Toro 22312, 22330, 22331, 22332, 12004 Operator's Manual

...

Form No. 3350-707

Twister

Model No. 12004—Serial No. 240000001 and Up Model No. 12004TC—Serial No. 240000001 and Up

1600 Utility Vehicle



Operator ’s Manual

Original Instructions (EN, GB)

Warning

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Important The engine in this product is not equipped

with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate this engine on any forest-covered, brush-covered, or grass-covered land as defined in CPRC 4126. Other states or federal areas may have similar laws.

This spark ignition system complies with Canadian ICES-002.

Ce système d’allumage par étincelle de véhicule est conforme à la norme NMB-002 du Canada.

The enclosed Engine Owner’s Manual is supplied for information regarding The U.S. Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance and warranty.

Keep this engine Owner’s Manual with your unit. Should this engine Owner’s Manual become damaged or illegible, replace immediately. Replacements may be ordered through the engine manufacturer.

Contents

Page

Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Before Operating 3. . . . . . . . . . . . . . . . . . . . . . . . .

While Operating 4. . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Slope Chart 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety and Instruction Decals 9. . . . . . . . . . . . . . . .

Specifications 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Specifications 11. . . . . . . . . . . . . . . . . . . . .

Setup 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loose Parts 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Crankcase Oil 12. . . . . . . . . . . . . . . . .

Fuel Tank 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Brake Fluid Level 13. . . . . . . . . . . . . .

Checking the Tire Pressure 13. . . . . . . . . . . . . . . . . .

Checking the Transmission Oil 14. . . . . . . . . . . . . .

Operation 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Think Safety First 14. . . . . . . . . . . . . . . . . . . . . . . . .

Controls 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pre-Starting Checks 16. . . . . . . . . . . . . . . . . . . . . . .

 2003 by The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196

Starting the Engine 16. . . . . . . . . . . . . . . . . . . . . . . .

Stopping the Vehicle 16. . . . . . . . . . . . . . . . . . . . . . .

Parking the Vehicle 16. . . . . . . . . . . . . . . . . . . . . . . .

Cargo Bed 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tailgate Latches 17. . . . . . . . . . . . . . . . . . . . . . . . . .

New Vehicle Break-In 17. . . . . . . . . . . . . . . . . . . . .

Transporting the Vehicle 17. . . . . . . . . . . . . . . . . . . .

Loading the Cargo Box 18. . . . . . . . . . . . . . . . . . . .

Towing the Vehicle 18. . . . . . . . . . . . . . . . . . . . . . . .

Towing a Trailer 18. . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Maintenance Schedule 19. . . . . . . . .

Maintaining the Vehicle under Special Operating

Conditions 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Jacking the Vehicle 20. . . . . . . . . . . . . . . . . . . . . . . .

Checking and Adjusting Neutral 21. . . . . . . . . . . . .

Servicing the Engine Oil 21. . . . . . . . . . . . . . . . . . .

Cleaning the Engine Cooling Areas 22. . . . . . . . . . .

Servicing the Air Cleaner 22. . . . . . . . . . . . . . . . . . .

Greasing the Machine 23. . . . . . . . . . . . . . . . . . . . . .

Servicing the Brakes 24. . . . . . . . . . . . . . . . . . . . . . .

Inspecting the Tires 24. . . . . . . . . . . . . . . . . . . . . . .

Adjusting the Front Suspension 24. . . . . . . . . . . . . .

Adjusting Front Wheel Toe-In 25. . . . . . . . . . . . . . .

Servicing the Drive Belt 26. . . . . . . . . . . . . . . . . . . .

Maintaining the Primary Drive Clutch 26. . . . . . . . .

Servicing the Fuel System 27. . . . . . . . . . . . . . . . . .

Spark Plugs 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing the Transaxle Fluid 28. . . . . . . . . . . . . . . .

Replacing the Fuses 28. . . . . . . . . . . . . . . . . . . . . . .

Replacing the Headlight Bulbs 29. . . . . . . . . . . . . . .

Servicing the Battery 29. . . . . . . . . . . . . . . . . . . . . .

Washing the Vehicle 30. . . . . . . . . . . . . . . . . . . . . . .

Schematics 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The Toro Total Coverage Guarantee 32. . . . . . . . . . . . .

Introduction

Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely.

You may contact Toro directly at www.Toro.com for product and accessory information, help finding a dealer, or to register your product.

Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and

Printed in the USA

Page

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

m–6044

Figure 1

1. Location of the model and serial numbers

Write the product model and serial numbers in the space below:

Model No.

Serial No.

This manual identifies potential hazards and has special safety messages that help you and others avoid personal injury and even death. Danger, Warning, and Caution are signal words used to identify the level of hazard. However, regardless of the hazard, be extremely careful.

Danger signals an extreme hazard that will cause serious injury or death if you do not follow the recommended precautions.

Warning signals a hazard that may cause serious injury or death if you do not follow the recommended precautions.

Caution signals a hazard that may cause minor or moderate injury if you do not follow the recommended precautions.

