Troy-Bilt 4510 User Manual

Safe Operation Practices • Set-Up • Operation • Maintenance • Service • Troubleshooting • Warranty

Op e r a t O r ’s Ma n u a l

Two Stage Snow Thrower — Polar Blast 4510

WARNING

READ AND FOLLOW ALL SAFETY RULES AND INSTRUCTIONS IN THIS MANUAL

BEFORE ATTEMPTING TO OPERATE THIS MACHINE.

FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.

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

Printed In USA

FORM NO. 769-04060

(June 6, 2008)

To The Owner

Thank You

Thank you for purchasing a Snow Thrower manufactured by
Troy-Bilt LLC. It was carefully engineered to provide excellent
performance when properly operated and maintained.

Please read this entire manual prior to operating the equipment.

It instructs you how to safely and easily set up, operate and

maintain your machine. Please be sure that you, and any other

persons who will operate the machine, carefully follow the
recommended safety practices at all times. Failure to do so could
result in personal injury or property damage.

All information in this manual is relative to the most recent
product information available at the time of printing. Review
this manual frequently to familiarize yourself with the machine,

its features and operation. Please be aware that this Operator’s

Manual may cover a range of product specifications for various
models. Characteristics and features discussed and/or illustrated
in this manual may not be applicable to all models. Troy-Bilt LLC
reserves the right to change product specifications, designs and
equipment without notice and without incurring obligation.

Table of Contents

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

Assembly & Set-Up .................................................. 7

Controls and Features ...........................................11

Operation ...............................................................14

Maintenance & Adjustment..................................16

1

If you have any problems or questions concerning the machine,
phone a authorized Troy-Bilt service dealer or contact us directly.
Troy-Bilt’s Customer Support telephone numbers, website
address and mailing address can be found on this page. We want
to ensure your complete satisfaction at all times.

Throughout this manual, all references to right and left side of the
machine are observed from the operating position

The engine manufacturer is responsible for all engine-related
issues with regards to performance, power-rating, specifications,

warranty and service. Please refer to the engine manufacturer’s
Owner’s/Operator’s Manual, packed separately with your

machine, for more information.

Service .....................................................................19

Troubleshooting .................................................... 24

Replacement Parts ................................................ 25

Warranty ..................................................Back Cover

Record Product Information

Before setting up and operating your new equipment, please
locate the model plate on the equipment and record the
information in the provided area to the right. You can locate the
model plate by standing at the operator’s position and looking
at the lower, rear section of the frame. This information will
be necessary, should you seek technical support via our web
site, Customer Support Department, or with a local authorized
service dealer.

MO d e l nu M b e r

se r i a l nu M b e r

Customer Support

Please do NOT return the unit to the retailer or dealer without first contacting our Customer Support Department.

If you have difficulty assembling this product or have any questions regarding the controls, operation, or maintenance of
this unit, you can seek help from the experts. Choose from the options below:

Visit us on the web at www.troybilt.com◊

Call a Customer Support Representative at [phone] or [phone]◊

Write us at Troy-Bilt LLC • P.O. Box 361131 • Cleveland, OH • 44136-0019◊

2

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!

CALIFORNIA PROPOSITION 65

WARNING! Engine Exhaust, some of its constituents, and certain vehicle components
contain or emit chemicals known to State of California to cause cancer and birth defects
or other reproductive harm.

DANGER: This machine was built to be operated according to the safe operation practices in
this manual. As with any type of power equipment, carelessness or error on the part of the
operator can result in serious injury. This machine is capable of amputating fingers, hands,
toes and feet and throwing foreign objects. Failure to observe the following safety
instructions could result in serious injury or death.

2

Training

Read, understand, and follow all instructions on the 1.
machine and in the manual(s) before attempting to
assemble and operate. Keep this manual in a safe place for
future and regular reference and for ordering replacement
parts.

Be familiar with all controls and their proper operation. 2.
Know how to stop the machine and disengage them
quick ly.

Never allow children under 14 years of age to operate this 3.
machine. Children 14 and over should read and understand

the instructions and safe operation practices in this manual
and on the machine and be trained and supervised by an
adult.

