Toro Twister 1600 Utility Vehicle User manual

Brand: Toro

Model: Twister 1600 Utility Vehicle

Category: Utility Vehicle

Type: User manual

Form No. 3355-562 Rev A

Twister® 1600 Utility Vehicle

Model No. 12004TC —Serial No. 260000001 and Up

T his spark ignition system complies with Canadian

ICES-002

Introduction

R ead this infor mation carefully to lear n ho w to

operate and maintain y our product properly and

to a v oid injur y and product damag e . Y ou are

responsible for operating the product properly

and safely .

Y ou ma y contact T oro directly at www .T oro .com

for product and accessor y infor mation, help

ﬁnding a dealer , or to register y our product.

W henev er y ou need ser vice , g en uine T oro par ts ,

or additional infor mation, contact an A uthorized

Ser vice Dealer or T oro Customer Ser vice and ha v e

the model and serial n umbers of y our product

ready . Figure 1 identiﬁes the location of the model

and serial n umbers on the product. W rite the

n umbers in the space pro vided.

Figure 1

1. Model and serial number location

Model No.

Serial No.

T his man ual identiﬁes potential hazards and has

safety messag es identiﬁed b y the safety aler t

symbol ( Figure 2 ), whic h signals a hazard that ma y

cause serious injur y or death if y ou do not follo w

the recommended precautions .

Figure 2

1. Safety alert symbol

T his man ual uses 2 other w ords to highlight

infor mation. Impor tant calls attention to special

mec hanical infor mation and Note emphasizes

g eneral infor mation w or th y of special attention.

Contents

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

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Sound Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Safety and Instr uctional Decals . . . . . . . . . . . . 8

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1 Installing the W heels . . . . . . . . . . . . . . . . . . . . . . . 11

2 Installing the Steering W heel . . . . . . . . . . . 11

3 Installing the Bumper . . . . . . . . . . . . . . . . . . . . . . 12

4 Installing the Seats . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5 Installing the Hitc h . . . . . . . . . . . . . . . . . . . . . . . . . 13

6 Installing the Carg o Bo x . . . . . . . . . . . . . . . . . . 13

7 Acti v ating the Batter y . . . . . . . . . . . . . . . . . . . . . . 14

8 Adjusting the F ront W heel

T oe-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

9 R eading the Man ual and Viewing

the Safety Video . . . . . . . . . . . . . . . . . 16

Product Ov er view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Speciﬁcations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

T hink Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Pre-Star ting Chec ks . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Chec king the Engine Oil . . . . . . . . . . . . . . . . . . . . 21

Chec king the Brak e Fluid

Lev el . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Chec king the Tire Pressure . . . . . . . . . . . . . . . . . 21

Adding Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Chec king the T ransmission Oil

Lev el . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Star ting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Stopping the V ehicle . . . . . . . . . . . . . . . . . . . . . . . . . . 23

P arking the V ehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Operating the Carg o Bo x . . . . . . . . . . . . . . . . . . . 23

Breaking in a New V ehicle . . . . . . . . . . . . . . . . . . 24

Loading the Carg o Bo x . . . . . . . . . . . . . . . . . . . . . . 25

T ranspor ting the V ehicle . . . . . . . . . . . . . . . . . . . . 25

T o wing the V ehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

T o wing a T railer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

8111 Lyndale Avenue South

Bloomington, MN 55420

Printed in the USA.

R ecommended Maintenance

Sc hedule(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Premaintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . 28

Maintaining the V ehicle under

Special Operating

Conditions . . . . . . . . . . . . . . . . . . . . . . . . 28

J ac king the V ehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Adding Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Ser vicing the Air Cleaner . . . . . . . . . . . . . . . . . . . 29

Ser vicing the Engine Oil . . . . . . . . . . . . . . . . . . . . 30

Ser vicing the Spark Plugs . . . . . . . . . . . . . . . . . . . 31

Fuel System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Inspecting Fuel Lines and

Connections . . . . . . . . . . . . . . . . . . . . . . 31

R e placing the Fuel Filter . . . . . . . . . . . . . . . . . . . . 31

Electrical System Maintenance . . . . . . . . . . . . . . . . . . . 32

R e placing the Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

R e placing the Headlights . . . . . . . . . . . . . . . . . . . 32

Ser vicing the Batter y . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Dri v e System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 34

Chec king and Adjusting

Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Inspecting the Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Adjusting the F ront

