Toro 38535, 38536, 38537, 38538 Operator's Manual
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. 38538—220000001 and Up
Operator ’s Manual
International English (GB)
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.
Contents
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Operating Practices 3. . . . . . . . . . . . . . . . . . . .
Toro Snowthrower Safety 4. . . . . . . . . . . . . . . . . . .
Sound Pressure Level 4. . . . . . . . . . . . . . . . . . . . . .
Sound Power Level 4. . . . . . . . . . . . . . . . . . . . . . .
Vibration Level 4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 5. . . . . . . . . . . . . . . .
Assembly 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Wheels 8. . . . . . . . . . . . . . . . . . . . . .
Installing the Handle 8. . . . . . . . . . . . . . . . . . . . . .
Installing the Discharge Chute 9. . . . . . . . . . . . . . .
Installing the Chute Crank 10. . . . . . . . . . . . . . . . . .
Before Starting 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mixing Gasoline and Oil 11. . . . . . . . . . . . . . . . . . .
Filling the Fuel Tank 12. . . . . . . . . . . . . . . . . . . . . .
Operation 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Controls 12. . . . . . . . . . . . . . . . . . . . . . . .
Starting the Engine 12. . . . . . . . . . . . . . . . . . . . . . . .
Stopping the Engine 13. . . . . . . . . . . . . . . . . . . . . . .
Starting the Rotor Blades 13. . . . . . . . . . . . . . . . . . .
Stopping the Rotor Blades 13. . . . . . . . . . . . . . . . . .
Adjusting the Discharge Chute 13. . . . . . . . . . . . . . .
Snowthrowing Tips 14. . . . . . . . . . . . . . . . . . . . . . .
Maintenance 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule 15. . . . . . . . .
Adjusting the Control Cable 16. . . . . . . . . . . . . . . . .
Replacing the Rotor Blades 17. . . . . . . . . . . . . . . . .
Replacing the Scraper 19. . . . . . . . . . . . . . . . . . . . . .
Replacing the Spark Plug 19. . . . . . . . . . . . . . . . . . .
Replacing the Drive Belt 20. . . . . . . . . . . . . . . . . . .
Emptying the Fuel Tank 20. . . . . . . . . . . . . . . . . . . .
Storage 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparing the Fuel System 21. . . . . . . . . . . . . . . . . .
Preparing the Engine 21. . . . . . . . . . . . . . . . . . . . . .
Preparing the Snowthrower 21. . . . . . . . . . . . . . . . .
Folding the Handle 21. . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
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.
Whenever you need service, genuine Toro parts, or
additional information, contact an Authorized Service
Dealer or Toro Customer Service and have the model and
serial numbers of your product ready. Figure 1 illustrates
the location of the model and serial numbers on the
product.
1
Figure 1
1. Location of the model and serial numbers
Write the product model and serial numbers in the space
below:
Model No.
Serial No.
This manual identifies potential hazards and has special
safety messages that help you and others avoid personal
injury and even death. Danger, Warning, and Caution are
signal words used to identify the level of hazard. However,
regardless of the hazard, be extremely careful.
Danger signals an extreme hazard that will cause serious
injury or death if you do not follow the recommended
precautions.
Warning signals a hazard that may cause serious injury or
death if you do not follow the recommended precautions.
Caution signals a hazard that may cause minor or moderate
injury if you do not follow the recommended precautions.
m5515
2001 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
All Rights Reserved
Printed in the USA
2
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.
Safety
Models 38537 and 38538 meet or exceed the ISO
standard 8437 in effect at the time of production.
To ensure maximum safety and best performance, and
to gain knowledge of the product, it is essential that you
and any other operator of the snowthrower read and
understand the contents of this manual before the
engine is ever started.
This is the safety alert symbol. It is used to alert you
to potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
Improperly using or maintaining this snowthrower
could result in injury or death. To reduce this potential,
comply with the following safety instructions.