Never allow adults to operate this machine without proper 4.
instruction.

Thrown objects can cause serious personal injury. Plan 5.
your snow-throwing pattern to avoid discharge of material
toward roads, bystanders and the like.

Keep bystanders, pets and children at least 75 feet from the 6.
machine while it is in operation. Stop machine if anyone
enters the area.

Exercise caution to avoid slipping or falling, especially 7.
when operating in reverse.

Preparation

Thoroughly inspect the area where the equipment is to be used.
Remove all doormats, newspapers, sleds, boards, wires and other
foreign objects, which could be tripped over or thrown by the
auger/impeller.

Always wear safety glasses or eye shields during operation 1.
and while performing an adjustment or repair to protect
your eyes. Thrown objects which ricochet can cause serious
injury to the eyes.

Do not operate without wearing adequate winter outer 2.
garments. Do not wear jewelry, long scarves or other loose
clothing, which could become entangled in moving parts.
Wear footwear which will improve footing on slippery
surfaces.

Use a grounded three-wire extension cord and receptacle 3.
for all machines with electric start engines.

Adjust collector housing height to clear gravel or crushed 4.
rock surfaces.

Disengage all control levers before starting the engine. 5.

Never attempt to make any adjustments while engine is 6.
running, except where specifically recommended in the
operator’s manual.

Let engine and machine adjust to outdoor temperature 7.
before starting to clear snow.

3

Safe Handling of Gasoline

To avoid personal injury or property damage use extreme care
in handling gasoline. Gasoline is extremely flammable and the
vapors are explosive. Serious personal injury can occur when
gasoline is spilled on yourself or your clothes which can ignite.
Wash your skin and change clothes immediately.

Use only an approved gasoline container.a.

Extinguish all cigarettes, cigars, pipes and other b.
sources of ignition.

Never fuel machine indoors. c.

Never remove gas cap or add fuel while the engine is d.
hot or running.

Allow engine to cool at least two minutes before e.
refueling.

Never over fill fuel tank. Fill tank to no more than ½ f.
inch below bottom of filler neck to provide space for
fuel expansion.

Replace gasoline cap and tighten securely.g.

If gasoline is spilled, wipe it off the engine and h.
equipment. Move machine to another area. Wait 5
minutes before starting the engine.

Never store the machine or fuel container inside i.
where there is an open flame, spark or pilot light
(e.g. furnace, water heater, space heater, clothes
dryer etc.).

Allow machine to cool at least 5 minutes before j.
storing.

Never fill containers inside a vehicle or on a truck k.
or trailer bed with a plastic liner. Always place
containers on the ground away from your vehicle
before filling.

If possible, remove gas-powered equipment from l.
the truck or trailer and refuel it on the ground. If this
is not possible, then refuel such equipment on a
trailer with a portable container, rather than from a
gasoline dispenser nozzle.

Keep the nozzle in contact with the rim of the fuel m.
tank or container opening at all times until fueling is
complete. Do not use a nozzle lock-open device.

Operation

Do not put hands or feet near rotating parts, in the auger/1.
impeller housing or chute assembly. Contact with the
rotating parts can amputate hands and feet.

The auger/impeller control lever is a safety device. Never 2.
bypass its operation. Doing so makes the machine unsafe
and may cause personal injury.

The control levers must operate easily in both directions 3.
and automatically return to the disengaged position when
released.

Never operate with a missing or damaged chute assembly. 4.
Keep all safety devices in place and working.

Never run an engine indoors or in a poorly ventilated area. 5.
Engine exhaust contains carbon monoxide, an odorless
and deadly gas.

Do not operate machine while under the influence of 6.
alcohol or drugs.

Muffler and engine become hot and can cause a burn. Do 7.
not touch. Keep children away.

Exercise extreme caution when operating on or crossing 8.
gravel surfaces. Stay alert for hidden hazards or traffic.

Exercise caution when changing direction and while 9.
operating on slopes.

Plan your snow-throwing pattern to avoid discharge 10.

towards windows, walls, cars etc. Thus, avoiding possible
property damage or personal injury caused by a ricochet.

Never direct discharge at children, bystanders and pets or 11.
allow anyone in front of the machine.