Suspension . . . . . . . . . . . . . . . . . . . . . . . . 35

Adjusting F ront W heel T oe-In . . . . . . . . . . . 36

Maintaining the Primar y Dri v e

Clutc h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Changing the T ransaxle Fluid . . . . . . . . . . . . . 37

Cooling System Maintenance . . . . . . . . . . . . . . . . . . . . . 38

Cleaning the Engine Cooling

Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Brak e Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Inspecting the Brak es . . . . . . . . . . . . . . . . . . . . . . . . . 38

Chec king the Brak e Fluid

Lev el . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Adjusting the P arking Brak e . . . . . . . . . . . . . . . 39

Belt Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Ser vicing the Dri v e Belt . . . . . . . . . . . . . . . . . . . . . 39

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

W ashing the V ehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Storag e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Sc hematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Safety

Improper use or maintenance b y the operator

or o wner can result in injur y . T o reduce the

potential for injur y , comply with these safety

instr uctions and alw a ys pa y attention to the safety

aler t symbol, whic h means Caution , W ar ning , or

Danger —“personal safety instr uction. ” F ailure to

comply with the instr uction ma y result in personal

injur y or death.

T he v ehicle is an of f-highw ay v ehicle

onl y and is not designed, equipped, or

man uf actur ed f or use on public str eets,

r oads, or highw ays.

Before Operating

• Operate the mac hine only after reading and

understanding the contents of this man ual.

• Nev er allo w c hildren to operate the v ehicle .

Any one who operates the v ehicle should ha v e

a motor v ehicle license .

• Nev er allo w other adults to operate the v ehicle

without ﬁrst reading and understanding the

Operator’ s Manual . Mak e sure that all operators

are ph ysically and mentally capable of operating

the v ehicle .

• T his v ehicle is designed to car r y onl y the

operator and one passenger in the seat

pro vided b y the man ufacturer . Nev er car r y

any other passeng ers on the v ehicle .

• Nev er operate the v ehicle when under

the inﬂuence of dr ugs or alcohol. Ev en

prescription dr ugs and cold medicines can

cause dro wsiness .

• Do not dri v e the v ehicle when y ou are tired.

Be sure to tak e occasional breaks . It is v er y

impor tant that y ou sta y aler t at all times .

• Become familiar with the controls and kno w

ho w to stop the engine quic kly .

• K ee p all shields , safety devices , and decals in

place . If a shield, safety device , or decal is

malfunctioning, illegible , or damag ed, re pair or

re place it before operating the mac hine .

• Alw a ys w ear substantial shoes . Do not operate

the mac hine while w earing sandals , tennis

shoes , or sneak ers . Do not w ear loose ﬁtting

clothing or jew elr y whic h could g et caught in

mo ving par ts and cause personal injur y .

• W earing safety glasses and long pants is

advisable .

• A v oid dri ving when it is dark, especially in

unfamiliar areas . If y ou m ust dri v e when it

is dark, be sure to dri v e cautiously , use the

headlights , and ev en consider adding additional

lights .

• Be extremely careful when operating around

people . Alw a ys be a w are of where b ystanders

might be .

• Before operating the v ehicle , alw a ys c hec k the

designated areas of the v ehicle that are stated

in the pre-star ting section of this man ual. If

something is wrong, do not use the v ehicle .

Mak e sure that the problem is cor rected before

the v ehicle or attac hment is operated.

• Since g asoline is highly ﬂammable , handle it

carefully .

– Use an appro v ed g asoline container .

– Do not remo v e the cap from the fuel tank

when the engine is hot or r unning .

– Do not smok e while handling g asoline .

– Fill the fuel tank outdoors , and ﬁll it to

about 1 inc h (25 mm) belo w the top of the

tank (the bottom of the ﬁller nec k). Do

not o v erﬁll it.

– Wipe up any spilled g asoline .

– Do not ﬁll fuel containers in the carg o bo x;

place fuel containers on the g round before

ﬁlling .

Operation

Engine exhaust contains carbon mono xide,

which is an odor less, deadl y poison that can

kill y ou.

Do not r un engine indoor s or in an enclosed

ar ea.

• T he operator and passeng er should remain

seated whenev er the v ehicle is in motion.

T he operator should k ee p both hands on the

steering wheel whenev er possible , and the

passeng er should use the hand holds pro vided.

K ee p y our ar ms and legs within the v ehicle

body at all times .

• Dri v e slo w er and tur n less shar ply when y ou

are car r ying a passeng er . R emember y our

passeng er ma y not be expecting y ou to brak e

or tur n and ma y not be ready .

