Toro 12004TC Twister 1600, Operator'S Manual

Page 1: ...Form No 3356 938 Rev A Twister 1600 Utility Vehicle Model No 12004TC Serial No 270000001 and Up G002164 Register at www Toro com Original Instructions EN ...

Page 2: ...pecial mechanical information and Note emphasizes general information worthy of special attention Contents Introduction 2 Safety 3 Before Operating 3 Operation 4 Maintenance 6 Sound Pressure 7 Vibration 7 Safety and Instructional Decals 7 Setup 10 1 Installing the Wheels 11 2 Installing the Steering Wheel 11 3 Installing the Bumper 12 4 Installing the Seats 12 5 Installing the Hitch 13 6 Installin...

Page 3: ...ctured for use on public streets roads or highways Before Operating Operate the machine only after reading and understanding the contents of this manual Never allow children to operate the vehicle Anyone who operates the vehicle should have a motor vehicle license Never allow other adults to operate the vehicle without first reading and understanding the Operator s Manual Make sure that all operat...

Page 4: ...esult in an accident tip over of the vehicle and serious injury or death Drive carefully To prevent tipping or loss of control Use extreme caution reduce speed and maintain a safe distance around sand traps ditches creeks ramps unfamiliar areas or any areas that have abrupt changes in ground conditions or elevation Watch for holes or other hidden hazards Use extra caution when operating the vehicl...

Page 5: ...all and you could lose headway on the hill This could result in personal injury Do not accelerate quickly or slam on the brakes when backing down a hill especially with a load If the engine stalls or you lose headway on a hill slowly back straight down the hill Never attempt to turn the vehicle around Operate the vehicle slowly on a hill and use caution Avoid turning on a hill Reduce your load and...

Page 6: ...control or cause the vehicle to tip over on hills or bumpy terrain Use extra caution if the load exceeds the dimensions of the box and when handling off center loads that cannot be centered Keep loads balanced and secure to prevent them from shifting Always secure loads so that they do not shift If a load is not secured or you are transporting a liquid in a large container such as a sprayer the lo...

Page 7: ...it does not exceed a hand arm vibration level of 2 5 m s2 based on measurements of identical machines per EN 1033 This unit does not exceed a whole body vibration level of 0 5 m s2 based on measurements of identical machines per EN 1032 Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger Replace any dec...

Page 8: ...surface 3 Entanglement hazard belt stay away from moving parts 4 Crushing hazard cargo box use the prop rod to support the cargo bed 99 7952 1 Choke 3 Neutral 2 Reverse 4 Forward 99 7954 1 Warning read the Operator s Manual 2 Falling hazard do not carry passengers in the cargo bed 3 Explosion hazard static discharge into fuel container do not fill fuel containers in the cargo bed place fuel contai...

Page 9: ... for the optional Electric Bed Lift Kit 2 10 amp fuse for the optional Road Light Kit 6 10 amp fuse for the low oil light and the hour meter 3 15 amp fuse for the optional Rear Lift Kit 7 10 amp fuse for the headlights 4 10 amp fuse open 8 25 amp fuse for the charge circuit 9 ...

Page 10: ...ft hand pivot bracket 1 Flange head screw 3 8 x 1 inch 4 Bolt 5 16 x 3 4 inch 1 6 Flange nut 5 16 inch 1 Install the cargo box 7 No parts required Activate the battery 8 No parts required Adjust the front wheel toe in Operator s Manual 1 Engine Operator s Manual 1 Parts Catalog 1 Safety Video 1 Registration Card 1 Predelivery Inspection Form 1 9 Key 2 Read the Operator s Manual and watch the video...

Page 11: ...n 2 Wheel nut 2 Installing the Steering Wheel Parts needed for this procedure 1 Steering wheel Procedure 1 Remove the nut and washer from the steering shaft 2 Slide the steering wheel and washer onto the shaft Position the steering wheel on the shaft so that the cross beam is horizontal when the tires are pointed straight ahead and the thicker spoke of the steering wheel is downward 3 Secure the s...

Page 12: ...lign the mounting holes and secure the bumper to the frame with the fasteners previously removed Figure 5 Figure 5 1 Bumper 3 Frame 2 Bolt 4 Lock nut 4 Installing the Seats Parts needed for this procedure 2 Seat Procedure Insert the seat bracket into the seat base opening and pivot the seat downward Figure 6 Figure 6 1 Seat bracket 2 Seat base 12 ...

