Toro CCR 2000 Snowthrower Operator's Manual

FORM NO. 3320-548
MODEL NO. 38181-0000001 & UP
MODEL NO. 38186-0000001 & UP
OPERATOR'S
MANUAL
_ CCR 2000™SNOWTHROWER
SAFETY INSTRUCTIONS
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This safety alert sym-
bol means CAUTION —
PERSONAL SAFETY
INSTRUCTION. Read
the instruction because
it has to do with safety.
Failure to comply with
the instruction may result in personal
injury.
The Snowthrower is designed and tested
to offer safe and effective service, pro-
vided it is operated in strict accordance
with the following Safety instructions.
Failure to comply with the following in-
structions MAY RESULT IN PERSON—
AL INJURY.
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BEFORE OPERATING
1. Read this manual carefully. Never allow
children to operate the snowthrower. Adults
should operate the snowthrower only after
reading this manual.
2. Be thoroughly familiar with controls and
proper use of the unit. Know how to stop
engine and snowthrower quickly.
3. Keep everyone, especially children and
pets, away from area of operation. Thoroughly
inspect area where snowthrower will be used.
Remove all doormats, sleds, boards, wires and
other foreign objects which might be picked
up and thrown.
4. Wear adequate winter clothing and foot-
wear which will improve footing on slippery
surfaces. Exercise caution to avoid slipping or
falling.
5. Since fuel is highly flammable, handle it
carefully.
A. Use an approved fuel container.
B. Fill fuel tank outdoors, not indoors. Never
add fuel to an engine that is running or
hot.
C. Install gas cap on fuel container and gas
tank, and wipe up spilled gasoline before
starting engine.
6. Keep all guards, shields and safety devices
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in place. If a guard, shield or safety device is
defective, repair before operating. Keep all
nuts, bolts and screws tight.
OPERATING
7. Use only the extension cord provided with
the CCR-2000 Electric Start Model. Do not plug
extension cord into outlet while standing in wa-
ter or when hands are wet. Do not use cord if
gasoline has been spilled. Replace damaged
extension cord immediately (Part No. 28-9170).
8. Allow engine to warm up outdoors before
operating. Do not run engine indoors.
9. Never operate snowthrower without good
visibility or light. Always maintain secure
footing and keep a firm grip on the handles.
Walk; never run. DO NOT USE SNOW-
THROWER ON ROOF.
10.Keep face, hands, feet and any other part
of your body or clothing away from concealed,
moving or rotating parts. ALWAYS STAY
CLEAR OF DISCHARGE AREA.
11.Use extreme caution when operating on
Or crossing gravel drives, walks or roads. Stay
alert for hidden hazards or traffic.
12.Never direct discharge toward or operate
snowthrower near glass enclosures, motor
vehicles, window wells or drop-offs.
13. Never direct discharge at bystanders or
allow anyone in front of the snowthrower.
14. Never clear snow off steep slopes or
across the faces of slopes. Exercise extreme
caution when changing direction on slopes.
15. Do not overload snowthrower by clearing
snow at too fast a rate.
16. After striking a foreign object or if snow-
thrower vibrates abnormally, stop engine by
turning key to OFF, Thoroughly inspect
snowthrower for any damage, obstruction or
loose parts. Repair damage before restarting
and operating.
17. WHENEVER YOU LEAVE THE OPERA-
TING POSITION, STOP ENGINE BY TURNING
KEY TO OFF. REMOVE KEY FROM SWITCH
IF UNIT WILL BE UNATTENDED.
18. Before inspecting, adjusting, repairing or
©The Toro Company — 1989
SAFETY INSTRUCTIONS
clearing snowthrower, stop engine by turning
key to OFF. Always wait for all moving parts to
stop. Do not make adjustments while engine is
running.
19. After clearing snow, let engine run for a
few minutes so moving parts do not freeze.