• Alw a ys w atc h out for and a v oid lo w o v erhangs

suc h as tree limbs , door jambs , and o v er -head

w alkw a ys . Mak e sure there is enough room

o v er head to easily clear the v ehicle and y our

head.

• Alw a ys shift into neutral and apply the parking

brak e before lea ving an idling v ehicle , or else

the v ehicle ma y cree p .

• F ailure to operate the v ehicle safely ma y result

in an accident, tip o v er of the v ehicle , and

serious injur y or death. Dri v e carefully . T o

prev ent tipping or loss of control:

– Use extreme caution, reduce speed, and

maintain a safe distance around sand traps ,

ditc hes , creeks , ramps , unfamiliar areas ,

or any areas that ha v e abr upt c hang es in

g round conditions or elev ation.

– W atc h for holes or other hidden hazards .

– Use extra caution when operating the

v ehicle on w et surfaces , in adv erse w eather

conditions , at higher speeds , or with a

full load. Stopping time and distance will

increase with a full load.

– A v oid sudden stops and star ts . Do not

g o from rev erse to forw ard or forw ard to

rev erse without ﬁrst coming to a complete

stop .

– Slo w do wn before tur ning . Do not attempt

shar p tur ns or abr upt maneuv ers or other

unsafe dri ving actions that ma y cause a loss

of v ehicle control.

– W hen dumping, do not let any one stand

behind the v ehicle and do not dump the

load on any one’ s feet. R elease the tailg ate

latc hes from the side of the bo x, not from

behind.

– Only operate the v ehicle when the carg o

bo x is do wn and latc hed.

– Before bac king up , look to the rear and

ensure that no one is behind y ou. Bac k up

slo wly .

– W atc h out for trafﬁc when y ou are near or

crossing roads . Alw a ys yield the right of

w a y to pedestrians and other v ehicles . T his

v ehicle is not designed for use on streets or

highw a ys . Alw a ys signal y our tur ns or stop

early enough so that other people kno w

what y ou plan to do . Obey all trafﬁc r ules

and regulations .

– T he electrical and exhaust systems of the

v ehicle can produce sparks capable of

igniting explosi v e materials . Nev er operate

the v ehicle in or near an area where there is

dust or fumes in the air whic h are explosi v e .

• Do not touc h the engine or m ufﬂer while the

engine is r unning or soon after it has stopped.

T hese areas ma y be hot enough to cause bur ns .

• If the mac hine ev er vibrates abnor mally , stop

immediately , w ait for all motion to stop , and

inspect the v ehicle for damag e . R e pair all

damag e before commencing operation.

• Before g etting off of the seat:

1. Stop the mo v ement of the mac hine .

2. Set the parking brak e .

3. T ur n the ignition k ey to Off .

4. R emo v e the ignition k ey .

Note: If the v ehicle is on an incline , bloc k

the wheels after g etting off of the v ehicle .

Braking

• Slo w do wn before y ou approac h an obstacle .

T his gi v es y ou extra time to stop or tur n a w a y .

Hitting an obstacle can damag e the v ehicle and

its contents . More impor tant, it can injure y ou

and y our passeng er .

• Gross V ehicle W eight (GVW) has a major

impact on y our ability to stop and/or tur n.

Hea vy loads and attac hments mak e a v ehicle

harder to stop or tur n. T he hea vier the load,

the long er it tak es to stop .

• Decrease the v ehicle speed if the carg o bo x has

been remo v ed and there is no attac hment on

the v ehicle . T he braking c haracteristics c hang e

and fast stops ma y cause the rear wheels to loc k

up , whic h ma y affect the control of the v ehicle .

• T urf and pa v ement are m uc h more slipper y

when they are w et. It can tak e 2 to 4 times

as long to stop on w et surfaces as on dr y

surfaces . If y ou dri v e through standing w ater

dee p enough to g et the brak es w et, they will

not w ork w ell until they are dr y . After dri ving

through w ater , y ou should test the brak es to

mak e sure they w ork properly . If they do not,

dri v e slo wly while putting light pressure on the

brak e pedal. T his will dr y the brak es out.

Operating on Hills

Operating the v ehicle on a hill may cause

tipping or r olling of the v ehicle, or the engine

may stall and y ou could lose head w ay on the

hill. T his could r esult in per sonal injur y .

• Do not accelerate quickl y or slam on

the brak es when backing do wn a hill,

especiall y with a load.