Page 13: ...r this procedure 1 Cargo box 1 Right hand pivot bracket 1 Left hand pivot bracket 4 Flange head screw 3 8 x 1 inch 1 Bolt 5 16 x 3 4 inch 1 Flange nut 5 16 inch Procedure 1 Position the cargo box onto the frame The cargo box must lay flat and be centered 2 Mount the left hand pivot bracket to the left rear corner of the frame with 2 flange head screws 3 8 x 1 inch Position the bracket as shown in ...

Page 14: ... electrolyte contains sulfuric acid which is a deadly poison and causes severe burns Do not drink electrolyte or allow it to contact your skin eyes or clothing Wear safety glasses to shield your eyes and rubber gloves to protect your hands Fill the battery where clean water is always available for flushing the skin 2 Remove the filler caps from the battery and slowly fill each cell until electroly...

Page 15: ... load most of the time set the toe in on the low side of the recommended amount 1 Measure the distance between both of the front tires at the axle height at both the front and rear of the front tires Figure 11 A fixture or alignment gauge is needed for the rear measurement of the front tires at axle height Use the same fixture or alignment gauge to accurately measure the front of the front tires a...

Page 16: ...perator s Manual 1 Parts Catalog 1 Safety Video 1 Registration Card 1 Predelivery Inspection Form 2 Key Procedure Read the Operator s Manual and Engine Operator s Manual View the safety video Fill out the registration card Complete the Predelivery Inspection Form and file it in your customer history portfolio 16 ...

Page 17: ...he brake pedal is used to stop or slow the vehicle Figure 14 Brakes can become worn or can be misadjusted resulting in personal injury If brake pedal travels to within 1 inch 25 mm of the vehicle floor board the brakes must be adjusted or repaired Parking Brake The parking brake is between the seats Figure 15 Whenever the engine is shut off the parking brake must be engaged to prevent accidental m...

Page 18: ...e to the Start position 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 17 1 Ignition switch 4 Oil light 2 Hour meter 5 Power Point 3 Light switch 6 Horn Button Hour Meter The hour meter Figure 17 indicates the total number of hours the engine has ru...

Page 19: ...re 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 Hip restraint 19 ...

Page 20: ...vailable for use with the machine to enhance and expand its capabilities Contact your Authorized Service Dealer or Distributor or go to www Toro com for a list of all approved attachments and accessories 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...

Page 21: ...nimized Lower pressure should not be used for heavy payloads at high speeds Higher pressures should be used for heavier payloads at higher speeds Do not exceed the maximum pressure 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 Important Never use gasoline containing methanol ...

Page 22: ...ck This space in the tank allows gasoline to expand Do not overfill 5 Install the fuel tank cap securely Wipe up any fuel that may have spilled Checking the Transmission Oil Level The transaxle fluid level should be at the bottom of the level indicator hole Figure 22 If it is not fill the reservoir with the appropriate fluid refer to Changing the Transaxle Fluid in Drive System Maintenance page 33...

Page 23: ...s and other body parts clear when lowering the box Pull the prop rod out of the detent slot and lower the box until it latches into place Adjusting the Box Latches If the box latch does not latch tightly vibrating up and down as you drive the vehicle you can adjust the latch posts to make the latches fit snugly 1 Loosen the nut on the end of the latch post Figure 25 Figure 25 1 Latch 3 Latch post ...

Page 24: ...spension in Drive System Maintenance page 33 Loading the Cargo Box The capacity of the cargo box is 13 ft3 0 37 m3 The amount volume of material that can be placed in the box without exceeding the vehicle load ratings can vary greatly depending on the density of the material For example a level box of wet sand weighs 1500 lb 680 kg which exceeds the load rating by 300 lb 136 kg But a level box of ...

Page 25: ...our 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 Always load a trailer with 60 of the cargo weight in the front of the trailer This places approximately 10 of the Gross Tra...

Page 26: ...r to Maintaining the Vehicle under Special Operating Conditions Change the oil filter twice as often in special operating conditions refer to Maintaining the Vehicle under Special Operating Conditions Check the operation of the Neutral gear shift position Inspect the condition and wear of the tires Torque the wheel lug nuts to 45 65 ft lb 61 88 N m Check the front wheel toe in and front suspension...

Page 27: ... all grease fittings and inspect air cleaner daily to prevent excessive wear Jacking the Vehicle Whenever the engine is run for routine maintenance and or engine diagnostics the rear wheels of the vehicle should be 1 inch 25 mm off the ground with the rear axle supported on jack stands The vehicle may be unstable when using a jack It could slip off the jack injuring anyone beneath it Do not start ...

