts that you earlier removed. Do not tighten
the nuts at this time. Make sure to place the cupped
side of the washer against the chipper chute.

Chipper
Chute

Flat

Washer

Hex Nuts

Brace

Cupped Washer

Weld Studs

Hex Bolt

Discharge
Chute

Figure 5

Attaching the Bag

• To attach the bag, place the opening of the bag
completely over the discharge chute.

• Depress the plunger on the drawstring and pull on
the drawstring until the bag is tight around chute
opening. Release plunger to lock it into position.

SECTION 3: KNOW YOUR CHIPPER SHREDDER

Read this operator’s manual and safety rules before
operating your chipper shredder. Compare the
illustrations in Figure 6 with your unit to familiarize
yourself with the location of various controls and
adjustments. Save this manual for future reference.

Starter Handle

The starter handle is located on the engine. Pull the
starter handle to start engine. See Figure 6.

Release Rod

The release rod is located on the impeller bracket
assembly and it is used to release or lock the hopper
when raising or lowering. See Figure 6.

Chipper Chute

Allow twigs and small branches up to 3” in diameter to
be fed into the impeller for chipping. See Figure 6.

Hopper Assembly

Allow leaves and small branches up to 1” diameter to
be fed into the impeller for chipping and shredding.
Material can be raked into hopper assembly by
lowering the hopper assembly. See Figure 6.

Bag (Not shown)

Collects shredded or chipped material fed through the
chipper chute or hopper assembly.

Tamper Plug (If equipped)

The tamper plug is designed to insert in the chipper
chute to push material toward the impeller.
See Figure 6.

Engine Controls

See the separate engine manual for the location and
function of the controls on the engine.

7

Stopping Engine

• Move throttle control lever to stop or off position.

• Disconnect spark plug wire from spark plug and

ground against the engine.

Discharge
Chute

Hopper
Assembly

Release
Rod

Rear Wheel
Lock Lever

Figure 6

Chipper
Chute

Starter Handle

SECTION 4: OPERATING YOUR CHIPPER SHREDDER

WARNING: The operation of any chipper
shredder can result in foreign objects
being thrown into the eyes, which can
damage your eyes severely. Always wear
the safety glasses provided with this unit
or eye shields before chipping or shred­ding and while performing any
adjustments or repairs.

Gas and Oil Fill-Up

Service the engine with gasoline and oil as instructed in
the separate engine manual packed with your chipper
shredder. Read instructions carefully.

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.

Starting Engine

• 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.

• 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.

• Grasp starter handle and pull rope out slowly until
engine reaches start of compression cycle (rope
will pull slightly harder at this point).

NOTE: A noise will be heard when finding the start of
the compression cycle. This noise is caused by the fails
and fingers, which are part of the shredding mecha­nism, and it 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: Never run the engine indoors
or in a poorly ventilated area. Engine
exhaust contains carbon monoxide, an
odorless and deadly gas.

Tamper Plug

8

To Empt y Bag

• Depress the plunger on the drawstring and slide the
plunger out to loosen bag from discharge chute
opening.

• Empty bag and reattach to the discharge chute
opening. Depress the plunger on the drawstring
and pull on the drawstring until the bag is tight
around the chute opening.

Lowering the Hopper Assembly

• With one hand grasp the handle at the top of the
hopper assembly and lift slightly.

• With the other hand pull out on the release rod and
lower the hopper assembly to the ground.
See Figure 7.

Hopper
Assembly

Using the Chipper Shredder

Yard waste such as leaves and pine needles can be
raked up through the hopper assembly for shredding.
After material has been shredded by the flail blades on
the impeller assembly, it will be discharged out of
opening or into catcher bag. 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. Twigs and small branches up to 3”
in diameter can be fed into the chipper chute. If
equipped, use the tamper plug to push material into the
chipper chute. Refer to Figure 6.

IMPORTANT:

housing in the discharge area. If the flail screen
becomes clogged, remove and clean as instructed in
SECTION 5: MAINTAINING YOUR CHIPPER
SHREDDER. For best performance, it is also important
to keep the chipper blade sharp.

The flail screen is located inside the

Release
Rod

Figure 7

SECTION 5: MAINTAINING YOUR CHIPPER SHREDDER

Customer Responsibilities

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MAINTENANCE

SCHEDULE

Lubricate Release Bracket

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Lubricate Hopper Assembly

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Lubricate Discharge Chute

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Check Chipper Blade

Check Oil

Change Oil

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Clean Air Filter

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Clean Engine

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SERVICE

DATES

Check Spark Plug

9

WARNING: Always stop engine, discon­nect spark plug, and ground against
engine before cleaning, lubricating or
doing any kind of maintenance on your
machine.