• If the engine stalls or y ou lose head w ay

on a hill, slo wl y back straight do wn the

hill. Nev er attempt to tur n the v ehicle

ar ound.

• Operate the v ehicle slo wl y on a hill and

use caution.

• A v oid tur ning on a hill.

• R educe y our load and the speed of the

v ehicle.

• A v oid stopping on hills, especiall y with

a load.

T hese extra cautions need to be tak en when

operating the v ehicle on a hill:

• Slo w do wn before star ting up or do wn a hill.

• If the engine stalls or y ou begin to lose headw a y

while climbing a hill, g radually apply the brak es

and slo wly bac k straight do wn the hill.

• T ur ning while tra v eling up or do wn hills can

be dang erous . If y ou ha v e to tur n while on a

hill, do it slo wly and cautiously . Nev er mak e

shar p or fast tur ns .

• Hea vy loads affect stability . R educe the w eight

of the load and y our speed when operating on

hills or if the load has a high center of g ra vity .

Secure the load to prev ent it from shifting and

tak e extra care when hauling loads that shift

easily (liquid, roc k, sand, etc .).

• A v oid stopping on hills , especially with a load.

Stopping while g oing do wn a hill will tak e

long er than stopping on lev el g round. If the

v ehicle m ust be stopped, a v oid sudden speed

c hang es , whic h ma y initiate tipping or rolling

of the v ehicle . Do not slam on the brak es

when rolling bac kw ard, as this ma y cause the

v ehicle to o v er tur n.

• W e strongly recommend installing the optional

R OPS Kit when operating on hilly ter rain.

Operating on Rough Terrain

R educe speed and load when operating on rough

ter rain, unev en g round, and near curbs , holes , and

other sudden c hang es in ter rain. Loads ma y shift,

causing the v ehicle to become unstable .

W e strongly recommend installing the optional

R OPS Kit when operating on rough ter rain.

Sudden changes in ter rain may cause a br upt

steering wheel mo v ement, possibl y r esulting

in hand and ar m injuries.

• R educe y our speed when operating on

r ough ter rain and near curbs.

• Grip the steering wheel loosel y ar ound

the perimeter . K eep y our hands clear of

the steering wheel spok es.

Loading and Dumping

T he w eight and position of the carg o and

passeng er can c hang e the v ehicle center of g ra vity

and v ehicle handling . T o a v oid loss of control and

personal injur y , follo w these guidelines:

• Do not car r y loads whic h ex ceed the load

limits described on the v ehicle w eight label;

refer to Speciﬁcations in Product Ov er view ,

pag e 17 , for v ehicle w eight limits . T he load

rating is for lev el surf aces onl y .

• R educe the w eight of the load when operating

on hills and rough ter rain to a v oid tipping or

o v er tur ning of the v ehicle .

• R educe the w eight of the load if the center of

g ra vity is high. Items suc h as bric ks , fer tilizer ,

or landscape timbers stac k higher in the bo x.

T he higher a load is stac k ed, the more lik ely

the v ehicle is to tip o v er . Distribute the load as

lo w as possible , making sure that the load does

not affect rear visibility .

• P osition the w eight of the load ev enly from

side to side . If y ou position the load to w ard

one of the sides , the v ehicle is more lik ely to

tip o v er while tur ning .

• P osition the w eight of a load ev enly from front

to bac k. If y ou position the load behind the

rear axle , it will reduce the w eight on the front

wheels . T his ma y result in a loss of steering

control or cause the v ehicle to tip o v er on hills

or bumpy ter rain.

• Use extra caution if the load ex ceeds the

dimensions of the bo x and when handling

off-center loads that cannot be centered. K ee p

loads balanced and secure to prev ent them

from shifting .

• Alw a ys secure loads so that they do not shift.

If a load is not secured, or y ou are transpor ting

a liquid in a larg e container suc h as a spra yer ,

the load can shift. T his shifting happens most

often while tur ning, g oing up or do wn hills ,

suddenly c hanging speeds , or while dri ving

o v er rough surfaces . Shifting loads can cause

the v ehicle to tip o v er .

T he w eight of the bo x may be hea vy .

Hands or other body par ts could be

cr ushed.

– K eep hands and other body par ts

clear when lo w ering the bo x.

– Do not dump materials on bystander s.

• Nev er dump a loaded carg o bo x while the

v ehicle is sidew a ys on a hill. T he c hang e in

w eight distribution ma y cause the v ehicle to

o v er tur n.

