Form No. 3350-707 Twister 1600 Utility Vehicle Model No. 12004—Serial No. 240000001 and Up Model No. 12004TC—Serial No. 240000001 and Up Operator’s Manual Register your product at www.Toro.
Warning Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . Stopping the Vehicle . . . . . . . . . . . . . . . . . . . . . . . Parking the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . Cargo Bed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tailgate Latches . . . . . . . . . . . . . . . . . . . . . . . . . . New Vehicle Break-In . . . . . . . . . . . . . . . . . . . . . Transporting the Vehicle . . . . . . . . . . . . . . . . . . . . Loading the Cargo Box . . . . .
serial numbers of your product ready. Figure 1 illustrates the location of the model and serial numbers on the product. CAUTION, WARNING, or DANGER—“personal safety instruction.” Failure to comply with the instruction may result in personal injury or death. Warning 1 This vehicle is an off-highway vehicle only and is not designed, equipped, or manufactured for use on public streets, roads, or highways.
• Before operating the vehicle, always check the designated areas of the vehicle that are stated in the pre-starting section of this manual. If something is wrong, do not use the vehicle. Make sure that the problem is corrected before the vehicle or attachment is operated. – Use extreme caution and reduce speed around unfamiliar areas or any areas that have abrupt changes in ground conditions or elevation. – Watch for holes or other hidden hazards.
• Turning while traveling up or down hills can be dangerous. If you have to turn while on a hill, do it slowly and cautiously. Never make sharp or fast turns. Braking • Slow down before you approach an obstacle. This gives you extra time to stop or turn away. Hitting an obstacle can damage the vehicle and its contents. More important, it can injure you and your passenger. • Heavy loads affect stability.
• Reduce the weight of the load if the center of gravity is high. Items such as bricks, fertilizer, or landscape timbers stack higher in the box. The higher a load is stacked, the more likely the vehicle is to tip over. Distribute the load as low as possible, making sure that the load does not affect rear visibility. Maintenance • Position the weight of the load evenly from side to side. If you position the load toward one of the sides, the vehicle is more likely to tip over while turning.
Slope Chart ALIGN THIS EDGE WITH A VERTICAL SURFACE (TREE, BUILDING, FENCEPOST, POLE, ETC.) FOLD ALONG APPROPRIATE LINE. EXAMPLE: COMPARE SLOPE WITH FOLDED EDGE.
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. 99-7350 1. Maximum tongue weight is 50 lb. (23 kg); maximum trailer weight is 400 lb. (181 kg). 99-7952 1. Choke 2. Reverse 3. Neutral 4. Forward 99-7954 1. Warning—read the Operator’s Manual. 2. Falling hazard—do not carry passengers in the cargo bed. 3.
4-6592 1. Read the Operator’s Manual. 2. The maximum combined operator and passenger weight is 400 lb. (181 kg.). 3. The maximum cargo weight is 1200 lb. (544 kg). 4. The base weight of the vehicle is 1100 lb. (500 kg). 5. The maximum gross vehicle weight is 2700 lb. (1225 kg). 107-0704 Warning—read the Operator’s Manual. Collision hazard—do not operate the vehicle on public streets, roads, or highways. Falling hazard—do not carry passengers in the cargo bed.
104-6581 1. Warning—read the Operator’s Manual. 2. Fire hazard—before fueling, stop the engine. 3. Tipping hazard—do not drive the vehicle across or up a slope greater than 12 degrees; drive slowly when turning, when carrying a full or heavy load, and when driving on rough terrain; keep the vehicle speed under 18 MPH (29 km/h). 4. Falling and arm/leg injury hazards—do not carry passengers in the cargo bed and keep arms and legs inside of the vehicle at all times.
Setup Note: Determine the left and right sides of the machine from the normal operating position. Loose Parts Description Qty. Use Key 2 Use in ignition. Operator’s Manual 1 Read before operating the machine. Engine Operator’s Manual 1 Read before operating the machine. Operator Video 1 Watch before operating the machine. Registration Card 1 Complete and return to Toro.