Lubrication

Release Rod: Lubricate the release rod and spring with
light oil once a season.

Hopper Assembly: Lubricate the pivot points on the
hopper assembly with light oil once a season.

Discharge Chute: Lubricate the pivot points on the
chute deflector with light oil once a season.

Engine: Follow the separate engine manual packed
with you unit for lubrication instructions.

Discharge
Chute

Hairpin
Clips

Wing Knobs

Maintenance

Engine

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.

Removing the Flail Screen

If the discharge area becomes clogged, remove the flail
screen and clean area as follows:

• Stop the engine and make certain the chipper
shredder has come to a complete stop.

• Disconnect spark plug wire from spark plug and
ground against the engine.

• Remove the two wing knobs on each side of the
discharge chute and lift the discharge chute up to
keep it out of the way. See Figure 8.

• Remove the two hairpin clips from each clevis pin
which extend through the housing and remove the
pins.

• Remove the flail screen from inside the housing
and clean the screen by scraping or washing with
water.

• Reinstall the screen, making certain to reassemble
the flail screen with the curve side down.

• Reattach the discharge chute with the hardware
previously removed and connect the bag (if
equipped) to unit.

Figure 8

Chipper Blades

• Disconnect the spark plug wire and ground against
the engine.

• Remove the flail screen as instructed in the
previous section.

• Remove the chipper chute by removing three hex
nuts and washers.

• Remove the chipper chute support brace from the
frame by removing the hex bolts.

• Rotate the impeller assembly by hand until you
locate one of the two chipper blades in the chipper
chute opening.

• Remove the blade using a 3/16” allen wrench on
the outside of the blade and an adjustable wrench
on the impeller assembly. See Figure 9.

Flat Screw

Blade

Figure 9

• Rotate the impeller to expose other blade and
remove in the same manner.

• Replace or sharpen blades.

• When sharpening the blade, protect hands by using

gloves and follow the original angle of grind. Also,

10

make sure to remove an equal amount from each
blade and torque to 250 - 300 in. lbs.

that each cutting edge receives an equal amount of
grinding to prevent an unbalanced blade.

NOTE: Make certain blades are reassembled with the
sharp edge facing upward.

Shredder Blade

• Disconnect the spark plug wire and ground against
the engine.

• Lower the hopper assembly and block up the
housing.

• Remove the six hex lock nuts and flat washers from
the weld studs on the flail housing.

• Separate the hopper assembly from the impeller
assembly and remove the support plate.

NOTE: When reassembling the support plate, the
embossed tab must face inward towards the impeller.

• Remove the two wing knobs and cupped washers
that secure the discharge chute and raise the
chute.

• Insert a 1/2” or 3/4” diameter pipe through the flail
screen into the impeller to keep it from turning or
remove the flail screen and insert a piece of wood
into the chute opening.

• Remove the two outside screws on the blade, using
a 3/16” allen wrench and a 1/2” wrench.
See Figure 10.

• Remove the blade by removing the center bolt, lock
washer, and flat washer.

NOTE: Use caution when removing the blade to avoid
contacting the weld studs on the housing.

• When sharpening the blade, follow the original
angle of grind as a guide. It is extremely important

Discharge Chute

Blade

Flat Screw

Hex Bolt

Figure 10

• An unbalanced blade will cause excessive vibration
when rotating at high speeds and may cause
damage to the unit. The blade can be tested by
balancing it on a screwdriver or nail. Remove metal
from the heavy side until it is balanced evenly.

• When reassembling the blade, tighten center bolt to
between 550 and 700 in.-lbs. and the two out bolts
to between 250 and 350 in.-lbs.

Weld Stud

Storing Your Chipper Shredder

• Clean the equipment thoroughly.

• Wipe equipment with an oiled rag to prevent rust.

• Refer to engine manual for correct engine storage

instructions

• Store unit in a clean, dry area. Do not store next to
corrosive materials such as fertilizer.

11

SECTION 6: TROUBLESHOOTING

Problem Cause Remedy

Engine fails to start 1. Spark plug wire disconnected.

2. Fuel tank empty or stale fuel.

3. Throttle control lever not in correct
starting position. (If Equipped)

4. Choke not in CHOKE position.
(If equipped)

5. Engine not primed.

6. Blocked fuel line.

7. Faulty spark plug.

Engine runs erratic 1. Spark plug wire loose.