This manual uses two other words to highlight information.

Important calls attention to special mechanical

information and Note: emphasizes general information worthy of special attention.

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

• 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 operators are physically and mentally capable of operating the vehicle.

• This vehicle is designed to carry only the operator and

one passenger in the seat provided by the manufacturer. Never carry any other passengers on the vehicle.

• Never operate the vehicle when under the influence of

drugs or alcohol. Even prescription drugs and cold medicines can cause drowsiness.

• Do not drive the vehicle when you are tired. Be sure to

take occasional breaks. It is very important that you stay alert at all times.

• Become familiar with the controls and know how to

stop the engine quickly.

• Keep all shields, safety devices, and decals in place. If a

shield, safety device, or decal is malfunctioning, illegible, or damaged, repair or replace it before operating the machine.

• Always wear substantial shoes. Do not operate the

machine while wearing sandals, tennis shoes, or sneakers. Do not wear loose fitting clothing or jewelry which could get caught in moving parts and cause personal injury.

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

• Wearing safety glasses and long pants is advisable.

• Avoid driving when it is dark, especially in unfamiliar

areas. If you must drive when it is dark, be sure to drive cautiously, use the headlights, and even consider adding additional lights.

• Be extremely careful when operating around people.

Always be aware of where bystanders might be.

• 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.

• Since gasoline is highly flammable, handle it carefully.

– Use an approved gasoline container.

– 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. – 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.

– Do not remove the cap from the fuel tank when the

engine is hot or running. – Do not smoke while handling gasoline. – Fill the fuel tank outdoors and to about 1 inch

(25 mm) below top of tank (bottom of the filler

neck). Do not overfill. – Wipe up any spilled gasoline. – Do not fill fuel containers in the cargo bed; place

fuel containers on the ground before filling.

While Operating

Warning

Engine exhaust contains carbon monoxide, which is an odorless, deadly poison that can kill you.

Do not run engine indoors or in an enclosed area.

• The operator and passenger should remain seated

whenever the vehicle is in motion. The operator should keep both hands on the steering wheel, whenever possible and the passenger should use the hand holds provided. Keep your arms and legs within the vehicle body at all times.

• Drive slower and turn less sharply when you are

carrying a passenger. Remember your passenger may not be expecting you to brake or turn and may not be ready.

• Always watch out for and avoid low overhangs such as

tree limbs, door jambs, and over-head walkways. Make sure there is enough room over head to easily clear the vehicle and your head.

• Always shift into neutral and apply the parking brake

before leaving an idling vehicle, or else the vehicle may creep.

• Failure to operate the vehicle safely may result in an

accident, tip over of the vehicle, and serious injury or death. Drive carefully. To prevent tipping or loss of control:

– Avoid sudden stops and starts. Do not go from

reverse to forward or forward to reverse without first coming to a complete stop.

– Slow down before turning. Do not attempt sharp

turns or abrupt maneuvers or other unsafe driving actions that may cause a loss of vehicle control.

– When dumping, do not let anyone stand behind the

vehicle and do not dump the load on anyone’s feet. Release the tailgate latches from the side of box, not from behind.

– Only operate the vehicle when the cargo box is

down and latched.

– Before backing up, look to the rear and ensure no

one is behind the vehicle. Back up slowly.

– Watch out for traffic when 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 other persons know what you plan to do. Obey all traffic rules and regulations.

– The electrical and exhaust systems of the vehicle

can produce sparks capable of igniting explosive materials. Never operate the vehicle in or near an area where there is dust or fumes in the air which are explosive.

• Do not touch the engine or muffler while the engine is

running or soon after it has stopped. These areas may be hot enough to cause burns.

• If the machine ever vibrates abnormally, stop

immediately, wait for all motion to stop, and inspect for damage. Repair all damage before commencing operation.

• Before getting off of the seat:

A. Stop the movement of the machine. B. Set the parking brake. C. Turn the ignition key to OFF. D. Remove the key from the ignition.

Note: If the vehicle is on an incline, block the wheels after getting off of the vehicle.

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.

• 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. The heavier the load, the longer it takes to stop.

• Decrease the vehicle speed if the cargo box has been

removed and there is no attachment on the vehicle. The braking characteristics change and fast stops may cause the rear wheels to lock up, which may affect the control of the vehicle.

• Turf and pavement are much more slippery when they

are wet. It can take 2 to 4 times 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.

Operating on Hills

• 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.

• Heavy loads affect stability. Reduce the weight of the

load and your speed when operating on hills or if the load has a high center of gravity. Secure the load to prevent it from shifting.

• 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.

• Travel straight up and down slopes whenever possible.

• We strongly recommend installing the optional ROPS

Kit when operating on hilly terrain.

Operating on Rough Terrain

Reduce speed and load when operating on rough terrain, uneven ground, and near curbs, holes, and other sudden changes in terrain. Loads may shift, causing the vehicle to become unstable.

We strongly recommend installing the optional ROPS Kit when operating on rough terrain.