Fuel Tank Filling the Fuel Tank Recommended Gasoline The fuel tank capacity is approximately 7 gallons (26.5 l). 1. Shut the engine off and set the parking brake. Use fresh, clean, unleaded regular gasoline suitable for automotive use (87 pump octane minimum). Leaded gasoline may be used if unleaded regular is not available. 2. Clean the area around the fuel tank cap (Fig. 3).
Checking the Transmission Oil Brake Pedal The transaxle fluid level should be at the bottom of the level indicator hole (Fig. 4). If it is not, fill the reservoir with the appropriate fluid; refer to Changing the Transaxle Fluid, page 28, steps 3 and 4. The brake pedal is used to stop or slow the vehicle (Fig. 5). Caution Brakes can become worn or can be misadjusted resulting in personal injury. If brake pedal travels to within 1 in.
Choke Control Hour Meter The choke control is located below and to the right of the operator’s seat. To start a cold engine, close the carburetor choke (Fig. 7) by pulling the choke control outward to the ON position. After the engine starts, regulate the choke to keep the engine running smoothly. As soon as possible, open the choke by pushing the control in to the OFF position. A warm engine requires little or no choking. The hour meter (Fig.
Passenger Hand Holds 4. After the engine starts and warms up, slowly return the choke knob to the Off position. If the engine stalls or hesitates, pull the Choke out for a few seconds. Then move it back to Off. The passenger hand holds are located on the right side of the dash panel and at the outside of each seat (Fig. 10). 2 1 5. Disengage the parking brake. 6. Slowly step on the accelerator pedal. Important Do not attempt to push or tow the vehicle to get it started.
3. Raise the bed to its full height; then lower it slightly to engage the prop rod (Fig. 12). 2. To close the tailgate latches, lift the handles upward and slide them toward the outside of the vehicle. 3. Push the latch handles downward to secure the latch and tailgate. New Vehicle Break-In 1 To provide proper performance and long vehicle life, follow these guidelines for the first 100 operating hours.
Warning Towing at excessive speeds could cause a loss of steering control, resulting in personal injury. Never tow the vehicle faster than 5 MPH (8 km/h). Towing the vehicle is a two person job. If the machine must be moved a considerable distance, transport it on a truck or trailer; refer to Transporting the Vehicle, page 17. 1 1 1. Remove the drive belt; refer to Replacing the Drive Belt, page 26, steps 1 and 2. Figure 14 2. Affix a tow line to the tongue on the front of the frame (Fig. 15). 1.
Avoid parking a vehicle with a trailer on a hill. If you must park on a hill, engage the parking brake and block the trailer tires. Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule Important Refer to your engine operator’s manual for additional maintenance procedures. Maintenance Service Interval After first 8 hours Every 8 hours After first 20 hours Maintenance Procedure • Change the engine oil.
Caution If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition and disconnect the wire(s) from the spark plug(s) before you do any maintenance. Set the wire(s) aside so that it does not accidentally contact the spark plug(s). Jacking the Vehicle Warning Whenever the engine is run for routine maintenance and/or engine diagnostics, the rear wheels of the vehicle should be 1 in.
3. Tighten one of the locknuts (Fig. 18) just enough to take the slack out of the shift cable. Note: You must hold the threaded shaft below the bracket to tighten the locknut on top. 4. Tighten the other locknut just enough to take the slack out of the other shift cable. 5. Pull up on each shift cable an ensure that there is no gap between the nut/washer and the neutral bracket (Fig. 19). If there is a gap, tighten the nut. 1 1 2 2 Figure 17 1.
