Form No. 3355-562 Rev A Twister® 1600 Utility Vehicle Model No. 12004TC—Serial No. 260000001 and Up Register your product at www.Toro.
This spark ignition system complies with Canadian ICES-002 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. Introduction Contents Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage. You are responsible for operating the product properly and safely. Introduction .............................
Recommended Maintenance Schedule(s) ............................... 27 Premaintenance Procedures....................... 28 Maintaining the Vehicle under Special Operating Conditions ........................ 28 Jacking the Vehicle............................. 28 Lubrication................................................ 28 Adding Grease .................................. 28 Engine Maintenance.................................. 29 Servicing the Air Cleaner ................... 29 Servicing the Engine Oil .....
Safety • Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means Caution, Warning, or Danger—“personal safety instruction.” Failure to comply with the instruction may result in personal injury or death. • • The vehicle is an off-highway vehicle only and is not designed, equipped, or manufactured for use on public streets, roads, or highways.
Keep your arms and legs within the vehicle body at all times. – Watch out for traffic when you are near or crossing roads. Always yield the right of way to pedestrians and other vehicles. This vehicle is not designed for use on streets or highways. Always signal your turns or stop early enough so that other people know what you plan to do. Obey all traffic rules and regulations. • Drive slower and turn less sharply when you are carrying a passenger.
as long to stop on wet surfaces as on dry surfaces. If you drive through standing water deep enough to get the brakes wet, they will not work well until they are dry. After driving through water, you should test the brakes to make sure they work properly. If they do not, drive slowly while putting light pressure on the brake pedal. This will dry the brakes out. • Avoid stopping on hills, especially with a load. Stopping while going down a hill will take longer than stopping on level ground.
the vehicle is to tip over. Distribute the load as low as possible, making sure that the load does not affect rear visibility. • The rear cargo space is intended for load carrying purposes only, not for passengers. • Never overload your vehicle. The decal (located on the rear frame) shows load limits for the vehicle. Never overload the attachments or exceed the Gross Vehicle Weight (GVW). • Position the weight of the load evenly from side to side.
Sound Pressure This unit does not exceed a whole body vibration level of 0.5 m/s2, based on measurements of identical machines per EN 1032. This unit has a maximum sound pressure level at the operator’s ear of 80 dBA, based on measurements of identical machines per EN 11094. Safety and Instructional Decals Vibration This unit does not exceed a hand/arm vibration level of 2.5 m/s2, based on measurements of identical machines per EN 1033.
9–7345 99–7350 1. Warning—read the Operator’s Manual. 2. Hot surface/burn hazard—stay a safe distance from the hot surface. 3. Entanglement hazard, belt—stay away from moving parts 4. Crushing hazard, cargo box—use the prop rod to support the cargo bed 1. Maximum tongue weight is 50 lb (23 kg); maximum trailer weight is 400 lb (181 kg). 104–6592 1. 2. 3. 4. Read the Operator’s Manual. The maximum combined 5. operator and passenger weight is 400 lb (181 kg).
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Step 1 2 3 4 5 6 7 8 9 Qty. Description Use Wheel assembly 4 Install the wheels. Steering wheel 1 Install the steering wheel. Bumper 1 Install the bumper. Seat 2 Install the seats. Hitch 1 Install the hitch. Cargo box Right-hand pivot bracket Left-hand pivot bracket Flange head screw (3/8 x 1 inch) Bolt (5/16 x 3/4 inch) Flange nut (5/16 inch) 1 1 1 4 1 1 Install the cargo box.
Step Step 1 2 Installing the Wheels Installing the Steering Wheel Parts needed for this step: 4 Parts needed for this step: Wheel assembly 1 Steering wheel Procedure 1. Remove the fasteners securing the wheels. Procedure 2. Remove the shipping bracket secured to the wheel studs. 1. Remove the nut and lock washer from the steering shaft. 3. Mount the wheels with the previously removed fasteners (Figure 3) and torque to 45-65 ft-lb (61-88 N⋅m). 2.
Step Step 3 4 Installing the Bumper Installing the Seats Parts needed for this step: Parts needed for this step: 1 Bumper 2 Seat Procedure Procedure 1. Remove the 4 bolts and lock nuts secured to the front of the frame. Insert the seat bracket into the seat base opening and pivot the seat downward (Figure 6). 2. Align the mounting holes and secure the bumper to the frame with the fasteners previously removed (Figure 5). Figure 6 1. Seat bracket Figure 5 1. Bumper 2. Bolt 3. 4.
