Form No. 3422-508 Rev A Greensmaster® 3120 2-Wheel Drive Traction Unit Model No. 04355—Serial No. 402990001 and Up Register at www.Toro.com.
Whenever you need service, genuine Toro parts, or additional information, contact an authorized Toro distributor and have the model and serial numbers of your product ready. Figure 2 identifies the location of the model and serial numbers on the product. Write the numbers in the space provided.
Contents Locating the Fuses ........................................... 32 Drive System Maintenance .................................. 32 Checking the Tire Pressure............................... 32 Checking the Torque of the Wheel Nuts .............................................................. 32 Adjusting the Transmission for Neutral.............. 33 Adjusting the Transport Speed.......................... 33 Adjusting the Mowing Speed ............................ 34 Brake Maintenance ................
Safety • Do not operate the machine without all guards and other safety protective devices in place and working on the machine. This machine has been designed in accordance with ANSI B71.4-2017 and meets these standards when you add the appropriate weight kit and ballast. • Keep clear of any discharge opening. Keep bystanders and pets a safe distance away from the machine. • Keep children out of the operating area. Never allow children to operate the machine.
decal104-7729 104-7729 1. Warning—read the instructions before servicing or performing maintenance. 2. Cutting/dismemberment hazard; hand or foot—shut off the engine and wait for moving parts to stop. decal115-8226 115-8226 1. Tipping hazard—read the Operator's Manual; always wear a seat belt when operating; do not remove the rollover protection system (ROPS). decal105-8305 105-8305 1. Lower and engage the reels. 2. Raise and disengage the reels. 3. Engine—shut off 4. On 5.
decal136-8506 136-8506 1. Warning—read the Operator’s Manual; receive training before operating the machine. 4. Tipping hazard—slow machine before turning, do not turn at high speeds. 2. Warning—hearing protection must be worn. 5. Thrown object hazard—keep bystanders a safe distance away from the machine. 6. Warning—engage the parking brake, shut off the engine, and remove the ignition key before leaving the machine. 3. Cutting/dismemberment hazard of hands or feet—keep all guards and shields in place.
decal131-2007 131-2007 1. Read the Operator’s Manual. 7. Continuous-variable setting 2. Failure/malfunction (Leak detector alarm test) 8. Fast 3. Off 9. Front and rear lights 4. Choke 10. Lights off 5. On 11. Front lights 6. Slow decal131-2794 131-2794 1. Read the Operator's Manual for more information on servicing the machine.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description 1 2 3 4 No parts required – Carriage bolt (5/16 x 3/4 inch) Nut (5/16 inch) Bolt (1/2 x 1-3/4 inches) Bolt (1/2 x 1-1/2 inches) Nut (1/2 inch) Cutting unit (obtain from your authorized Toro distributor) Grass basket 2 2 2 6 8 5 No parts required 6 Rear Weight Kit (Part No. 100-6441)—purchase separately 19.5 kg (43 lb) of calcium chloride (purchase separately) 7 8 Use Qty.
1 Activating and Charging the Battery No Parts Required Procedure g032705 Use only electrolyte (1.265 specific gravity) to fill battery initially. 1. Figure 4 1. Electrolyte Remove the wing nuts, washers, and battery clamp and lift out the battery. 4. Allow approximately 20 to 30 minutes for the electrolyte to soak into the plates. Fill as necessary to bring the electrolyte to within about 6 mm (1/4 inch) of the bottom of the fill well (Figure 4). 5.
2 Installing the Battery Parts needed for this procedure: 2 Carriage bolt (5/16 x 3/4 inch) 2 Nut (5/16 inch) Procedure 1. 2. g032706 Figure 5 Mount the battery with the battery terminals toward the front of the machine. Connect the positive battery cable (red) from the starter solenoid to the positive post (+) of the battery (Figure 5). Secure it with a carriage bolt and nut. 1. Negative (-) 3. Battery clamp 2. Positive (+) 4. Wing nut 3.
6. 3 Torque the fasteners to 91 to 115 N∙m (67 to 85 ft-lb). WARNING Installing the Roll Bar Failure to wear the seat belt while operating the vehicle can result in you being thrown from the seat and injured during a rollover accident. Parts needed for this procedure: 2 Bolt (1/2 x 1-3/4 inches) 6 Bolt (1/2 x 1-1/2 inches) 8 Nut (1/2 inch) Always use the seat belt. 4 Procedure 1. Remove the screws and nuts supporting the jack pad on the right side of the machine. 2.
g005101 Figure 7 1. Lift arm 2. Lift hook g020795 Figure 9 3. Slide the sleeve back on the ball joint receiver and hook the receiver onto the cutting unit ball stud. Release the sleeve so that it slides over the stud and locks the assemblies together (Figure 8). 1. Pull arm 3. Ball joint 2. Jam nut 6. Ensure that there is approximately 13 mm (1/2 inch) of threads exposed on each reel drive motor mounting bolt (Figure 10). g020794 Figure 8 1. Pull frame 2. Pull arm 4. 3.
