Form No. 3328-504 Twister 1600 Utility Vehicle Model No. 12004—Serial No. 230000001 and Up Model No. 12004TC—Serial No.
Warning Think Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pre-Starting Checks . . . . . . . . . . . . . . . . . . . . . . . . Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . Stopping the Vehicle . . . . . . . . . . . . . . . . . . . . . . . Parking the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . Cargo Bed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. 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.
• 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 extra caution when operating the vehicle on wet surfaces, in adverse weather conditions, at higher speeds, or with a full load. Stopping time and distance will increase with a full load. – Avoid sudden stops and starts.
• Avoid stopping on hills, especially with a load. Stopping while going down a hill will take longer than stopping on level ground. If the vehicle must be stopped, avoid sudden speed changes, which may initiate tipping or rolling of the vehicle. Do not slam on the brakes when rolling backward, as this may cause the vehicle to overturn. • Gross Vehicle Weight (GVW) has a major impact on your ability to stop and/or turn. Heavy loads and attachments make a vehicle harder to stop or turn.
• Position the weight of a load evenly from front to back. If you position the load behind the rear axle, it will reduce the weight on the front wheels. This may result in a loss of steering control or cause the vehicle to tip over on hills or bumpy terrain. • Never use an open flame to check the level or leakage of fuel or battery electrolyte.
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). 99-7951 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.
Checking the Crankcase Oil Fuel Tank The engine is shipped with oil in the crankcase; however, the level of the oil must be checked before and after the engine is first started. Recommended Gasoline 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. 1. Position the machine on a level surface. 2. Clean around the oil dipstick (Fig. 2) so dirt cannot fall into the hole and damage the engine.
Filling the Fuel Tank Checking the Transmission Oil The fuel tank capacity is approximately 7 gallons (26.5 l). 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. 1. Shut the engine off and set the parking brake. 2. Clean the area around the fuel tank cap (Fig. 3). 1 1 m–4849 Figure 4 Figure 3 1. Level indicator hole 1. Fuel tank cap 3.
Brake Pedal Choke Control The brake pedal is used to stop or slow the vehicle (Fig. 5). 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.
Light Switch Passenger Hand Holds Toggle the switch to activate the headlights. Push to turn the lights on (Fig. 8). 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 Power Point The power point is used to power 12 volt, optional electrical accessories (Fig. 8). 3 4 m–4887 Figure 10 1. Passenger hand hold 2 1 5 Pre-Starting Checks m–4885 Safe operation begins before taking the vehicle out for a day’s work.
3. Insert the key into the ignition switch, turn it clockwise to the Start position, and pull the choke out. When the engine starts, release the key. 3. Raise the bed to its full height; then lower it slightly to engage the prop rod (Fig. 12). Note: An engine that has been running and is warm may not require pulling the choke out. 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.
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 To provide proper performance and long vehicle life, follow these guidelines for the first 100 operating hours. • Check the fluid and engine oil levels regularly and be alert for indications of overheating in any component of the vehicle.
Towing a Trailer Warning 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 Dealer for details. 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). When hauling cargo or towing a trailer, do not overload your vehicle or trailer.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule Maintenance Service Interval After first 8 hours Every 8 hours After first 20 hours Maintenance Procedure • Change the engine oil. • Check the drive belt tension. • Check the engine oil. • Check the tire pressure. • Check the front wheel toe-in at the proper ride height. Every 50 hours • Check the battery fluid level. • Check the battery cable connections.
The jacking point at the front of the vehicle is on the front of the frame behind the towing tongue (Fig. 16) The jacking point at the rear of the vehicle is under the axle tubes (Fig. 17). Warning The bed must be raised to perform some routine maintenance. The bed could fall and injure persons that are underneath it. • Always use prop rod to hold bed up before working under raised bed. • Remove any load material from bed before working under raised bed.
Servicing the Engine Oil Check the oil level before each use. 2 Change the oil after the first 8 operating hours and every 50 hours thereafter. 1 Replace the oil filter every 100 hours. Note: Change the oil and oil filter more frequently when operating conditions are extremely dusty or sandy. Oil Type: Detergent oil (API service SF, SG, SH, SJ, or higher) Crankcase Capacity: 48 oz./1-1/2 qt. (1.4 liters) when the filter is changed USE THESE SAE VISCOSITY OILS Figure 18 1. Neutral bracket 2.
Servicing the Air Cleaner Check the air cleaner body for damage which could possibly cause an air leak. Replace a damaged air cleaner body. Ensure that the cover is sealing around the air cleaner body. Air Cleaner Filter: Inspect after every 100 operating hours; replace after every 200 hours or sooner if dirty or damaged. 1 Note: Service the air cleaner more frequently (every few hours) if operating conditions are extremely dusty or sandy. 2 Figure 20 1. Engine oil drain plug 2.
B. After soaking the filter for 15 minutes, rinse it with clear water. Rinse the filter from the clean side to the dirty side. 2. Pump grease into the bearing or bushing. 3. Wipe off excess grease. Important To prevent damage to the filter element, maximum water pressure must not exceed 40 psi (276 kPa). C. Dry the filter element using warm, flowing air at 160°F (71°C) maximum, or allow the element to air-dry. Important Do not use a light bulb to dry the filter element because damage could result. 2.
• Measure the ride height with the wheels facing straight ahead and a 175–225 lb. (79–102 kg) operator in the driver’s seat. 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. Note: The driver should drive up to the measurement area and stay seated in the vehicle while the measurement is being taken. 1.
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, page 25. Adjust if necessary. 2. Measure the distance between both of the front tires at the axle height at both the front and rear of the front tires (Fig. 27).
Servicing the Fuel System 4. Rotate both tie rods to move the front of the tire inward or outward. Fuel Lines and Connections 5. Tighten the tie rod jam nuts when the adjustment is correct. Check lines and connections every 400 hours or yearly, whichever occurs first. Inspect for deterioration, damage, or loose connections. 6. Ensure that there is full travel of the steering wheel in both directions.
Checking and Replacing the Spark Plug 1. Clean the area around the spark plugs so that foreign matter cannot fall into the cylinder when the spark plug is removed. 2. Pull the spark plug wires off of the spark plugs and remove the plugs from the cylinder head. 1 3. Check the condition of the side electrode, center electrode, and center electrode insulator to ensure that there is no damage. 2 m–4849 0.030 in. (0.76 mm) Figure 32 1. Drain plug 2. Level indicator hole 3. Fill the reservoir (Fig.
Replacing the Fuses 3 There are 4 fuses in the electrical system. They are located beneath the bed in a box on the right hand side of the frame (Fig. 34). Low oil light, hour meter 10 amp. Headlights 10 amp. Charge circuit 25 amp. Power point 4 2 m–4849 10 amp. (15 amp. max.) 1 2 1 Figure 35 1. Lamp assembly 2. Reflector 3 3. Tabs 4. Slots 4. Push the replacement lamp assembly onto the wire harness. 4 5.
Warning Warning Incorrect battery cable routing could damage the vehicle and cables, causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Charging the battery produces gasses that can explode. Never smoke near the battery and keep sparks and flames away from battery. • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable.
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.
