Form No. 3322-821 Rev A CCR 2450 GTS CCR 3650 GTS Snowthrower Model No. 38428—200000001 and Up Model No. 38429—200000001 and Up Model No. 38441—200000001 and Up Model No.
Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Snowthrower Safety . . . . . . . . . . . . . . . . . Toro Snowthrower Safety . . . . . . . . . . . . . . . . . . . Sound Pressure Level . . . . . . . . . . . . . . . . . . . . . . . Sound Power Level . . . . . . . . . . . . . . . . . . . . . . . . Vibration Level . . . . . . . . . . . . . . . . . . . . . . . . . . . .
• Do not operate the equipment without wearing adequate winter garments. Wear footwear which will improve footing on slippery surfaces. This manual uses two other words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention. • Handle fuel with care; it is highly flammable. • Use an approved fuel container. Safety • Never add fuel to a running or hot engine. • Fill fuel tank outdoors with extreme care.
• Run the machine a few minutes after throwing snow to prevent freeze-up of the collector (auger)/impeller. (With the engine running, pull the recoil starter handle several times.) wire, and keep the wire away from the plug to prevent accidental starting. Disconnect the cable on electric motors. • Do not run the engine indoors, except when starting it and for moving the snowthrower in or out of the building. Open the outside doors; exhaust fumes are dangerous.
• When storing the snowthrower for more than 30 days, drain the gasoline from the fuel tank to prevent a potential hazard. Store gasoline in a safety approved, red metal container. Remove the key from the ignition switch before storing the snowthrower. • To ensure the best performance and safety, purchase only genuine Toro replacement parts and accessories to keep the Toro all Toro. Do not use “Will Fit” replacement parts and accessories as they could cause a safety hazard.
Symbol Glossary Safety alert triangle – symbol within triangle indicates a hazard Do not open or remove safety shields while engine is running Safety alert symbol Stay a safe distance from the machine Read operator’s manual Stay a safe distance from the machine – single stage snowthrower Consult technical manual for proper service procedures Stay a safe distance from the machine – two stage snowthrower Shut off engine and remove key before performing maintenance or repair work Thrown or flying obje
Hot surfaces – burns to fingers or hands Machine loss of control – uphill slope Caustic liquids – chemical burns to fingers or hands Machine loss of control downhill slope Do not tip battery Traction drive Keep dry Snowthrower collector auger Machine travel direction – forward Engage Machine travel direction – rearward Disengage On/start Choke Off/stop Engine speed (Throttle) 7
Fast Neutral Slow Snowthrower collector auger/impeller Decreasing/Increasing Lock Engine start Unlock Engine stop Lever operation Snowthrower chute direction Lever operation Primer (start aid) Unleaded fuel Primer operation Cutting of fingers or hand 8
Cutting of foot Throttle operation PowerShift operation Belt routing Assembly Note: Determine the left and right sides of the snowthrower by standing in the normal operating position. Loose Parts DESCRIPTION QTY.
DESCRIPTION QTY. Knobs 2 Curved washers 2 Cable guide 1 Handle locks 2 Control bar 1 Upper handle 1 Spring 1 Spring cover 1 Cable adjuster 1 Control cable 1 Installing the Wheels USE Installing the handle Installing the control cable 6. Slide the long spacer and a wheel onto the left axle end. 1. Turn the snowthrower onto its left side and place a wood block under the left axle end (Fig. 3). The side of the wheel with six spokes must face downward. 2.
3. Align the hole in the back of the chute with the center hole in the ring. 2 3 2 636 1 1 5 Figure 5 1. Chute ring 2. Discharge chute 4 Installing the Chute Crank m-3277 Figure 4 1. Chute ring 2. Discharge chute 3. Chute handle Models 38441 and 38442 only 4. Carriage bolt 5. Locknut 1. Insert the flattened end of the chute crank through the hole in the shroud while aligning the mounting bracket with the holes in the lower handle (Fig. 6). 2.
Installing the Control Cable 2 Models 38428 and 38429 only 1 5 m-4503 4 Figure 7 1. Upper handle 6 2. Control bar 7 3 2 1 2 Figure 10 1 1. 2. 3. 4. m-4504 Figure 8 1. Upper handle m-2708 Cable guide Control cable Spring cover Control bar bracket 5. Top hole 6. Bottom hole 7. 1/16 to 1/8 in. (0.16 to 0.32 cm) gap 2. Control bar 1. Hook the spring to the round hole at the end of the cable adjuster (Fig. 11). 3. Install the upper handle as illustrated in Figure 9. 2.