MAINTENANCE AND STORAGE
20. REMOVE KEY FROM SWITCH when
storing snowthrower. Store key in memorable
place.
21. Never store snowthrower with fuel in the
fuel tank inside a building where open flame
or sparks are present. Allow engine to cool
before storing. Never store snowthrower in
house (living area) or basement because gasoline
and fumes are highly flammable, explosive and
dangerous if inhaled.
22. Keep all nuts, bolts and screws tight to
assure snowthrower is in proper working
condition.
23. Perform maintenance and use storage
instructions described in this manual. Re-
install fuel tank cap if upper shroud is removed
for maintenance.
24. ALWAYS USE GENUINE TORO RE-
PLACEMENT PARTS AND ACCESSORIES
TO ASSURE SAFETY AND OPTIMUM PER-
FORMANCE. NEVER USE “WILL FIT”
PARTS AND ACCESSORIES.
SYMBOL GLOSSARY
A
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Do not direct discharge at
bystanders or windows
Rotor drive - Engaged
bh
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Rotor drive - Disengaged
=~ Avoid injury from rotating
Shut off engine before
unclogging discharge chute
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Choke
Stop engine to adjust,
unclog or remove debris
2
auger, keep hands, feet and
clothing away.
Ignition
110 volt starter
Read and understand
operator's manual
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Ignition
on Recoil starter
la 4
50:1
50:1 ratio unleaded gasoline
to 2-cycle oil
off
ASSEMBLY INSTRUCTIONS
INSTALL WHEELS (Fig. 1)
1. Slide a short spacer and a wheel onto right
hand end of axle. Side of wheel with six spokes
must face center of axle.
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Figure 1
1. Short Spacer 3. Push Nut
2. Long Spacer
2. Place a push nut onto end of axle and drive
on using a hammer. Place a wood block under
opposite end of axle when mounting push nut.
3. Slide a long spacer and wheel onto opposite
end of axle. Side of wheel with six spokes must
face center of axle.
4. Using a hammer, drive a push nut onto axle.
Place a wood block under opposite end of axle
when mounting push nut.
INSTALL CHUTE CRANK (Fig. 2)
1. Insert flattened end of chute crank thru
hole in shroud while aligning mounting bracket
with holes in lower handle. Slowly rotate crank
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Figure 2
1. Chute Crank
2. Mounting Bracket
3. Gear
3
until flattened end fits into hidden gear opening
and chute ring turns with crank. Secure mount-
ing bracket to handle with (2) capscrews and
locknuts. Lo
INSTALL DISCHARGE CHUTE (Fig. 3)
1. Set discharge chute onto chute ring. Secure
back of chute to center hole in ring with a car-
riage bolt and sems locknut: but do not tighten.
Position nut on outside of chute.
Figure 3
7. Chute Ring 2. Discharge Chute
Note: Chute ring may be rotated to ease as-
sembly of discharge chute.
2. Secure chute to remaining holes in chute
ring and tighten all nuts.
INSTALL HANDLE (Fig. 4)
1. Remove tie securing control cable to lower
handle.
2. Secure upper and lower handles in place with
(3) handle bolts, (1) eyebolt and (4) locknuts.
Use eyebolt to mount lower left side of handle.
Eyebolt must be positioned perpendicular to
handle when tightened.
/
Figure 4
1. Lower Handle
2. Upper Handle
3. Handle Bolt
4. Eyebolt
ASSEMBLY INSTRUCTIONS
INSTALL CONTROL CABLE (Fig. 5)
1. Route control cable thru eyebolt and hook
upper end in rear hole (hole with arrow) in
control bar bracket.
~ 2. Move control bar back toward handle until
slack in cable is removed. Gap between control
bar bracket and handle should be approximate-
ly 1/16-1/8". If an adjustment is required,
refer to Adjusting Control Bar, page 7, step 3.
