Form No. 3326-129 CCR 2450 GTS CCR 3650 GTS Snowthrower Model No. 38535—220000001 and Up Model No. 38536—220000001 and Up Model No. 38537—220000001 and Up Model No.
This spark ignition system complies with Canadian ICES-002. Introduction Ce système d’allumage par étincelle de véhicule est conforme à la norme NMB-002 du Canada. Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely. Contents Introduction . . . . . . . . . . . . . . .
• Handle fuel with care; it is highly flammable. This manual uses 2 other words to highlight information. Important calls attention to special mechanical information and Note: emphasizes general information worthy of special attention. – Use an approved fuel container. – Never add fuel to a running or hot engine. – Fill the fuel tank outdoors with extreme care. Never fill the fuel tank indoors. Safety – Replace the fuel tank cap securely and wipe up any spilled fuel.
• If a shield, safety device, or decal is damaged, illegible, or lost, repair or replace it before beginning operation. Also, tighten any loose fasteners. • Never operate the snowthrower without proper guards, plates, or other safety protective devices in place. • Never operate the snowthrower near glass enclosures, automobiles, window wells, and drop-offs without properly adjusting the snow discharge angle. Keep children and pets away. • Do not smoke while handling gasoline.
Safety and Instruction Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. 94-2561 1. Hot surface; do not touch 2. Stay a safe distance from the machine 94-2577 1. Squeeze the control bar to engage the rotor blades 94-2901 2. Release the control bar to release the rotor blades 1.
105-3522 (Model 38535) or 105-1963 (Model 38537) 1. Warning—read the Operator’s Manual 2. Stay away from moving parts, and stop the engine before leaving the machine 3. Thrown object hazard—keep bystanders away 4. Push the button 5. Primer 6. Ignition off 7. Ignition on 8. Recoil starter 105-3524 (Model 38536) or 105-1962 (Model 38538) 1. Warning—read the Operator’s Manual 2. Stay away from moving parts, and stop the engine before leaving the machine 3. Thrown object hazard—keep bystanders away 4.
Assembly Note: Determine the left and right sides of the machine from the normal operating position. Loose Parts DESCRIPTION QTY.
Installing the Wheels Installing the Handle 1. Turn the snowthrower onto its left side and place a wood block under the left axle end (Fig. 2). 1. Cut the plastic tie that secures the control cable to the handle (Fig. 4). 1 1 2 3 2 m 4498 m 5575 Figure 4 Figure 2 1. Pushnut 1. Handle 2. Plastic tie 2. Short spacer 2. Slide the short spacer and a wheel onto the right axle end (Fig. 2). 3. Control cable Important If you do not cut the plastic tie, the rotor brake will not function properly.
Important Ensure that the control cable is not pinched by the upper handle or the handle lock. 1 6. Tighten the knobs until they are snug. 3 7. Adjust the control cable. Refer to Adjusting the Control Cable on page 16. 2 4 Installing the Discharge Chute Models 38535 and 38536 m 5573 1. Place the discharge chute over the chute ring, and align the hole in the back of the discharge chute with the center hole in the chute ring (Fig. 9). Figure 6 1. Knob (2) 2. Curved washer (2) 3. Upper handle 4.
Models 38537 and 38538 Installing the Chute Crank 1. Place the discharge chute over the chute ring, and align the hole in the back of the discharge chute with the center hole in the chute ring (Fig. 10). Models 38537 and 38538 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. 11). 2 3 1 1 2 m 5520 Figure 10 1. Chute ring 2. Discharge chute m 5545 2.
Before Starting Danger Mixing Gasoline and Oil When fueling, under certain circumstances, a static charge can develop, igniting the gasoline. A fire or explosion from gasoline can burn you and others and damage property. Your Toro snowthrower is powered by a 2-cycle engine that requires a 50:1 gasoline-to-oil mixture. Use only clean, unleaded gasoline no more than 30 days old and with an octane rating of 87 or higher.
3. Install the cap on the fuel container. 3 2 4. Shake the container to mix the gasoline and oil thoroughly. 4 1 5. Slowly remove the cap and add the remaining amount of gasoline. Filling the Fuel Tank Important Do not overfill the fuel tank. The gasoline-and-oil mixture must have room to expand. 1. Clean around the fuel tank cap; do not allow snow or water to enter the fuel tank. 5 2. Remove the fuel tank cap and fill the fuel tank with the gasoline-and-oil mixture until the level is 1/4 to 1/2 in.