2. Unit running on CHOKE.
(If equipped)

3. Blocked fuel line or stale fuel.

4. Water or dirt in fuel system.

5. Dirty air cleaner.

6. Carburetor out of adjustment.

Too much vibration 1. Loose parts or damaged impeller. 1. See authorized service dealer.
Engine overheats 1. Engine oil level low.

2. Dirty air cleaner.

3. Carburetor not adjusted properly.

Occasional skip (hesitates)
at high speed

Unit does not discharge 1. Discharge chute clogged.

Rate of discharge slows
considerably or
composition of discharged
material changes.

NOTE: For repairs beyond the minor adjustments listed above, contact your nearest authorized service dealer.

1. Spark plug gap too close. 1. Adjust gap to.030”.

2. Foreign object lodged in impeller.

3. Low engine RPM.

1. Low engine RPM.

2. Chipper blade dull.

1. Connect wire to spark plug.

2. Fill tank with clean, fresh gasoline.

3. Move throttle lever to FAST position.

4. Move choke to CHOKE position.

5. Prime engine.

6. Clean fuel line.

7. Clean, adjust gap, or replace.

1. Connect and tighten spark plug wire.

2. Move choke lever to OFF position.

3. Clean fuel line; fill tank with clean, fresh
gasoline

4. Drain fuel tank. Refill with fresh fuel.

5. Clean or replace air cleaner.

6. See authorized service dealer.

1. Fill crankcase with proper oil.

2. Clean or replace air cleaner.

3. See authorized service dealer.

1. Stop engine immediately and
disconnect spark plug wire. Clean flail
screen and inside of discharge opening.

2. Stop engine and disconnect spark plug
wire. Remove lodged object.

3. Always run engine at full throttle.

1. Always run engine at full throttle.

2. Replace chipper blade or see your
authorized service dealer.

12

Notes

13

SECTION 7: PARTS LIST FOR MODEL 494

11

15

21

27

22

2

95

92

96

6

97

8

97

19

30

26

96

20

1

12

4

94

93

6
8

23

9

10

3

16

29

13

98

6

8

14

5

18

7

98

28

33

18

7

99

37

48

41

38

38

43

39

44

13

26

37

45

39

40

41

43

67

83

55

85

82

67

24

17

53

44

56

65

55

70

43

63

43

61

58

57

56

32

50

59

8

49

52

44

81

89

78

74

72

51

71

73

75

70

76

69

83

78

68

79

87

D

88

80

79

90

91

14

Model 494

Ref.

No.

1 11480 Stop Washer
2 681-0118 Inlet Guide Assembly
3 681-0144 Arm Bracket Assembly
4 710-0542 Hex Flange Bolt: 5/16-18 x 8.375”
5 710-0607 Hex Washer Screw: 5/16-18 x 0.5”
6 710-3256 Button-Head Screw 1/4-20 x 0.5”
7 712-0429 Lock Nut: 5/16-18
8 712-3027 Hex Flange Lock Nut: 1/4-20

9 714-0104 Internal Cotter Pin
10 715-0129 Spiral Pin
11 726-0106 Cap Nut
12 726-0135 Speed Cap Nut
13 728-0175 Pop Rivet
14 732-0546 Torsion Spring
15 732-0629 Hopper Door Spring
16 735-0127 Rubber Washer
17 735-0651 Hopper Flap
18 736-0119 Lock Washer
19 738-0137A Shdr. Scr: .340 x .285 x 1/4-20
20 738-0946 Shdr. Scr: .56 x .165 x 5/16-18
21 747-0531A Rel. Rod: 5/16” dia.
22 747-0747 Hopper Door Rod
23 747-1124 Flap Retaining Rod
24 747-1125 Flap Retaining Bail
25 781-0492A Hopper Pivot Door
26 781-0633 Chute Flap Strip
27 781-0698 Hopper Lock Bracket
28 781-0715 Shredder Plate
29 781-0752 Flap Mounting Bracket
30 781-0754 Upper Hopper
31 781-0755 Lower Hopper
32 738-0813 Shredder Axle
33 731-1899 Chipper Chute
37 710-0751 Hex Bolt 1/4-20 x .625
38 736-0173 Flat Washer .28 I.d. x .74 O.d.
39 712-3027 Flanged Lock Nut
40 749-1004 Chipper Chute Support
41 710-0106 Hex Scr. 1/4-20 x .625 (Gr. 2)
43 712-3010 Hex Nut 5/16-18 Thd. (Gr. 5)
44 736-0242 Bell Washer .345” I.d. x .88”
45 735-0249 Shredder Chute Flap
48 681-0068A Chipper Chute Assembly
49 726-0214 Push Cap 5/8” dia.