5 6 Marking the Outer Grass Baskets Adding Rear Ballast and Weight Kit No Parts Required Parts needed for this procedure: Procedure 1 Rear Weight Kit (Part No. 100-6441)—purchase separately To assist in aligning the machine for successive cutting passes, do the following procedure to the No. 2 and No. 3 cutting unit baskets: 1 19.5 kg (43 lb) of calcium chloride (purchase separately) 1. Measure in approximately 12.7 cm (5 inches) from the outer edge of each basket. 2.
Product Overview 7 Reducing the Tire Pressure No Parts Required Procedure The tires are over-inflated at the factory for shipping purposes. Reduce the pressure to the proper levels before starting the machine. Refer to Checking the Tire Pressure (page 32). 8 Burnishing the Brakes g014674 Figure 12 No Parts Required 1. Engine 2. Roll bar 6. Traction pedal Procedure 3. Control panel 7. Footrest 4. Seat 8.
g033365 Figure 15 g032580 Figure 13 1. Traction pedal 1. Choke lever 3. Light-switch position 2. Throttle lever 4. Hour meter 3. Parking-brake tab 2. Brake pedal Choke Lever To start a cold engine, close the carburetor choke by pushing the choke lever forward (Figure 15) to the [ | ] ON position. After the engine starts, adjust the choke lever to keep the engine running smoothly. As soon as possible, open the choke by pulling the lever rearward to the [ 0 ] OFF position.
Raise/Lower Mow Control Move the raise/lower mow control (Figure 17) forward during cutting operation lowers the cutting units and starts the reels. Pull back the control to stop the reels and raise the cutting units. To stop the reels without raising the cutting units, pull back the control momentarily and release it; start the reels again by moving the control forward. g033366 Figure 18 1.
Operation Note: Determine the left and right sides of the machine from the normal operating position. Before Operation Safety General Safety • Never allow children or untrained people to g007385 Figure 21 1. Backup lever 2. Reel-speed control • Reel-Speed Control • Use the reel-speed control (Figure 21) to adjust the speed of the reels. • Specifications • Note: Specifications and design are subject to change without notice. Width of cut 151 cm (59.5 inches) Wheel tread 128 cm (50.
4. Gasoline with 15% ethanol (E15) by volume is not approved for use. • Never use gasoline that contains more than 10% ethanol by volume, such as E15 (contains 15% ethanol), E20 (contains 20% ethanol), or E85 (contains up to 85% ethanol). • Do not use fuel that contains methanol. • Do not store fuel either in the fuel tank or fuel containers over the winter, unless you use a fuel stabilizer. • Do not add oil to gasoline. • For best results, use only clean, fresh (less than 30 days old) fuel.
• • • • • • • • • • over if a wheel goes over the edge or if the edge gives way. Stop the cutting units whenever you are not mowing. Stop the machine and inspect the cutting units after striking an object or if there is an abnormal vibration in the machine. Make all necessary repairs before resuming operation. Slow down and use caution when making turns and crossing roads and sidewalks with the machine. Always yield the right-of-way.
6. Since the first hours of operation are critical to future dependability of the machine, monitor its functions and performance closely so that minor difficulties, which could lead to major problems, are noted and can be corrected. Inspect the machine frequently during break-in for signs of oil leakage, loose fasteners, or any other malfunction. Note: When the machine is new and the bearings and reels are tight, it is necessary to set the throttle lever to the FAST position for this check.
• The parking brake is disengaged. • You are seated in the operator's seat. • The functional-control lever is in the MOW position 3. The engine should shut off, which indicates that the interlock system is operating correctly. Correct the problem if it is not operating properly. or the TRANSPORT position. The safety-interlock system prevents the reels from operating unless the functional-control lever is in the MOW position.
direction of the uncut portion; a tear-shaped turn (Figure 23) to quickly line up for your next pass. previous mowing so that the grass blades are less apt to lay down and therefore be difficult to trap between the reel blades and the bedknife. Cutting the Green 1. Approach the green with the functional-control lever in the MOW position and the throttle at full speed. 2. Start on 1 edge of the green so that you can use the ribbon procedure of cutting.
Inspecting and Cleaning after Mowing damage to the turf may result. Stopping the machine on a wet green may leave marks or indentations from the wheels. After mowing, thoroughly wash the machine with a garden hose without a nozzle so that excessive water pressure does not contaminate and damage the seals and bearings. Do not wash a warm engine or the electrical connections with water. Cutting the Periphery and Finishing Job 1. Finish cutting the green by mowing the outer periphery.