• W hen operating with a hea vy load in the carg o

bo x, reduce y our speed and allo w for sufﬁcient

braking distance . Do not suddenly apply the

brak es . Use extra caution on slopes .

• Be a w are that hea vy loads increase y our

stopping distance and reduce y our ability to

tur n quic kly without tipping o v er .

• T he rear carg o space is intended for load

car r ying pur poses only , not for passeng ers .

• Nev er o v erload y our v ehicle . T he decal

(located on the rear frame) sho ws load limits

for the v ehicle . Nev er o v erload the attac hments

or ex ceed the Gross V ehicle W eight (GVW).

Maintenance

• Before ser vicing or making adjustments to

the mac hine , stop the engine , set the parking

brak e , and remo v e the k ey from the ignition

to prev ent someone from accidentally star ting

the engine .

• T o mak e sure that the entire mac hine is in

g ood condition, k ee p all n uts , bolts , and screws

properly tightened.

• T o reduce the potential for ﬁre , k ee p the engine

area free of ex cessi v e g rease , g rass , lea v es , and

accum ulation of dir t.

• Nev er use an open ﬂame to c hec k the lev el or

leakag e of fuel or batter y electrolyte .

• If the engine m ust be r unning to perfor m a

maintenance adjustment, k ee p y our hands ,

feet, clothing, and any par ts of y our body a w a y

from the engine and any mo ving par ts . K ee p

ev er y one a w a y .

• Do not use open pans of fuel or ﬂammable

cleaning ﬂuids for cleaning par ts .

• If major re pairs are ev er needed or assistance

is required, contact an A uthorized T oro

Distributor .

• T o be sure of optim um perfor mance and safety ,

alw a ys purc hase g en uine T oro re placement

par ts and accessories . R e placement par ts and

accessories made b y other man ufacturers

could be dang erous . Altering this v ehicle in

any manner that ma y affect v ehicle operation,

perfor mance , durability , or its use , ma y result

in injur y or death. Suc h use could v oid the

product w ar ranty .

Sound Pressure

T his unit has a maxim um sound pressure lev el

at the operator’ s ear of 80 dB A, based on

measurements of identical mac hines per EN

11094.

Vibration

T his unit does not ex ceed a hand/ar m vibration

lev el of 2.5 m/s

, based on measurements of

identical mac hines per EN 1033.

T his unit does not ex ceed a whole body vibration

lev el of 0.5 m/s

, based on measurements of

identical mac hines per EN 1032.

Safety and Instructional

Decals

Safety decals and instr uctions are easily visible to the operator and are located near any

area of potential dang er . R e place any decal that is damag ed or lost.

107–0704

1. Warning—read the Operator’s Manual.

7. Ignition—Off

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

roads, or highways.

8. Ignition—On

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

9. 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.

4. Falling hazard—do not allow children to operate the vehicle. 10. To stop the engine, release the accelerator pedal, set the

parking brake, turn the ignition key off, and remove the

ignition key.

5. Hour meter

11. Electrical power (power point)

6. Headlights

12. Horn

104–6581

1. Warning—read the Operator’s Manual .

2. Fire hazard—before fueling, stop the engine.

3. Tipping hazard—receive training before operating the machine, use caution and drive slowly while on slopes; drive slowly when

turning, keep the vehicle speed under 19 MPH (31 km/h) when carrying a full or heavy load and when driving on rough terrain .

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.

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

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 ll fuel containers in the cargo bed; place fuel containers

on the ground before lling.

99–7350

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

weight is 400 lb (181 kg).

104–6592

1. Read the Operator’s

Manual.

4. The base weight of the

vehicle is 1100 lb (500 kg).

2. The maximum combined

operator and passenger

weight is 400 lb (181 kg).

5. The maximum gross

vehicle weight is 2700 lb

(1225 kg).

3. The maximum cargo

weight is 1200 lb (544 kg).

99–7958

1. Read the Operator’s Manual

for information on fuses.

5. 15 amp. fuse 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

Setup

Loose Parts

Use the chart below to verify that all parts have been shipped.

Step

Description

Qty.

Use

Wheel assembly

Install the wheels.

Steering wheel

Install the steering wheel.

Bumper 1

Install the bumper.

Seat 2

Install the seats.

Hitch

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)

Install the cargo box.

No parts required

–

Activate the battery.

No parts required

–

Adjust the front wheel toe-in.

Operator’s Manual

Engine Operator’s Manual

Parts Catalog

Safety Video

Registration Card

Predelivery Inspection Form

Key 2

Read the Operator’s Manual and

watch the video before operating

the machine.