Do not overload machine capacity by attempting to clear 12.
snow at too fast of a rate.

Never operate this machine without good visibility or light. 13.
Always be sure of your footing and keep a firm hold on the
handles. Walk, never run.

Disengage power to the auger/impeller when transporting 14.
or not in use.

Never operate machine at high transport speeds on 15.
slippery surfaces. Look down and behind and use care
when backing up.

If the machine should start to vibrate abnormally, stop 16.
the engine, disconnect the spark plug wire and ground it
against the engine. Inspect thoroughly for damage. Repair
any damage before starting and operating.

Disengage all control levers and stop engine before you 17.
leave the operating position (behind the handles). Wait
until the auger/impeller comes to a complete stop before
unclogging the chute assembly, making any adjustments,
or inspections.

Never put your hand in the discharge or collector 18.
openings. Always use the clean-out tool provided to
unclog the discharge opening. Do not unclog chute
assembly while engine is running. Shut off engine and
remain behind handles until all moving parts have stopped
before unclogging.

Use only attachments and accessories approved by the 19.
manufacturer (e.g. wheel weights, tire chains, cabs etc.).

When starting engine, pull cord slowly until resistance 20.
is felt, then pull rapidly. Rapid retraction of starter cord
(kickback) will pull hand and arm toward engine faster than
you can let go. Broken bones, fractures, bruises or sprains
could result.

If situations occur which are not covered in this manual, use 21.
care and good judgment. Contact Customer Support for
assistance and the name of your nearest servicing dealer.

4 se c t i O n 2 — iM p O r t a n t sa f e Op e r a t i O n pr a c t i c e s

Maintenance & Storage

Never tamper with safety devices. Check their proper 1.
operation regularly. Refer to the maintenance and
adjustment sections of this manual.

Before cleaning, repairing, or inspecting machine 2.
disengage all control levers and stop the engine. Wait until
the auger/impeller come to a complete stop. Disconnect
the spark plug wire and ground against the engine to
prevent unintended starting.

Check bolts and screws for proper tightness at frequent 3.
intervals to keep the machine in safe working condition.
Also, visually inspect machine for any damage.

Do not change the engine governor setting or over-speed 4.
the engine. The governor controls the maximum safe
operating speed of the engine.

Snow thrower shave plates and skid shoes are subject to 5.
wear and damage. For your safety protection, frequently
check all components and replace with original equipment

manufacturer’s (OEM) parts only. “Use of parts which do

not meet the original equipment specifications may lead to
improper performance and compromise safety!”

Check control levers periodically to verify they engage 6.
and disengage properly and adjust, if necessary. Refer
to the adjustment section in this operator’s manual for
instructions.

Maintain or replace safety and instruction labels, as 7.
necessa ry.

Observe proper disposal laws and regulations for gas, oil, 8.
etc. to protect the environment.

Prior to storing, run machine a few minutes to clear snow 9.

from machine and prevent freeze up of auger/impeller.

Never store the machine or fuel container inside where 10.
there is an open flame, spark or pilot light such as a water
heater, furnace, clothes dryer etc.

Always refer to the operator’s manual for proper 11.
instructions on off-season storage.

Check fuel line, tank, cap, and fittings frequently for cracks 12.
or leaks. Replace if necessary.

Do not crank engine with spark plug removed.13.

According to the Consumer Products Safety Commission 14.
(CPSC) and the U.S. Environmental Protection Agency (EPA),

this product has an Average Useful Life of seven (7) years,

or 60 hours of operation. At the end of the Average Useful
Life have the machine inspected annually by an authorized

service dealer to ensure that all mechanical and safety
systems are working properly and not worn excessively.
Failure to do so can result in accidents, injuries or death.

Do not modify engine

To avoid serious injury or death, do not modify engine in any
way. Tampering with the governor setting can lead to a runaway
engine and cause it to operate at unsafe speeds. Never tamper
with factory setting of engine governor.

Notice Regarding Emissions

Engines which are certified to comply with California and federal

EPA emission regulations for SORE (Small Off Road Equipment)

are certified to operate on regular unleaded gasoline, and
may include the following emission control systems: Engine

Modification (EM), Oxidizing Catalyst (OC), Secondary Air

Injection (SAI) and Three Way Catalyst (TWC) if so equipped.