Adjusting the Discharge Chute Caution Models 38535 and 38536 If you leave the snowthrower plugged into a power outlet, someone can inadvertently start the snowthrower and injure people or damage property. Move the chute handle left and right to adjust the direction of the snow stream (Fig. 13). The chute deflector handle on top of the discharge chute controls the height of the snow stream. Unplug the power cord whenever you are not starting the snowthrower. 1 B. Push the starter button.
• Do not attempt to clear snow from a crushed-rock or gravel surface. This product is intended for use only on paved surfaces. Models 38537 and 38538 Rotate the chute crank clockwise to move the discharge chute to the right or counterclockwise to move the chute to the left (Fig. 14). The chute deflector handle on top of the discharge chute controls the height of the snow stream. • In snowy and cold conditions, some controls and moving parts may freeze.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule Maintenance Service Interval Maintenance Procedure Initially • Check the control cable both initially and after the first hour of operation; adjust it if necessary. Refer to Adjusting the Control Cable on page 16. • Check for loose fasteners and tighten them if necessary. Annually • Check the control cable and adjust it if necessary.
Models 38537 and 38538 Adjusting the Control Cable Check the control cable for proper adjustment initially, after the first operating hour, and then annually thereafter. 2 3 Checking the Cable 4 1 5 1. Stop the engine and wait for all moving parts to stop. 2. Move the control bar back toward the handle to remove the slack in the cable as shown in Figure 15 (for models 38535 and 38536) or Figure 16 (for models 38537 and 38538). 1 Models 38535 and 38536 m-5519 Figure 16 4 1. Cable 2. Control bar 3.
Note: Moving the Z-fitting to a hole closer to the spring decreases the gap between the control bar and the handle; moving it to a hole farther from the spring increases the gap. After extended use, the drive belt may wear and lose its proper belt tension. Improper belt tension causes the belt to slip and decreases the performance under a heavy load. Belt slippage may occur after 2 or 3 seasons of normal usage (10 to 15 hours).
Removing the Old Rotor Blades 3 1. Remove the 4 torx screws and the 4 locknuts that secure the outer edges of the rotor blade to the rotor assembly (Fig. 20). 1 2 4 1 6 4 m-5538a/m-5059 7 Figure 21 5 3 8 1. Thick rubber side 2. Wear indicator hole 4 2 3. Thin rubber side 4. Inside of curved surface 680 Install the new rotor blade with the thick rubber layer on the inside of the curved surface (Fig. 21). If you do not install the rotor blade properly, it will wear out more quickly.
2 Replacing the Scraper Note: If the rotor blades are partially or completely worn, replace the rotor blades when you replace the scraper. This ensures proper snowthrower operation and performance. 1 1. Stop the engine and wait for all moving parts to stop. m-5061a 2. Remove the key from the switch. Figure 23 3. Remove the control panel and disconnect the wire from the spark plug. Refer to steps 3 through 5 of Replacing the Spark Plug on page 19. 1. Control panel 4.
5. Pull up on the idler pulley and remove the old drive belt from the rotor pulley, the brake arm assembly, and the engine pulley (Fig. 27). 1 2 m-3215 1 Figure 25 4 1. 0.030 in. (0.76 mm) 10. Install the spark plug by hand and then torque it to 15 ft-lb (20.4 N m). If you do not have a torque wrench, tighten the plug firmly. 6 11. Connect the wire to the spark plug. 12. Install the control panel. 13. Insert the key in the switch.
5. Start the engine and run it until it stops. Danger 6. Choke or prime the engine, start it a third time, and run the engine until it will not start. Gasoline is highly flammable; it can ignite and cause serious personal injury. 7. Dispose of unused fuel properly. Recycle it according to local codes, or use it in your automobile. • • • • Drain gasoline outdoors. Drain gasoline from a cold engine only. Wipe up any gasoline that may have spilled.
Troubleshooting Toro designed and built your snowthrower for trouble-free operation. Check the following components and items carefully, and refer to Maintenance on page 15 for more information. If a problem continues, contact an Authorized Service Dealer. Problem Electric starter does not turn (electric-start models only) Engine does not start or starts hard Engine runs rough Possible Causes Corrective Action 1. The power cord is disconnected at the outlet or the snowthrower. 1.
Problem Engine runs, but the snowthrower discharges snow poorly or not at all Snowthrower does not properly clear snow off the surface Snowthrower does not self-propel Rotor blades do not stop properly Possible Causes Corrective Action 1. You are walking too fast or too slow. 1. Change your walking speed. 2. You are trying to remove too much snow per swath. 2. Reduce the amount of snow removed per swath. 3. You are trying to remove extremely heavy or wet snow. 3.