Note: Deter mine the left and right sides of the

mac hine from the nor mal operating position.

Step

Installing the Wheels

Parts needed for this step:

Wheel assembly

Procedure

1. R emo v e the fasteners securing the wheels .

2. R emo v e the shipping brac k et secured to the

wheel studs .

3. Mount the wheels with the previously remo v ed

fasteners ( Figure 3 ) and tor que to 45-65 ft-lb

(61-88 N ⋅ m).

Figure 3

1. Wheel assembly

3. Wheel stud (rear wheel hub

shown)

2. Wheel nut

Step

Installing the Steering

Wheel

Parts needed for this step:

Steering wheel

Procedure

1. R emo v e the n ut and loc k w asher from the

steering shaft.

2. Slide the steering wheel and w asher onto the

shaft. P osition the steering wheel on the shaft

so that the cross beam is horizontal when the

tires are pointed straight ahead and the thic k er

spok e of the steering wheel is do wnw ard.

3. Secure the steering wheel to the shaft with the

n ut ( Figure 4 ).

Figure 4

1. Steering wheel 3. Washer

2. Nut

4. Foam seal

Step

Installing the Bumper

Parts needed for this step:

1 Bumper

Procedure

1. R emo v e the 4 bolts and loc k n uts secured to

the front of the frame .

2. Align the mounting holes and secure the

bumper to the frame with the fasteners

previously remo v ed ( Figure 5 ).

Figure 5

1. Bumper

3. Frame

2. Bolt 4. Lock nut

Step

Installing the Seats

Parts needed for this step:

2 Seat

Procedure

Inser t the seat brac k et into the seat base opening

and pi v ot the seat do wnw ard ( Figure 6 ).

Figure 6

1. Seat bracket 2. Seat base

Step

Installing the Hitch

Parts needed for this step:

Hitch

Procedure

1. R emo v e the 4 bolts and n uts from the inside

rear of the frame .

2. Align the hitc h with the mounting holes on the

frame . Secure the hitc h with the screws and

n uts ( Figure 7 ).

Figure 7

1. Hitch

Step

Installing the Cargo Box

Parts needed for this step:

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. P osition the carg o bo x onto the frame . T he

carg o bo x m ust la y ﬂat and be centered.

2. Mount the left hand pi v ot brac k et to the left

rear cor ner of the frame with 2 ﬂang e head

screws (3/8 x 1 inc h). P osition the brac k et as

sho wn in Figure 8 .

Figure 8

1. Pivot bracket

3. Slide the carg o bo x mounting hole onto the

pi v ot brac k et ( Figure 9 ).

Figure 9

1. Cargo box 3. Cargo box mounting hole

2. Pivot bracket

4. Inser t the right hand pi v ot brac k et into the

mounting hole in the carg o bo x and then

mount it to the frame .

5. Ha v e another person help to raise the carg o

bo x.

6. Loosen the bolt securing the prop rod clip to

the frame until y ou can slide the J-hook end of

the prop rod under the clip ( Figure 10 ).

Figure 10

1. Prop rod

3. Bolt (5/16 x 3/4 inch)

2. Prop rod clip

4. Flange nut (5/16 inch)

7. Tighten the bolt and secure the other side of

the clip with a new bolt (5/16 x 3/4 inc h) and

ﬂang e n ut (5/16 inc h) ( Figure 10 ).

8. Lo w er the carg o bo x.

Step

Activating the Battery

No Parts Required

Procedure

None

Note: T his procedure is only needed for Model

No . 07277TC .

If the batter y is not ﬁlled with electrolyte or

acti v ated, it m ust be remo v ed from the v ehicle ,

ﬁlled with electrolyte , and c harg ed. Bulk electrolyte

with 1.260 speciﬁc g ra vity m ust be purc hased from

a local batter y supply outlet.

1. R emo v e the batter y hold-do wn and lift the

batter y out of the batter y base .

Batter y electr ol yte contains sulfuric acid

which is a deadl y poison and causes

sev er e bur ns.

• Do not drink electr ol yte or allo w it to

contact y our skin, ey es or clothing .

W ear safety g lasses to shield y our

ey es and r ub ber g lo v es to pr otect y our

hands.

• Fill the batter y wher e clean w ater is

al w ays a v aila ble f or ﬂushing the skin.

2. R emo v e the ﬁller caps from the batter y and

slo wly ﬁll eac h cell until electrolyte is just abo v e

the plates .