Page 28: ...ery 100 operating hours replace after every 200 hours or sooner if dirty or damaged Note Service the air cleaner more frequently every few hours if operating conditions are extremely dusty or sandy Removing the Filter Element 1 Park the machine on a level surface set the parking brake turn the ignition off and remove the key 2 Raise the bed and secure it with the prop rod 3 Release the latches sec...

Page 29: ...nsert the new filter into air cleaner body Ensure the filter is sealed properly by applying pressure to the outer rim of the filter when installing it Do not press on the flexible center of the filter 3 Install the cover and secure the latches Servicing the Engine Oil Check the oil level before each use Change the oil after the first 8 operating hours and every 50 hours thereafter Change the oil t...

Page 30: ...o ensure proper engine performance and reduce the exhaust emission level Type Champion RC 14YC or equivalent Air Gap 0 030 inch 0 762 mm Note The spark plugs usually lasts a long time however the plugs should be removed and checked whenever the engine malfunctions 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 ...

Page 31: ...hose ends off of the filter hose fittings Figure 37 1 Fuel filter 4 Install the replacement filter to the fuel lines with the clamps previously removed Mount the filter so that the arrow points toward the carburetor Electrical System Maintenance Replacing the Fuses There are 3 fuses in the electrical system They are located beneath the bed in a box on the right hand side of the frame Figure 38 Cha...

Page 32: ...s Sparks can cause the battery gasses to explode resulting in personal injury Always disconnect the negative black battery cable before disconnecting the positive red cable Always reconnect the positive red battery cable before reconnecting the negative black cable Always keep the battery strap in place to protect and secure the battery Battery terminals or metal tools could short against metal ve...

Page 33: ...e Checking and Adjusting Neutral When performing routine maintenance and or engine diagnostics the transaxle must be shifted into neutral Figure 40 The vehicle has a neutral position on the shift lever which controls the neutral in the transaxle The following steps should be taken to make sure that the neutral shift lever operates the transaxle neutral correctly 1 Set the shift lever into the Neut...

Page 34: ... and stay seated in the vehicle while the measurement is being taken 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 in Premaintenance Procedures page 27 2 Remove the travel limiting bolt Figure 42 3 Loosen the centering bolts in the front A arm Figure 42 4 Remove the ride...

Page 35: ... 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 Measure the distance between both of t...

Page 36: ...ray available through your Authorized Toro Dealer or Distributor Figure 47 6 Install the clutch cover and secure it with the 3 bolts removed previously Changing the Transaxle Fluid Change the transaxle fluid every 800 operating hours or yearly whichever occurs first 1 Position the vehicle on a level surface set the parking brake turn the ignition off and remove the key 2 Remove the drain plug from...

Page 37: ...ke pad thickness is less than 1 16 inch 1 6 mm the brake shoes should be replaced Inspect the backing plate and other components for signs of excessive wear or deformation If any deformation is found the appropriate components must be replaced Check the brake fluid level refer to Checking the Brake Fluid Level Checking the Brake Fluid Level The brake fluid reservoir is filled and shipped from the ...

Page 38: ...after the first day of operation and every 200 operating hours thereafter 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 52 1 Drive belt 3 Secondary clutch 2 Primary clutch ...

Page 39: ...d the battery 3 Inspect the brakes refer to Inspecting the Brakes in Brake Maintenance page 37 4 Service the air cleaner refer to Servicing the Air Cleaner in Engine Maintenance page 28 5 Grease the machine refer to Lubrication page 28 6 Change the engine oil refer to Servicing Engine Oil in Engine Maintenance page 28 7 Check the tire pressure refer to Checking the Tire Pressure in Drive System Ma...

Page 40: ...stem Maintenance page 31 Note Do not connect the battery cables to the battery posts during storage Important The battery must be fully charged to prevent it from freezing and being damaged at temperatures below 32 F 0 C A fully charged battery maintains its charge for about 50 days at temperatures lower than 40 F 4 C If the temperatures will be above 40 F 4 C check the water level in the battery ...

Page 41: ... SWITCH 5 2 3 6 4 1 99 7410 PRESSURE LOW OIL M R 3 2 CLOSED IN NEUTRAL 1 99 7429 IGNITION SWITCH M M S VIO F3 25 A F1 99 7416 99 741 1 POWER POINT W BK PK BU F5 10 A NEUTRAL SW A B RUN START OFF Y S BN GY 99 7428 BK Start FRAME GROUND AC AC ENGINE GROUND REG FUSIBLE LINK 99 7427 MAG IGNITION MODULES SP ARK PLUG 66 8800 99 7404 BU BK R HR 94 4208 HOUR METER P3 4 P3 2 SOLENOID STSP R 28 4210 G006342...

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