Safe Operating Practices
The following instructions have been adapted from the
ANSI/OPEI B71.3–1995 standard and the ISO 8437:1989
standard.
• Handle fuel with care; it is highly flammable.
– 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.
– Replace the fuel tank cap securely and wipe up any
spilled fuel.
• Use only the power cord supplied with the snowthrower
and a receptacle appropriate for use with the power cord
for electric-start motors.
• Never attempt to make any adjustments while the
engine is running, except where specifically
recommended by Toro.
• Let the engine and the snowthrower adjust to the
outdoor temperature before starting to clear snow.
• Operating any powered machine can result in foreign
objects being thrown into the eyes. Always wear safety
glasses or eye shields while operating, adjusting, or
repairing the snowthrower.
Operation
• Do not put hands or feet near or under rotating parts.
Keep clear of the discharge opening at all times.
• Exercise extreme caution when crossing gravel drives,
walks, or roads. Stay alert for hidden hazards or traffic.
Training
• Read the operator’s manual carefully. Be thoroughly
familiar with the controls and the proper use of the
equipment. Know how to stop the unit and disengage
the controls quickly.
• Never allow children to operate the snowthrower. Never
allow adults to operate the snowthrower without proper
instruction.
• Keep the area of operation clear of all persons
(particularly small children) and pets.
• Exercise caution to avoid slipping or falling.
Preparation
• Thoroughly inspect the area where you will use the
snowthrower. Remove all doormats, sleds, boards,
wires, and other foreign objects.
• Release the control bar to disengage the rotor blades
before starting the engine.
• Do not operate the snowthrower without wearing
adequate winter garments. Wear footwear that will
improve your footing on slippery surfaces.
• Do not attempt to clear snow from a crushed-rock or
gravel surface. This product is intended for use only on
paved surfaces.
• After striking a foreign object, stop the engine, remove
the ignition key, thoroughly inspect the snowthrower for
any damage, and repair the damage before operating the
snowthrower.
• If the unit should start to vibrate abnormally, stop the
engine and check immediately for the cause. Vibration
is generally a warning of trouble.
• Stop the engine whenever you leave the operating
position, before unclogging the discharge chute, and
when making any repairs, adjustments, or inspections.
• When cleaning, repairing, or inspecting, make certain
that the rotor blades and all moving parts have stopped.
• 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.
• Do not clear snow across the face of slopes. Exercise
extreme caution when changing direction on slopes. Do
not attempt to clear steep slopes.
3
• 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 overload the machine capacity by attempting to
clear snow at too fast a rate.
• Look behind and use care when backing up with the
snowthrower.
• Never direct the discharge at bystanders or allow
anyone in front of the unit.
• Never operate the snowthrower without good visibility
or light. Always be sure of your footing, and keep a
firm hold on the handle. Walk; never run.
Maintenance and Storage
• Check all fasteners at frequent intervals for proper
tightness to be sure that the equipment is in safe
working condition.
• Never store the machine with fuel in the fuel tank inside
a building where ignition sources are present, such as
hot water and space heaters and clothes dryers. Allow
the engine to cool before storing in any enclosure.
• Always refer to this operator’s manual for important
details if the snowthrower is to be stored for an
extended period.
• If a shield, safety device, or decal is damaged, illegible,
or lost, repair or replace it before beginning operation.
Also, tighten any loose fasteners.
• Do not smoke while handling gasoline.
• Do not use the snowthrower on a roof.
• Do not touch the engine while it is running or soon after
it has stopped because the engine may be hot enough to
cause a burn.
• Perform only those maintenance instructions described
in this manual. Before performing any maintenance,
service, or adjustment, stop the engine and remove the
key. If major repairs are ever needed, contact your
Authorized Service Dealer.
• Do not change the governor settings on the engine.
• When storing the snowthrower for more than 30 days,
drain the fuel from the fuel tank to prevent a potential
hazard. Store fuel in an approved fuel 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.