3. R e place the ﬁller caps and connect a 3 to

4 amp . batter y c harg er to the batter y posts .

Charg e the batter y at a rate of 3 to 4 amperes

for 4 to 8 hours (12 v olts). Do not o v erc harg e

the batter y .

Charging the batter y pr oduces gasses

that can explode.

Nev er smok e near the batter y and k eep

spar ks and ﬂames a w ay fr om batter y .

4. W hen the batter y is c harg ed, disconnect the

c harg er from the electrical outlet and batter y

posts .

5. R emo v e the ﬁller caps . Slo wly add electrolyte

to eac h cell until electrolyte is up to the ﬁll line .

Install the ﬁller caps .

Important: Do not o v erﬁll the batter y .

Electr ol yte will o v erﬂo w onto other par ts

of the v ehicle and sev er e cor r osion and

deterioration will r esult.

6. Install the batter y; refer to Installing the

Batter y , Electrical System Maintenance ,

pag e 32 .

Step

Adjusting the Front Wheel

Toe-in

No Parts Required

Procedure

T he toe-in should be 1/8-5/8 inc h (3-16 mm) with

the follo wing parameters:

• T he tire pressure should be at 12 psi (83 kP a).

• T he ride height should be cor rect before

setting the toe-in; refer to the Adjusting the

F ront Suspension procedure in Maintenance ,

pag e 27 .

• T he v ehicle should be dri v en bac k and for th a

few times to relax the A-ar ms .

• Measure the toe-in with the wheels facing

straight ahead and a 175-225 lb (79-102 kg)

operator in the dri v er’ s seat.

Note: T he dri v er should dri v e up to the

measurement area and sta y seated in the v ehicle

while the measurement is being tak en.

If the v ehicle will be r un with medium to hea vy

loads most of the time , set the toe-in on the

high side of the recommended amount. If it

is g oing to be r un with a light load most of

the time , set the toe-in on the lo w side of the

recommended amount.

1. Measure the distance betw een 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 g aug e is needed for the rear

measurement of the front tires at axle height.

Use the same ﬁxture or alignment g aug e to

accurately measure the front of the front tires

at axle height ( Figure 11 ).

Figure 11

1. Tire center line-back

4. Fixture

2. Tire center line-front 5. Axle center line distance

3. Axle center line

6. 6 inches (15 cm) ruler

2. If the measurement does not fall within the

speciﬁed rang e (refer to the dimensions and

parameters at the beginning of this procedure),

loosen the jam n uts at both ends of the tie

rods ( Figure 45 ).

Figure 12

1. Jam nut

2. Tie rod

3. R otate both tie rods to mo v e the front of the

tire inw ard or outw ard.

4. Tighten the tie rod jam n uts when the

adjustment is cor rect.

5. Ensure that there is full tra v el of the steering

wheel in both directions .

Step

Reading the Manual and

Viewing the Safety Video

Parts needed for this step:

Operator’s Manual

Engine Operator’s Manual

Parts Catalog

Safety Video

Registration Card

Predelivery Inspection Form

2 Key

Procedure

• R ead the Operator’ s Manual and Engine Operator’ s

Manual .

• View the safety video .

• Fill out the registration card.

• Complete the Pr edeli ver y Inspection F or m and ﬁle

it in y our customer histor y por tfolio .

Product Overview

Figure 13

1. Steering wheel 3. Parking brake 5. Cargo box 7. Cargo box release lever

2. Gear shift selector 4. Fuel cap

6. Towing tounge

Controls

Accelerator Pedal

T he accelerator pedal ( Figure 14 ) gi v es the

operator the ability to v ar y g round speed of the

v ehicle . Pressing the pedal increases g round

speed. R eleasing the pedal will slo w the v ehicle .

Maxim um forw ard speed is 18 mph (26 km/h).

Figure 14

1. Accelerator pedal 2. Brake pedal

Brake Pedal

T he brak e pedal is used to stop or slo w the v ehicle

( Figure 14 ).

Brak es can become w or n or can be

misadjusted r esulting in per sonal injur y .

If brak e pedal tra v els to within 1 inch

(25 mm) of the v ehicle ﬂoor board, the

brak es must be adjusted or r epair ed.

Parking Brake

T he parking brak e is betw een the seats ( Figure 15 ).

W henev er the engine is shut off , the parking brak e

m ust be eng ag ed to prev ent accidental mo v ement

of the v ehicle . T o eng ag e the parking brak e , pull

bac k on the lev er . T o diseng ag e , push the lev er

forw ard. If the v ehicle is park ed on a stee p g rade ,

mak e sure that the parking brak e is applied. Place

bloc ks at the do wnhill side of the wheels .