Models 38441 and 38442 only DANGER 1. Hook the upper end of the control cable in the bottom hole in the control bar bracket (Refer to the inset in Fig. 12). POTENTIAL HAZARD • In certain conditions gasoline is extremely flammable and highly explosive. 2. Move the control bar back toward the handle to remove the slack in the cable. WHAT CAN HAPPEN • A fire or explosion from gasoline can burn you, others, and cause property damage. 3. Ensure that a 1/16 to 1/8 in. (0.16 to 0.
1. Pour a half gallon (1.9 liters) of gasoline into an approved gasoline container (preferably plastic, not metal). 5 3 Note: Do not mix gasoline and oil in the fuel tank. Oil at room temperature mixes easier and more thoroughly than cold oil. Oil below 32°F (0°C) requires additional mixing. 1 2. Add the proper amount of a high grade, NMMA- or TCW-certified two-cycle oil. 6 4 2 For best results, use Toro Heavy Duty 50:1 All Season 2-Cycle Engine Oil with Fuel Stabilizer. Figure 14 1. 2. 3. 4. 3.
IMPORTANT: Running the electric starter extensively can overheat and damage the starter. IMPORTANT: Do not use the chute handle to lift the snowthrower. This can damage the chute handle. If the engine does not start after the second attempt, bring the snowthrower to an Authorized Service Dealer for service. Models 38441 and 38442 only Rotate the chute crank clockwise to move the discharge chute to the right or counterclockwise to move the chute to the left (Fig. 16).
• To clear snow from crushed rock or gravel, push down on the handle to raise the rotor blades clear of the loose material and push the snowthrower forward. • After clearing the snow, let the engine run for a few minutes to prevent moving parts from freezing. While the engine runs, pull the recoil starter two or three times to prevent it from freezing. Shut off the engine and remove all ice and snow from the snowthrower.
• For Models 38441 and 38442: Reposition the upper cable end into the upper hole of the control bar bracket (Fig. 12). B. Slide the spring cover off the spring and the cable adjuster. C. Unhook the Z fitting from the cable adjuster and reposition the Z fitting in a higher or lower hole on the adjuster to obtain a proper gap of 1/16 to 1/8 in. (0.16 to 0.32 cm) between the control bar bracket and the handle (Fig. 11).
2 1 2 4 6 1 644 Figure 19 1. Scraper 3 2. Carriage bolts and locknuts (3) 5 6. Install the new scraper to the housing using the carriage bolts and locknuts. 626 Figure 21 4. Brake arm assembly 5. Rotor pulley 6. Belt guide 1. Engine pulley 2. Idler pulley 3. Roller Replacing the Drive Belt Inspect the drive belt before each season, and replace it if it is worn or damaged. IMPORTANT: The drive belt must be on top of the roller as shown in Figure 21. 1. Stop the engine. 5.
3. Pull the wire off the spark plug and remove the spark plug (Fig. 23). 1 1 Figure 25 628 1. Wear indicator hole Figure 23 1. Spark plug wire Note: Replace the scraper whenever you replace the rotor blades. This ensures proper snowthrower operation and performance. 4. Examine the spark plug and replace it if it is cracked, fouled, or dirty. Note: The running time and the roughness of the driveway or the sidewalk determines the wear rate of the rotor blades.
4 6 1 7 5 4 3 8 2 680 Figure 26 1. Rotor blade (2) 2. Rotor half (2) 3. Torx screw (8) 4. Locknut (13) 5. Hex-head capscrew (4) 6. Spacer (4) 7. Auger shaft assembly 8. Hex-head screw Installing a New Blade 2. Insert the new rotor blade between the rotor halves. 1. Examine a new rotor blade edge for the difference in layer thickness (Fig. 27). Some rotor blades have a part number on the thick side of the blade. 3.
2. Run the engine for five minutes to distribute the conditioned fuel through the fuel system. 3. Stop the engine, allow it to cool, and drain the fuel tank. 4. Start the engine again and run it until it stops. 5. Prime the engine, start it a third time, and run it until it will not restart. 6. Recycle the fuel according to local codes. Preparing the Engine This procedure allows you to close both the intake and the exhaust ports of the engine, preventing cylinder bore corrosion. 1.