Spark Arrestor

WARNING! This machine is equipped with an

internal combustion engine and should not be used
on or near any unimproved forest-covered, 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.

5se c t i O n 2 — iM p O r t a n t sa f e Op e r a t i O n pr a c t i c e s

Safety Symbols

This page depicts and describes safety symbols that may appear on this product. Read, understand, and follow all instructions on the
machine before attempting to assemble and operate.

Symbol Description

READ THE OPERATOR’S MANUAL(S)
Read, understand, and follow all instructions in the manual(s) before attempting to
assemble and operate

WARNING— ROTATING BLADES
Keep hands out of inlet and discharge openings while machine is running. There are rotating
blades inside

WARNING— ROTATING BLADES
Keep hands out of inlet and discharge openings while machine is running. There are rotating
blades inside

WARNING— ROTATING AUGER
Do not put hands or feet near rotating parts, in the auger/impeller housing or chute
assembly. Contact with the rotating parts can amputate hands and feet.

WARNING—THROWN OBJECTS
This machine may pick up and throw and objects which can cause serious personal injury.

WARNING—GASOLINE IS FLAMMABLE
Allow the engine to cool at least two minutes before refueling.

WARNING— CARBON MONOXIDE

Never run an engine indoors or in a poorly ventilated area. Engine exhaust contains carbon
monoxide, an odorless and deadly gas.

WARNING— ELECTRICAL SHOCK
Do not use the engine’s electric starter in the rain

WARNING! Your Responsibility—Restrict the use of this power machine to persons who read, understand and

follow the warnings and instructions in this manual and on the machine.

6 se c t i O n 2 — iM p O r t a n t sa f e Op e r a t i O n pr a c t i c e s

SAVE THESE INSTRUCTIONS!

Assembly & Set-Up

Contents of Carton

One Snow Thrower• Two Replacement Auger Shear Pins• One Chute Assembly•

One Snow Thrower Operator’s •

Manual

One Briggs & Stratton Engine •
Operator’s Manual

3

One Product Registration Card•

Assembly

IMPORTANT: Two replacement auger shear pins are included

with this manual (or stowed in the plastic handle panel). Refer to
the Maintenance section for more information regarding shear
pin replacement.

NOTE: All references in this manual to the left or right side of the
snow thrower is from the operating position only. Exceptions, if
any, will be specified.

IMPORTANT: This unit is shipped with the engine full of oil.

After assembly, refer to the separate Engine Owner’s Manual

included with this unit for fuel and oil fill-up details.

NOTE: Specifications are subject to change without notification
or obligation. Images may not reflect your exact model and are
for reference purposes only.

Handle

Remove any packaging material from the upper handle. 1.

Remove the lower plastic wing nut, belleville washer and 2.
carriage bolt from each side of the upper handle; then raise
the upper handle assembly until it snaps over the lower

handle. See Figure 3-1.

Secure the upper handle and lower handle with the two 4.
wing nuts and carriage bolts removed earlier. Tighten the
two wing nuts already installed in the upper holes to firmly
secure the upper handle and support tubes. See Figure 3-2.

Figure 3-2

Align the upper and lower shift rods, then slide the shift rod 5.
connector down over the end of the lower shift rod. Tap
the connector until the lower rod is completely through
the connector. See Figure 3-3.

Figure 3-1

Looking beneath the handle panel, check that all of the 3.
cables (steering, auger, and drive) are properly routed
and not pinched or kinked. Make certain the springs at
the lower end of the auger and drive cables are securely
hooked into their respective actuator bracket.

Figure 3-3

7

NOTE: If the connector is not properly assembled, the shift rod

a

b

will pivot and you will not be able to change speeds or direction.
If the full range of speeds (forward and reverse) can not be

achieved, refer to the “Maintenance and Adjustments” section.

Chute Directional Control

Remove the internal cotter pin from the upper chute crank. Slide
the upper chute crank into the sleeve on the lower chute crank.