Figure 15

1. Parking brake lever

Choke Control

T he c hok e control is located belo w and to the

right of the operator’ s seat. T o star t a cold engine ,

pull the c hok e control outw ard ( Figure 16 ). After

the engine star ts , regulate the c hok e to k ee p the

engine r unning smoothly . As soon as possible ,

push the control in to the Off position. A w ar m

engine requires little or no c hoking .

Figure 16

1. Choke 2. Gear shift selector

Gear Shift Selector

T he g ear shift selector has three positions:

F orw ard, R ev erse , and Neutral ( Figure 16 ). T he

g ear shift selector m ust be in Neutral to star t the

engine .

Note: If the g ear shift selector is in R ev erse when

the ignition is tur ned on, a buzzer will sound to

w ar n the operator .

Important: Al w ays stop the v ehicle bef or e

changing gear s.

Ignition Switch

T he ignition switc h ( Figure 17 ), used to star t and

stop the engine , has three positions: On, Off , and

Star t. R otate the k ey cloc kwise to the Star t position

to star t the engine . W hen the engine star ts , release

the k ey . W hen the v ehicle is stopped, rotate the

k ey countercloc kwise to the Off position to stop

the engine . R emo v e the k ey 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

T he hour meter ( Figure 17 ) indicates the total

n umber of hours the engine has r un.

Oil Light

T he oil light w ar ns the operator if the engine oil

lev el drops belo w a safe lev el ( Figure 17 ). If the

light comes on and remains lit, the oil lev el should

be c hec k ed and oil added if necessar y; refer to

Chec king the Engine Oil in Operation , pag e 21 .

Note: T he oil light ma y ﬂic k er . T his is nor mal

and no action needs to be tak en.

Light Switch

T og gle the switc h to acti v ate the headlights . Push

to tur n the lights on ( Figure 17 ).

Power Point

Use the po w er point to po w er 12 v olt optional

electrical accessories ( Figure 17 ).

Horn Button

Press the hor n button to sound the hor n

( Figure 17 ).

Fuel Gauge

T he fuel g aug e ( Figure 18 ) sho ws the amount of

fuel in the tank.

Figure 18

1. Fuel gauge

Passenger Hand Holds

T he passeng er hand holds are located on the right

side of the dash panel and at the outside of eac h

seat ( Figure 19 ).

Figure 19

1. Passenger hand hold

2. Hip restraint

Specications

Note: Speciﬁcations and design are subject to c hang e 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 (90.7 kg)

passenger, load, trailer tongue weight, gross trailer weight, accessories, and

attachments

Maximum gross vehicle weight

(GVW) (on level ground)

2700 lb (1225 kg) total, including all of the weights listed above

Maximum cargo capacity (on

level ground)

1200 lb (544 kg) total, including trailer tongue weight and gross trailer weight

Tow capacity:

Standard Hitch

Tongue weight 50 lb (23 kg) Maximum trailer weight 400 lb (182 kg)

Heavy Duty Hitch

Tongue weight 100 lb (45 kg) Maximum trailer weight 800 lb (363 kg)

Overall width

59 inches (150 cm)

Overall length

115 inches (292 cm)

Ground clearance

9-1/4 inches (23.5 cm) at the front with no load or operator, 7 inches (18 cm) at

the rear with no load or operator

Wheel base

79 inches (200.7 cm)

Wheel tread (center line to center

line)

49 inches (124.5 cm) in the front, 48-1/4 inches (122.6 cm) in the rear

Cargo box length

46 inches (116.8 cm) inside, 51 inches (129.5 cm) outside

Cargo box width

49 inches (124.5 cm) inside, 54 inches (137.2 cm) outside

Cargo box height

10 inches (25.4 cm) inside

Attachments/Accessories

A selection of T oro appro v ed attac hments and accessories are a v ailable for use with the mac hine to

enhance and expand its capabilities . Contact y our A uthorized Ser vice Dealer or Distributor or g o to

www .T oro .com for a list of all appro v ed attac hments and accessories .

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Toro Twister 1600 Utility Vehicle User manual

Brand: Toro

Model: Twister 1600 Utility Vehicle

Category: Utility Vehicle

Type: User manual

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Toro Twister 1600 Utility Vehicle User manual

Toro Twister 1600 Utility Vehicle User manual

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