USE THESE SAE VISCOSITY OILS Changing the Oil Filter Replace the oil filter every 100 operating hours or yearly, whichever occurs first. 1. Drain the oil from the engine; refer to Changing and Draining the Oil, page 22. 2. Remove the existing oil filter (Fig. 20). Apply a light coat of clean oil to the new filter gasket. –20 °F 0 –30 °C –20 20 –10 40 0 60 10 80 20 100 30 3. Screw the filter on until gasket contacts mounting plate, then tighten filter an additional 1/2 to 3/4 turn further.
4. Gently slide the filter out of the air cleaner body to reduce the amount of dust dislodged (Fig. 21). Avoid knocking the filter against the air cleaner body. 2. Compressed air method: A. Blow compressed air from the inside to the outside of the dry filter element. Keep the air hose nozzle at least 2 inches (51 mm) from the filter and move the nozzle up and down while rotating the filter element. 5. Inspect the filter and discard it if it is damaged.
Checking the Brake Fluid Level The brake fluid reservoir is filled and shipped from the factory with DOT 3 brake fluid. Check the level before the engine is first started and every 8 hours or daily, thereafter. 1. Park the machine on a level surface, set the parking brake, turn the ignition off, and remove the key. 2. Look at the side of the reservoir. The level should be above the Minimum line (Fig. 24).
• Measure the ride height on a flat surface, from the bottom of the front tongue to the ground. 1. Jack the front end of the vehicle off of the ground; refer to Jacking the Vehicle, page 20. 2. Remove the travel limiting bolt (Fig. 25). 3. Loosen the centering bolts in the front A-arm (Fig. 25). 4. Remove the ride height adjustment bolt (Fig. 25). 2 1 m–5640 Figure 26 1. Left-hand A-arm 6. Torque the ride height adjustment bolt to 135–165 ft.-lb. (183–224 N⋅m). 3 2 1 7.
If the vehicle will be run with medium to heavy loads most of the time, set the toe-in on the high side of the recommended amount. If it is going to be run with a light load most of the time, set the toe-in on the low side of the recommended amount. 4. Rotate both tie rods to move the front of the tire inward or outward. 1. Ensure that the front suspension is adjusted properly; refer to Adjusting the Front Suspension, page 24. Adjust if necessary. 6.
Servicing the Fuel System 3. Remove the 3 bolts securing the cover to the clutch and remove the cover (Fig. 30). Fuel Lines and Connections Check lines and connections every 400 hours or yearly, whichever occurs first. Inspect for deterioration, damage, or loose connections. Replacing the Fuel Filter 1 2 Replace the fuel filter after every 800 operating hours or yearly, whichever occurs first. m–6988 1. Raise the bed and support it with the prop rod. Figure 30 1. Cover 2.
2. Pull the spark plug wires off of the spark plugs and remove the plugs from the cylinder head. 3. Check the condition of the side electrode, center electrode, and center electrode insulator to ensure that there is no damage. 1 0.030 in. (0.76 mm) 2 m–4849 Figure 34 Figure 33 1. Drain plug Important A cracked, fouled, dirty or malfunctioning spark plug must be replaced.
1 2 3 Servicing the Battery 4 Warning Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. m–5362 Figure 36 1. Charge circuit 2. Headlights Important 3. Power point 4. Low oil light, hour meter Do not jump start the vehicle. Replacement bulb: GE #862 Always keep the battery clean and fully charged. Use a paper towel to clean the battery and battery box.
3. Install the battery in the chassis; refer to Installing the Battery, page 30. Warning Battery terminals or metal tools could short against metal vehicle components, causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Storing the Battery If the machine will be stored for more than 30 days, remove the battery and charge it fully. Either store it on the shelf or on the machine. Leave the cables disconnected if it is stored on the machine.
Schematics m-7377 Electrical Schematic 31
The Toro Total Coverage Guarantee Consumer Vehicles A One-Year Limited Warranty Conditions and Products Covered Items and Conditions Not Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair any Toro Product used for residential or commercial use if defective in materials or workmanship for a period of one year from the date of purchase.