1/16-1/8"
Figure 5
1. Eyebolt 3. Rear Hole
2. Control Bar Bracket
BEFORE OPERATING
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DANGER: Gasoline is extremely flammable and explosive under certain conditions. Do
not smoke when handling fuel and keep fuel far away from open flames and sparks. Never buy
more than a 30 day supply of gasoline and store it in an approved container. Keep gasoline out
Refuel outdoors, only when engine is cold. Fill tank to within % to %" (6 to 13 mm) from top
of filler neck, not into filler neck. This space is for expansion of fuel. Use funnel or spout to
prevent spilling. Wipe up any spilled gas. Assure area is dry before starting engine.
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MIX GASOLINE AND OIL (Fig. 6)
1. APPROVED OIL — For simplicity and best
engine performance, mix the contents of one
8-ounce bottle of Toro 50:1 Two-Cycle Oil with
two gallons of fresh, unleaded regular gasoline.
Leaded regular gasoline may be used if unleaded
regular is not available.
Toro Two-Cycle Oil is specially formulated to
provide superior lubrication, make starting easy,
and prolong engine life. If Toro Two-Cycle Oil
is not available, mix two gallons of gasoline and
8 ounces of another high grade two-cycle oil that
has the NMMA or BIA-TCW certification printed
on the label.
IMPORTANT: YOU CAN ALSO USE TORO
“EASYMIX"” TWO-CYCLE OIL (3.2 OUNCE
BOTTLE MIXED ONE PER GALLON OF GAS-
OLINE 40:1 RATIO) IN THIS TORO TWO-
CYCLE ENGINE.
NEVER USE AUTOMOTIVE OIL (i.e. SAE 30,
10W30 etc.), TWO-CYCLE OIL THAT IS NOT
CERTIFIED NMMA/BIA-TCW OR THE
WRONG MIX RATIO BECAUSE THE ENGINE
CAN BE DAMAGED, AND IT WOULD NOT BE
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COVERED BY THE TORO WARRANTY.
2. Mixing Gasoline and Oil — Pour correct
amount of two-cycle oil into an approved gasoline
container (preferably plastic, not metal) and add
a half gallon of gasoline. Install cap on gasoline
container and shake the container to mix oil and
gas thoroughly. Remove cap and add remaining
amount of gasoline.
IMPORTANT: NEVER USE METHANOL,
GASOLINE CONTAINING METHANOL, GAS-
OHOL CONTAINING MORE THAN 10%
ETHANOL, PREMIUM GASOLINE, OR WHITE
GAS BECAUSE ENGINE FUEL SYSTEM
DAMAGE COULD RESULT.
DO NOT USE FUEL ADDITIVES OTHER
THAN THOSE MANUFACTURED FOR FUEL
STABILIZATION DURING STORAGE (SUCH
AS TORO'S PRESERVIT OR A SIMILAR
PRODUCT). ADDITIVES SHOULD NOT BE
USED TO TRY TO ENHANCE POWER OR
PERFORMANCE OF MACHINE.
NOTE: Do not mix gasoline and oil in the pro-
duct fuel tank. Qil that is at room temperature
mixes easier and more thoroughly than cold oil.
50:1 GAS/OIL Mixing Chart
U.S. GALLON
Gasoline Oil
1 Gallon 2.6 oz.
2 gallon 5.2 oz.
O
Add oil to small
amount of gasoline.
e
Install cap and
shake can to mix.
O
Add remaining
amount of gasoline.
Figure 6
5
OPERATING INSTRUCTIONS
STARTING/STOPPING ENGINE (Fig. 7)
1. CONTROLS -Key switch, primer, electric start
button and recoil start are located on control
panel. Choke is just below control panel.
Figure 7
1. Key Switch 5. Elec. start button*
2. Primer 6. Cord connection*
3. Recoil Start * ELEC START MODEL
4. Choke
2. Turn key to ON and pull choke out.
3. Cover hole in center of primer with thumb
and push once. An additional prime may be
necessary in extremely cold temperatures.