Sound Pressure Level
This unit has a sound pressure at the operator’s ear of
91 dB(A), based on measurements of identical machines
per Directive 84/538/EEC.
• Maintain or replace safety and instruction labels when
necessary.
Toro Snowthrower Safety
The following list contains safety information specific to
Toro products or other safety information that you must
know.
• Rotating rotor blades can injure fingers or hands. Stay
behind the handles and away from the discharge
opening while operating the snowthrower. Keep your
face, hands, feet, and any other part of your body or
clothing away from moving or rotating parts.
• Before adjusting, cleaning, repairing, and inspecting the
snowthrower, and before unclogging the discharge
chute, stop the engine, remove the key, and wait for all
moving parts to stop.
• Use a stick, not your hands, to remove obstructions
from the discharge chute.
• Before leaving the operating position, stop the engine,
remove the key, and wait for all moving parts to stop.
• Do not wear loose-fitting clothing that could get caught
in moving parts.
Sound Power Level
This unit has a sound power level of 104 LwA, based on
measurements of identical machines per Directive
84/538/EEC.
Vibration Level
This unit has a maximum hand-arm vibration level of
15.5 m/s, based on measurements of identical machines
per EN 1033.
4
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
94-2577
1. Squeeze the control bar
to engage the rotor
blades
the machine
2. Release the control bar to
release the rotor blades
94-2901
1. Cutting/dismemberment in impeller hazard—stay away from
moving parts, stop the engine, and remove the key before
performing maintenance
60-9480
104-9742
5
1. Warning—read the
Operator’s Manual
2. Stay away from moving
parts, and stop the engine
before leaving the machine
105-3522 (Model 38535) or 105-1963 (Model 38537)
3. Thrown object hazard—keep
bystanders away
4. Push the button
5. Primer
6. Ignition off
7. Ignition on
8. Recoil starter
1. Warning—read the
Operator’s Manual
2. Stay away from moving
parts, and stop the engine
before leaving the machine
105-3524 (Model 38536) or 105-1962 (Model 38538)
3. Thrown object hazard—keep
bystanders away
4. Push the button
5. Primer
6. Ignition off
7. Ignition on
6
8. Electric starter
9. Recoil starter
Assembly
Note: Determine the left and right sides of the machine from the normal operating position.
Loose Parts
DESCRIPTION QTY. USE
Short spacer (right side)
Long spacer (left side)
Pushnuts
Wheels
Upper handle section
Knobs
Curved washers
Handle locks
Screws
Locknuts
Washers
Discharge chute
Chute handle (Models 38535 and 38536 only)
Bolts
Locknuts
Chute crank and mounting bracket
Ignition key 1 Starting and stopping the engine
1
1
2
2
1
2
2
2
3
3
3
1
1
2
2
1
Installing the wheels
Installing the handle
Installing the discharge chute
Installing the chute crank (Models 38537 and
38538 only)
7
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
2
m4498
Figure 2
1. Pushnut 2. Short spacer
2. Slide the short spacer and a wheel onto the right axle
end (Fig. 2).
Note: The side of the wheel with 6 spokes must face
downward.
3. Slide a pushnut onto the end of the axle (Fig. 2).
4. Strike the pushnut with a hammer to seat it firmly in
place.
1. Cut the plastic tie that secures the control cable to the
handle (Fig. 4).
1
2
3
m5575
Figure 4
1. Handle
2. Plastic tie
3. Control cable
Important If you do not cut the plastic tie, the rotor
brake will not function properly.
2. Position the upper handle as shown in Figure 5.
5. Turn the snowthrower over onto its right side and place
a wood block under the right axle end.
6. Slide the long spacer and a wheel onto the left axle end
(Fig. 3).
2
1
m-4499
Figure 3
1. Long spacer 2. Pushnut
Note: The side of the wheel with 6 spokes must face
downward.
7. Repeat steps 3 and 4.
1
m5516a
Figure 5
1. Upper handle
3. Loosely install the handle locks, curved washers, and
knobs as shown in Figure 6.
8
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