Part No. Part Description

Ref.

No.

50 734-0255 Air Valve
51 750-0793 Chute Hinge Spacer
52 712-3027 Hex Ctr. Lock Nut 1/4-20 Thd.
53 714-0149B Internal Cotter Pin
55 720-0170 Hand Knob
56 710-0805 Hex Bolt 5/16-18 x 1.5”
57 781-0510B Shredder Frame
58 736-0366 Flat Washer 1.12 x .64 x .120
59 734-1797 Wheel Assembly
61 736-0170 Special Lock Washer
63 681-0117 Flail Housing Ass’y. (Inner)
65 710-0157 Hex Bolt 5/16-24 x .75” Lg.

67. 731-1617 Tamper Plug (If Equipped)
68 742-0544 Chipper Blade
69 712-0411 Hex Top Lock Nut 5/16-24
70 736-0119 Lock Washer 5/16” I.d.
71 681-0030 Impeller assembly
72 742-0571 Shredder Blade
73 781-0457 Shredder Screen
74 681-0094 Discharge Chute Assembly
75 781-0735 Retaining Clip
76 715-0166 Spring Roll Pin
78 710-1054 Flat Head Scr. 5/16-24 x .75”
79 710-3008 Hex Bolt 5/16-18 x .75”
80 681-0004A Flail Housing Ass’y. (Outer)
82 710-0825 Hex Bolt 1/4-20 x 3.75”
83 726-0211 U Nut 5/16-18
85 711-0835 Clevis Pin
87 719-0329 Flail Blade
88 711-0833B Clevis Pin
89 710-1254 Hex Patch Bolt 3/8-24 x 2.25”
90 736-0217 Lock Washer 3/8”
91 736-0247 Flat Washer .406” I.d. x 1.25”
92 732-0306 Compression Spring
93 736-0117 Flat Washer
94 714-0104 Internal Cotter Pin
95 711-1304 Axle Shaft
96 736-0160 Flat Washer
97 634-04009 Complete Wheel: Grey
98 726-0299 Push Cap
99 747-0982 Lock Rod

100 764-0501 Shredder Bag

Part No. Part Description

15

MANUFACTURER’S LIMITED WARRANTY FOR:

The limited warranty set forth below is given by Troy-Bilt LLC
with respect to new merchandise purchased and used in the
United States, its possessions and territories.

Troy-Bilt LLC warrants this product against defects 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 accessory or attachment not approved by Troy-Bilt
LLC for use with the product(s) covered by this manual will
void your warranty as to any resulting damage.

Normal wear parts or components thereof are subject to
separate terms as follows: All normal wear parts or
component failures will be covered on the product for a period
of 90 days regardless of cause. After 90 days, but within the
two year period, normal wear part failures will be covered
ONLY IF caused by defects in materials or workmanship of
OTHER component parts. Normal wear parts and
components include, but are not limited to: batteries, belts,
blades, blade adapters, grass bags, rider deck wheels, seats,
snow thrower skid shoes, shave plates, auger spiral rubber,
and tires.

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, check your
Yellow Pages, or contact Troy-Bilt LLC at P.O. Box 361131,
Cleveland, Ohio 44136-0019, or call 1-866-840-6483 or 1­330-558-7220, or log on to our Web site at www.troybilt.com.

This limited warranty does not provide coverage in the
following cases:

a. The engine or component parts thereof. These items

carry a separate manufacturer’s warranty. Refer to
applicable manufacturer’s warranty for terms and
conditions.

b. Log splitter pumps, valves, and cylinders have a sepa

rate 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. Troy-Bilt LLC does not extend any warranty for

products sold or exported outside of the United States,
its possesions and territories, except those sold
through Troy-Bilt LLC’s authorized channels of export
distribution.

e. Parts that are not genuine Troy-Bilt parts are not

covered by this warranty.

f. Service completed by someone other than an

authorized service dealer is not covered by this
warranty.

g. Transportation charges and service calls are not

covered.

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 LLC. 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. Troy­Bilt LLC 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.

Troy-Bilt LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019; Phone: [phone]