Note: Choke and primer are usually not neces-
sary when warm engine is being started.
4. ELECTRIC STARTING — Connect exten-
sion cord to snowthrower and standard
household power outlet. Push starter button.
IMPORTANT: Excessive running of the electric
starter could damage the starter due to over-
heating. To prevent possible damage, do not run
electric starter more than 10 times at intervals
of 5 seconds ‘ON’/S seconds ‘OFF’; then wait 40
minutes before continuing to run starter to
allow starter to cool. Before repeating engine
starting procedure, check that ignition key switch
is ‘ON’, and that there is fresh fuel in fuel tank.
If engine continues to fail to start, servicing
may be needed.
5. RECOIL STARTING — Hold snowthrower
with one hand and pull recoil starter vigorously
with other hand.
6. When engine starts, push in choke slowly.
7. TO ENGAGE ROTOR — Squeeze control
bar to handle.
8. TO STOP ENGINE — Release control bar,
turn key to OFF and wait for all moving parts
to stop before leaving operator's position.
1. Chute Crank 2. Chute Deflector Handle
3. Deflector Mounting Nuts
OPERATING TIPS (Fig. 8)
1. ADJUSTING DISCHARGE CHUTE—Rotate
chute crank clockwise to move discharge chute
to the right and counterclockwise to move chute
to the left. Deflector handle on top of dis-
charge chute is used to control the height of the
snow stream. Do not over tighten deflector
mounting nuts (Fig. 8) so excessive force is
required to operate deflector,
2. SELF PROPELLING ACTION — The snow-
thrower clears down to the ground and propels
itself forward when rotor blades strike the
ground. However, depth and height of snow will
affect forward speed. Always overlap each swath
and discharge downwind when possible.
3. In some snow and cold weather conditions,
some controls and moving parts may freeze
solid. Therefore, when any control becomes hard
to operate, stop the engine; then check all
parts for freeze up. DO NOT USE EXCESSIVE
FORCE WHEN TRYING TO OPERATE THE
CONTROLS IF FROZEN. Free all controls
and moving parts before operating.
4, AFTER CLEANING SNOW-Let engine
run for a few minutes so ice does not freeze
moving parts solid. After engine is shut off,
wipe ice and snow off entire unit. Operate
chute crank several times to clear mechanism
of snow,
IMPORTANT — STORE SNOWTHROWER IN
OPERATING POSITION ON ITS WHEELS.
TIPPING OR STORING UNIT ON ITS NOSE
MAY CAUSE HARD STARTING.
MAINTENANCE
GENERAL MAINTENANCE
Normally, the only maintenance required is
cleaning the unit and tightening nuts, bolts, and
screws. However, the scraper, drive belt, rotor
blades and spark plug should be checked
once a year.
ADJUSTING CONTROL BAR (Fig. 9 & 10)
Periodically check control bar for proper
adjustment,
1. Turn ignition key to OFF.
2. CHECK ADJUSTMENT-(Fig. 9) — Move
control bar back toward handle until slack in
cable is removed. Gap between control bar
bracket and handle should be approximately
1/16-1/8”. If cable is too loose or too tight
proceed to step 3 for adjustment procedure.
1/16-1/8”
Figure 9
7. Eyebolt 3. Rear Hole
2. Control Bar Bracket
3. ADJUST CABLE-(Fig. 10) — Unhook upper
cable end from hole in control bar bracket.
Slide spring cover up cable to expose cable
adjuster. Unhook cable end from cable adjuster
and reposition in a higher or lower hole on ad-
juster as required to attain proper gap of
1/16-1/8"". Reinstall upper cable end into rear
hole (hole with arrow) in control bar bracket.
Slide spring cover over cable adjuster and re-
check adjustment.