Warning

Operating the vehicle on a hill may cause tipping or rolling of the vehicle, or the engine may stall and you could lose headway on the hill. This could result in personal injury.

• Do not exceed slopes greater than 12.

• 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.

• Never drive across a steep hill; always drive

straight up or down or go around the hill.

• Avoid turning on a hill.

• Reduce your load and the speed of the vehicle.

• Avoid stopping on hills, especially with a load.

These extra cautions need to be taken when operating the vehicle on a hill:

• Slow down before starting up or down a hill.

• If the engine stalls or you begin to lose headway while

climbing a hill, gradually apply the brakes and slowly back straight down the hill.

Warning

Sudden changes in terrain may cause abrupt steering wheel movement, possibly resulting in hand and arm injuries.

• Reduce your speed when operating on rough

terrain and near curbs.

• Grip the steering wheel loosely around the

perimeter. Keep your hands clear of the steering wheel spokes.

Loading and Dumping

The weight and position of the cargo and passenger can change the vehicle center of gravity and vehicle handling. To avoid loss of control and personal injury, follow these guidelines:

• Do not carry loads which exceed the load limits

described on the vehicle weight label; refer to Specifications, page 11, for vehicle weight limits. The load rating is for level surfaces only.

• Reduce the weight of the load when operating on hills

and rough terrain to avoid tipping or overturning of the vehicle.

• 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.

• 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.

• 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.

• 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 load can shift. This shifting happens most often while turning, going up or down hills, suddenly changing speeds, or while driving over rough surfaces. Shifting loads can cause the vehicle to tip over.

Warning

The weight of the box may be heavy. Hands or other body parts could be crushed.

Maintenance

• Before servicing or making adjustments to the machine,

stop the engine, set the parking brake, and remove the key from the ignition to prevent someone from accidentally starting the engine.

• To make sure the entire machine is in good condition,

keep all nuts, bolts, and screws properly tightened.

• To reduce potential fire hazard, keep the engine area

free of excessive grease, grass, leaves, and accumulation of dirt.

• Never use an open flame to check the level or leakage

of fuel or battery electrolyte.

• If the engine must be running to perform a maintenance

adjustment, keep hands, feet, clothing, and any parts of the body away from the engine and any moving parts. Keep everyone away.

• Do not use open pans of fuel or flammable cleaning

fluids for cleaning parts.

• If repairs are ever needed or assistance is required,

contact an Authorized Toro Dealer.

• To be sure of optimum performance and safety, always

purchase genuine Toro replacement parts and accessories. Replacement parts and accessories made by other manufacturers could be dangerous. Altering this vehicle in any manner may affect vehicle operation, performance, or durability. This may result in injury or death. Such use could void the product warranty.

• Keep hands and other body parts clear when

lowering the box.

• Do not dump materials on bystanders.

• Never dump a loaded cargo box while the vehicle is

sideways on a hill. The change in weight distribution may cause the vehicle to overturn.

• When operating with a heavy load in the cargo box,

reduce your speed and allow for sufficient braking distance. Do not suddenly apply the brakes. Use extra caution on slopes.

• Be aware that heavy loads increase your stopping

distance and reduce your ability to turn quickly without tipping over.

• The rear cargo space is intended for load carrying

purposes only, not for passengers.

• Never overload your vehicle. The name plate (located

under dash on center column) shows load limits for the vehicle. Never overload the attachments or exceed the Gross Vehicle Weight (GVW).

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.

99-7952

1. Choke

2. Reverse

3. Neutral

4. Forward

99-7350

1. Maximum tongue weight is 50 lb. (23 kg); maximum trailer weight is 400 lb. (181 kg).

99-7349

1. Unlock the cargo bed 2. Lock the cargo bed

99-7958

1. Read the

2. 10 amp. fuse for the optional Road Light Kit

3. 15 amp. fuse for the optional Rear Lift Kit

4. 10 amp. fuse—open

5. 25 amp. fuse for the charge circuit

6. 10 amp. fuse for the headlights

7. 10 amp. fuse for the low oil light and the hour meter

8. 15 amp. fuse for the optional Electric Bed Lift Kit

Operator’s Manual

for information on fuses.

99-7954

1. Warning—read the

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 containers on the ground before filling.

Operator’s Manual.

99-7345

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.

104-6592

1. Read the

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).

Operator’s Manual.

107-0704

1. Warning—read the

2. Collision hazard—do not operate the vehicle on public streets, roads, or highways.

3. Falling hazard—do not carry passengers in the cargo bed.

4. Falling hazard—do not allow children to operate the vehicle.

5. Hour meter

6. Headlights

7. Engine—stop

8. Engine—run

9. Engine—start

10. To start the engine, sit on the operator’s seat, put the gear selector in Neutral, turn the ignition key on, pull the choke lever out (if needed), and press the accelerator pedal.

11. To stop the engine, release the accelerator pedal, set the parking brake, turn the ignition key off, and remove the ignition key.

12. Electrical power (power point)

13. Horn

Operator’s Manual.

+ 22 hidden pages