Align the hole in the upper chute crank with the hole in the
sleeve (If necessary, use a pair of pliers to assist in aligning holes).
Insert the internal cotter pin through the holes to secure the

chute crank. See Figure 3-4.

Place chute assembly onto chute base as shown in Figure 3-5.

Make sure that the chute notches engage with the spiral end
of chute directional control, and the two flange keepers are
beneath the flange on the chute base.

Secure flange keeper removed earlier with lock nuts and screws.
Tighten down nuts securing the other two flange keepers. See
Figure 3-6.

Figure 3-4

Chute Assembly

Remove lock nuts and screws securing one of the flange keepers
to the chute assembly. Loosen the fasteners of the other two
flange keepers. See Figure 3-5.

Figure 3-6

Check that the chute cables are properly routed through the
cable guide attached to the lower handle assembly. See Figure
3-5.

Figure 3-5

8 se c t i O n 3— as s e M b l y & se t -up

Se t-Up

Lower

Shave
Plate

Raise

Shave
Plate

Shave
Plate

Shear Pins

A pair of replacement auger shear pins and bow tie cotter pins
have been included with your snow thrower. Store the pins in
a convenient place for use if an original equipment shear pin
should break.

Chute Clean-Out Tool

The chute clean-out tool is fastened to the top of the auger
housing with a mounting clip and a cable tie at the factory. Cut
the cable tie before operating the snow thrower.

Tire Pressure (Pneumatic Tires)

The tires are over-inflated for shipping purposes. Check the tire
pressure before operating the snow thrower. Refer to the tire
side wall for tire manufacturer’s recommended psi and deflate
(or inflate) the tires as necessary.

NOTE: If the tire pressure is not equal in all tires, the unit may
pull to one side or the other and the shave plate will not sit level
on the ground.

IMPORTANT: Under any circumstance do not exceed

manufacturer’s recommended psi. Equal tire pressure should be
maintained at all times. Excessive pressure when seating beads
may cause tire/rim assembly to burst with force sufficient to
cause serious injury. Refer to sidewall of tire for recommended
pressure.

Adjustments

Skid Shoes

The snow thrower skid shoes are adjusted upward at the
factory for shipping purposes. Adjust them downward prior to
operating the snow thrower.

CAUTION: It is not recommended that you operate

this snow thrower on gravel as it can easily pick up
and throw loose gravel, causing personal injury or
damage to the snow thrower and surrounding
property.

For close snow removal on a smooth surface, adjust the skid
shoes so that the shave plate on the bottom of the auger
housing is just off the ground.

Adjust the skid shoes to a lower position to raise the shave plate
off the ground when clearing uneven areas, such as a ribbon
type driveway or a gravel driveway

NOTE: If you choose to operate the snow thrower on a gravel
surface, keep the skid shoes in position for maximum clearance
between the ground and the shave plate.

Figure 3-7

Auger and Drive Control Cables

WARNING! Prior to operating your snow thrower,

carefully read and follow all instructions below.

Perform all adjustments to verify your snow thrower

is operating safely and properly.

Testing Auger Drive Control

When the auger control is released and in the disengaged “up”
position, the cable should have very little slack. It should NOT be

tight. Refer to Figure 3-8.

Chute Tilt Control

Auger
Control

Auger
Control
Cable

Shift Lever

Drive
Control

Drive
Control
Cable

To adjust the skid shoes:

Adjust skid shoes by loosening the six (three on each side) hex 1.
nuts, washers, and carriage bolts securing the skid shoes
to the auger housing. Refer to Figure 3-7.

While observing the distance between the shave plate and the 2.
ground, adjust the skids shoes up or down to achieve the
desired shave plate height. See Figure 3-7.

Make certain the entire bottom surface of skid shoes are against 3.
the ground to avoid uneven wear on the skid shoes; then
tighten nuts and bolts securely.

Figure 3-8

In a well-ventilated area, start the snow thrower engine as 1.
instructed in Section 5 - Operation.

While standing in the operator’s position (behind the snow 2.
thrower), engage the auger.

Allow the auger to remain engaged for approximately ten 3.

(10) seconds before releasing the auger control. Repeat this

several times.

9se c t i O n 3 — as s e M b l y & se t -up