4. After extended use the drive belt may wear
and proper belt tension may not be maintained
using above procedure. If drive belt slips (con-
tinuous squealing noise) under heavy load, belt
tension may be increased by repositioning
upper cable end into forward hole in control
bar bracket and readjusting as instructed in
steps 2 and 3.
7
Figure 10
1. Spring Cover 2. Cable Adjuster
Important: Unnecessary use of forward adjust-
ing hole in control bar bracket will reduce drive
belt life. Occasional belt slippage (squealing)
may occur in extremely wet conditions. To
remove moisture from drive system, engage
rotor and operate under no load for a short
time.
DRAINING GASOLINE
1. Stop engine. Remove key from switch,
2. Remove cap from fuel tank and use pump-
type syphon to drain fuel into clean gas can.
Note: This is the only procedure recommended
for draining fuel.
REPLACING SCRAPER (Fig. 11-12)
Before each season, inspect scraper for wear. If
thickness of bottom of scraper is less than 1/16"
Figure 11
7. Scraper
MAINTENANCE
(1.6 mm), (See Figure 11), replace scraper.
1. Turn ignition key to OFF.
2. Drain gasoline from fuel tank: refer to
Draining Gasoline, page 7.
3. Tip snowthrower up onto its nose. Remove
carraige bolts and locknuts holding scraper in
place (Fig. 12). Remove scraper by sliding to
right and down.
—
Figure 12
1. Scraper 2. Carriage Bolts & Locknuts
4. Install new scraper to housing with carriage
bolts and nuts,
REPLACING DRIVE BELT (Fig. 13 & 14)
Inspect drive belt before each season. If ribs on
inside of belt are damaged or belt is worn,
replacement is necessary.
1. Turn ignition key to OFF.
2. Remove (3) seif tapping screws, (2) capscrews,
(1) washer and (2) nuts securing belt cover to
snowthrower frame (Fig. 13). Set belt cover
aside.
Figure 13
1. Capscrew & Nut 3. Long Self Tapping
2. Capscrew, Screw
4. Short Self Tapping
Screw
Nut & Washer
3. REMOVING BELT (Fig. 14) — Push down
on idler pulley allowing belt to be removed from
rotor pulley, brake arm assembly, and engine
pulley.
4. INSTALLING BELT (Fig. 14) — Loop belt
around engine pulley, under idler pulley over
roller, thru brake assembly and around rotor
pulley.
Important: Belt must be on top of roller as
shown.
5. Install belt cover. Tighten fasteners securely
but DO NOT OVERTIGHTEN.
Figure 14
1. Engine Pulley 4. Brake Assembly
2. Idler Pulley 5. Rotor Pulley
3. Roller 6. Belt Guide
REPLACING SPARK PLUG (Fig. 15, 16 & 17)
Before each snow season, check spark plug.
If electrodes in center of plug are dark or have
deteriorated, install a new plug. Use a NGK
BPMRA4A and set gap at .032” (.81 mm).
1. REMOVE CONTROL PANEL (Fig. 15) —
Remove (3) capscrews securing control panel
to housing. Remove ignition key and lift off
panel, allowing it to hang on recoil rope.
Figure 15
1. Control Panel 2. Mounting Screws
MAINTENANCE
2. REMOVE SPARK PLUG (Fig. 16) — Pull
wire off spark plug and remove plug. Examine
the plug and replace if cracked, fouled, or
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Figure 16
1. Spark Plug Wire
dirty. DO NOT SANDBLAST, SCRAPE OR
CLEAN SPARK PLUG BECAUSE DIRT MAY
RELEASE AND FALL INTO CYLINDER
CAUSING ENGINE DAMAGE.
3. INSTALL SPARK PLUG — Set air gap
(Fig. 17) between electrodes at .032” (8.1 mm).
Install plug and tighten to 15 ft-Ib (20.4 N.m).
If torque wrench is not used, tighten plug firmly.
Push wire onto spark plug and reinstall control
panel with (3) capscrews.