Step Step 5 6 Installing the Hitch Installing the Cargo Box Parts needed for this step: Parts needed for this step: 1 1 1 1 4 1 1 Hitch Procedure 1. Remove the 4 bolts and nuts from the inside rear of the frame. 2. Align the hitch with the mounting holes on the frame. Secure the hitch with the screws and nuts (Figure 7). Cargo box Right-hand pivot bracket Left-hand pivot bracket Flange head screw (3/8 x 1 inch) Bolt (5/16 x 3/4 inch) Flange nut (5/16 inch) Procedure 1.
Step 7 Activating the Battery No Parts Required Procedure None Figure 9 1. Cargo box 2. Pivot bracket 3. Note: This procedure is only needed for Model No. 07277TC. Cargo box mounting hole If the battery is not filled with electrolyte or activated, it must be removed from the vehicle, filled with electrolyte, and charged. Bulk electrolyte with 1.260 specific gravity must be purchased from a local battery supply outlet. 4.
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. Charging the battery produces gasses that can explode. Never smoke near the battery and keep sparks and flames away from battery. 1.
Figure 12 1. Jam nut 2. Tie rod 3. Rotate both tie rods to move the front of the tire inward or outward. 4. Tighten the tie rod jam nuts when the adjustment is correct. 5. Ensure that there is full travel of the steering wheel in both directions.
Product Overview Figure 13 1. Steering wheel 2. Gear shift selector 3. 4. Parking brake Fuel cap 5. Cargo box 6. Towing tounge 7. Cargo box release lever Controls Brake Pedal Accelerator Pedal The brake pedal is used to stop or slow the vehicle (Figure 14). The accelerator pedal (Figure 14) gives the operator the ability to vary ground speed of the vehicle. Pressing the pedal increases ground speed. Releasing the pedal will slow the vehicle. Maximum forward speed is 18 mph (26 km/h).
to start the engine. When the engine starts, release the key. When the vehicle is stopped, rotate the key counterclockwise to the Off position to stop the engine. Remove the key from the ignition. Figure 15 1. Parking brake lever Choke Control The choke control is located below and to the right of the operator’s seat. To start a cold engine, pull the choke control outward (Figure 16). After the engine starts, regulate the choke to keep the engine running smoothly.
Figure 18 1. Fuel gauge Passenger Hand Holds The passenger hand holds are located on the right side of the dash panel and at the outside of each seat (Figure 19). Figure 19 1. Passenger hand hold 2.
Specications Note: Specifications and design are subject to change without notice. Base weight Dry 1050 lb (476 kg) Rated capacity (on level ground) 1600 lb (726 kg) total, including 200 lb (90.7 kg) operator and 200 lb (90.
Operation Note: Determine the left and right sides of the machine from the normal operating position. Think Safety First Please carefully read all of the safety instructions and decals in the safety section. Knowing this information could help you or bystanders avoid injury. Figure 20 1. Oil dipstick Pre-Starting Checks 3. Remove the oil dipstick and wipe the end clean. Check the following items each time you begin using the vehicle for the day: 4.
Adding Fuel 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. In certain conditions during fueling, static electricity can be released causing a spark which can ignite the gasoline vapors. A fire or explosion from gasoline can burn you and others and can damage property.
Stopping the Vehicle space in the tank allows gasoline to expand. Do not overfill. To stop the vehicle, remove your foot from the accelerator pedal and slowly press the brake pedal. 5. Install the fuel tank cap securely. Wipe up any fuel that may have spilled. Note: Stopping distance may vary depending on the vehicle load and speed. Checking the Transmission Oil Level Parking the Vehicle The transaxle fluid level should be at the bottom of the level indicator hole (Figure 22).
2. Turn the latch post clockwise until it is snug against the latch and then tighten the nut (Figure 25). 3. Repeat this procedure for the latch on the other side of the vehicle. Operating the Tailgate Latches 1. To open the tailgate latches, lift the latch handles up (Figure 26). The latches will spring out toward the center of the tailgate. Slowly lower the tailgate. Figure 24 1.
• Vary the vehicle speed during operation. Avoid fast starts and quick stops. Loose seats may fall off of the vehicle and trailer when transporting and land on another vehicle or become an obstruction on the road. • A break-in oil for engine is not required. Original engine oil is the same type specified for regular oil changes. • Refer to the Maintenance section for any special low hour checks. Remove the seats or make sure that the seats are securely fastened in the detents.
Figure 28 1. Towing tongue and tie down point Towing a Trailer The vehicle is capable of pulling trailers. Two types of tow hitches are available for the vehicle, depending on your application. Contact your Authorized Toro Distributor for details. When hauling cargo or towing a trailer, do not overload your vehicle or trailer. Overloading can cause poor performance or damage to the brakes, axle, engine, transaxle, steering, suspension, body structure, or tires.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the rst 8 operating hours • Change the engine oil. • Check the condition and tension of the drive belt. After the rst 25 operating hours • Check the front wheel toe-in and front suspension. Before each use or daily • • • • Check the engine oil. Check the tire pressure. Check the transmission oil level.
Premaintenance Procedures (Figure 29) The jacking point at the rear of the vehicle is under the axle tubes (Figure 30). Maintaining the Vehicle under Special Operating Conditions If the vehicle is subjected to any of the conditions listed below, maintenance should be performed twice as frequently.
4. Gently slide the filter out of the air cleaner body to reduce the amount of dust dislodged (Figure 33). Avoid knocking the filter against the air cleaner body. Figure 31 Figure 33 1. 2. Figure 32 Air cleaner latches Cover 3. Filter 5. Inspect the filter and discard it if it is damaged. Engine Maintenance Cleaning the Filter Element Important: Do not wash or reuse a damaged filter.
1. 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. Viscosity: See the table below Important: To prevent damage to the filter element, do not exceed 100 psi (689 kPa) air pressure. 2. Inspect the filter element for holes and tears by looking through the filter toward a bright light.
6. Pour oil into the fill opening until the oil level is up to the Full mark on the dipstick. Add the oil slowly and check the level often during this process. Do not overfill. 7. Install the oil fill cap and dipstick firmly in place. 8. Connect the spark plug wires and battery cables. 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 the Oil. 2. Remove the existing oil filter (Figure 35). 3.
3. Remove the clamps securing the fuel filter to the fuel lines (Figure 37), as follows: A. Squeeze the clamp tabs together and slide the clamps up the hose off of the filter hose fittings. B. Pull the hose ends off of the filter hose fittings. Figure 38 1. Charge circuit 2. Lights 3. 4. Power point Low oil light and hour meter Replacing the Headlights Figure 37 Specification: GE #862 1. Set the parking brake, turn the ignition off, and remove the key. 2. Switch the headlights off. 3.
Servicing the Battery Important: Do not jump start the vehicle. 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. Always keep the battery clean and fully charged. Use a paper towel to clean the battery and battery box. If the battery terminals are corroded, clean them with a solution of four parts water and one part baking soda.
Charging the battery produces gasses that can explode. Never smoke near the battery and keep sparks and flames away from battery. 3. Install the battery in the chassis; refer to Installing the Battery. 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.
Inspecting the Tires Check the tire condition at least every 100 hours of operation. Operating accidents, such as hitting curbs, can damage a tire or rim and also disrupt wheel alignment, so inspect tire condition after an accident. Check the wheels to ensure that they are mounted securely. Torque the lug nuts to 45-65 ft-lb (61-88 N⋅m). Adjusting the Front Suspension Figure 42 The ride height of each side of the vehicle can be adjusted separately. The ride height should be 8-3/4 to 9-1/2 inches (22.
Note: The driver should drive up to the measurement area and stay seated in the vehicle while the measurement is being taken. 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. 1. Ensure that the front suspension is adjusted properly; refer to Adjusting the Front Suspension. Adjust if necessary. 2.
The dust in the clutch will become airborne and could damage your eyes or you could inhale it causing breathing difficulties. Wear safety goggles and a dust mask or other eye and respiratory protection when performing this procedure. Figure 45 1. Jam nut 2. Tie rod 5. Lubricate the moving parts in the areas circled in Figure 47 using Toro Dry Lubricant Spray, available through your Authorized Toro Dealer or Distributor. 4. Rotate both tie rods to move the front of the tire inward or outward. 5.
Important: Never clean the engine with pressurized water because water could contaminate the fuel system. Brake Maintenance Inspecting the Brakes Brakes are a critical safety component of the vehicle. As with all safety components, they should be closely inspected at regular intervals to ensure optimum performance and safety. The following inspections should be done every 100 hours: Figure 48 1. Drain plug 2. Level indicator hole 3. Fill the reservoir (Figure 49) with approximately 1-1/2 qt. (1.
1. Park the machine on a level surface, shift into Neutral, set the parking brake, turn the ignition off, and remove the key. 2. Raise the bed and secure it with the prop rod. 3. Rotate and inspect the belt (Figure 52) for excessive wear or damage. Replace the belt if necessary. Figure 50 1. Brake uid reservoir 2. Minimum line Adjusting the Parking Brake Check the parking brake adjustment every 200 hours. 1. Pry the rubber cover off of the parking brake. 2.
Storage G. Dispose of fuel properly. Recycle as per local codes. 1. Position the machine on a level surface, set the parking brake, stop the engine, and remove the ignition key. 2. Clean dirt and grime from the entire machine, including the outside of the engine’s cylinder head fins and blower housing. 3. 4. 5. 6. 7. 8. Important: Do not store stabilizer/conditioned gasoline over 90 days 9. Remove the spark plugs and check their condition; refer to Changing Spark Plugs in Engine Maintenance, page 29.
Schematics Electrical Schematic (Rev.