L 0.032”
{0.813 тт)
Figure 17
ADJUSTING CARBURETOR
The carburetor has been set at the factory, so no
adjustment is required. However, when opera-
ting snowthrower at altitudes of 5000 feet
above sea level or higher, carburetor jets may
have to be changed. Contact your local Authori-
zed Service dealer for assistance.
INSPECTING ROTOR BLADES (Fig. 18)
Before each season, inspect rotor blades for
wear. On the front (concave) side of the blade,
In the center, measure distance from end of
rotor blade to steel plate. If distance is less than
1-9/16” (39.7 mm), blades must be replaced to
assure proper performance and avoid damaging
underside of snowthrower. See figure 18 for
measuring location.
Note: Whenever rotor blades are replaced,
scraper should also be replaced to assure proper
snowthrower operation and performance.
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1-9/16”
Figure 18
1. Rotor Blade 2. Steel Plate
1. REMOVING BLADE (Fig. 19) — Remove (8)
7/16" bolts, (4) washers, and (8) locknuts se-
curing blade to rotor shaft assembly.
Figure 19
1. Bolt 4. Locknut
2. Washer 5. Thick side
3. Bushing 6. Thin side
2. Slide the blade out from between the stee
plates and push the (8) bushings out of the
blade holes (Fig. 19).
3. INSTALLING NEW BLADE — The roto
blades are made of laminated rubber. Examine
the edge of a blade to see.the difference ir
layer thicknesses (Fig.*19). (Some blades have г
part number on the thick side of the blade.
Both blades must be installed with the thick side
MAINTENANCE
facing down. If one blade is installed with the
thicker layer facing up and the other blade
installed with the thicker layer facing down, the
blades will be unbalanced, causing the snow-
thrower to “hop” or “bounce.”
4. Press the (8) bushings into the holes in the
new blade.
5, Insert the new blade between the steel plates.
Secure it to the steel plates with (4) 7/16” bolts
and (4) locknuts. Position bolt heads on thick
(bottom) side of blade. Curve the blade, and
secure it with the remaining (4) bolts, washers,
and locknuts (position bolt heads and washers
on thick side of blade). Tighten all bolts.
STORING SNOWTHROWER
1. DRAIN GASOLINE — Refer to Draining
Gasoline, page 7.
2. RUN ENGINE DRY — Start engine and let
run until it stops because there is no fuel.
When engine begins to sputter, pull out choke.
If engine does not start, pull recoil starter 5-10
times. IMPORTANT Draining fuel and
letting engine run out of fuel prevents gum-
like deposits from forming in the fuel system.
If fuel is left in the snowthrower, these deposits
will form and cause starting problems next
season.
3. CYLINDER/PISTON CARE — Slowly pull
recoil starter until resistance is felt due to
compression pressure, then stop. Release
starter tension slowly to prevent engine from
reversing due to compression pressure. This
position will close both the intake and exhaust
ports to prevent corrosion of cylinder bore,
4. TIGHTEN FASTENERS AND CLEAN —
Tighten screws, bolts, and nuts if necessary.
Repair or replace damaged parts. Clean unit
thoroughly.
5, STORE SNOWTHROWER — Cover snow-
thrower and store in a clean, dry place.
NEVER STORE SNOWTHROWER
HOUSE OR BASEMENT.
IN THE
PRODUCT IDENTIFICATION
MODEL AND SERIAL NUMBER
A model and serial number decal is located
on rear cross member, above axle. Always
refer to specific numbers on this decal in
correspondence and when replacement
parts are needed,
TORO SERVICE SUPPORT
If help — concerning safety, set-up, operation and maintenance or troubleshooting — is ever
needed, contact the local Authorized TORO Service Dealer or Distributor. Refer to the “Yellow
Pages” for assistance. In addition to skilled service technicians, the dealer and distributor have
factory approved accessories and replacement parts. Keep your TORO all TORO. Buy genuine
TORO replacement parts and accessories.
10