Maintenance WARNING Failure to properly maintain the machine could result in premature failure of machine systems causing possible harm to you or bystanders. Keep the machine well maintained and in good working order as indicated in these instructions. Note: Determine the left and right sides of the machine from the normal operating position. Note: Download a free copy of the electrical or hydraulic schematic by visiting www.Toro.com and searching for your machine from the Manuals link on the home page.
Maintenance Service Interval Every 800 hours Every 2 years Maintenance Procedure • • • • • • Replace the spark plugs. Replace the fuel filter (sooner if the fuel flow is restricted). Change the hydraulic fluid. Change the hydraulic filters Check the engine speed (at idle and full throttle). Check the valve clearance. • Check the fuel lines and connections. • Replace moving hoses. Daily Maintenance Checklist Duplicate this page for routine use. Maintenance Check Item For the week of: Mon. Tues. Wed.
Notation for Areas of Concern Inspection performed by: Item Date Information Pre-Maintenance Procedures Removing the Seat Assembly Pre-Maintenance Safety Note: If you remove the seat assembly frequently, you can replace the roll pin with an R-key pin (Part No. 3290-467). • Before adjusting, cleaning, repairing, or leaving Remove the seat assembly to access the valve block area of the machine. the machine, do the following: – Park the machine on a level surface. 1.
Lubrication Raising the Machine CAUTION Greasing the Machine If the machine is not properly supported, it could fall, crushing you or others. Service Interval: Every 50 hours (Immediately after every washing) Before servicing, support the machine with jack stands or blocks of wood. Lubricate the grease fittings regularly with No. 2 lithium grease. Locate the grease fitting as follows: Before raising the machine, lower the cutting units.
• Lift cylinders (3) (Figure 32) g005119 Figure 29 g005123 • Pull-frame shaft and roller (12) (Figure 30) Figure 32 • Traction pedal (Figure 33) g005120 Figure 30 • Steering-cylinder end (Figure 31) g032715 Figure 33 g005121 1. Wipe the grease fitting clean. 2. Pump grease into the bearing or bushing until the grease is visible. Clean off excess grease. 3. When you remove the cutting unit(s) for maintenance, apply grease to the spline shaft of the reel motor and to the lift arm.
Engine Maintenance Engine Safety • Shut off the engine before checking the oil or adding oil to the crankcase. • Do not change the governor speed or overspeed the engine. Servicing the Air Cleaner Service Interval: Every 50 hours—Service the air-cleaner foam element (more frequently when operating conditions are dusty or dirty). g005126 Figure 35 1. Foam element Every 100 hours—Service the air-cleaner paper element (more frequently when operating conditions are dusty or dirty). 1. 2. Paper element 5.
2. Clean the threads of the drain plug, apply PTFE sealant, and install the drain plug (Figure 37). 3. Remove the oil filter (Figure 37). 4. Apply a light coat of clean oil to the new filter gasket. 5. Thread the oil filter onto the engine by hand until the gasket contacts the filter adapter, then tighten the filter 3/4 to 1 turn further. Important: Do not overtighten the oil filter. 6. Add oil to the crankcase; refer to Engine Oil Specification (page 29) and Checking the Engine Oil (page 29). 7.
Fuel System Maintenance Electrical System Maintenance Replacing the Fuel Filter Electrical System Safety Service Interval: Every 800 hours (sooner if the fuel flow is restricted). • Disconnect the battery before repairing the machine. Disconnect the negative terminal first and the positive last. Connect the positive terminal first and the negative last. The in-line fuel filter is in the fuel line between the fuel tank and carburetor (Figure 39).
Drive System Maintenance Note: Only raise the electrolyte level to the bottom of the split ring inside each cell. 3. Clean the top of the battery by washing it periodically with a brush dipped in ammonia or bicarbonate of soda solution. 4. Flush the top surface of the battery with water after cleaning it. Checking the Tire Pressure Service Interval: Before each use or daily Important: Do not remove the fill caps while cleaning the battery.
Adjusting the Transmission Adjusting the Transport for Neutral Speed If the machine creeps when the traction control pedal is in the NEUTRAL position, adjust the neutral-return mechanism. 1. Ensure that the bypass valve is closed. 2. Lift the machine and support it at the frame with jack stands so that the front wheels are off the floor. 3. At the traction-hydraulic pump (inboard) remove the control linkage from the control arm (Figure 41).
Brake Maintenance Adjusting the Mowing Speed Adjusting the Brakes Factory setting: 6.1 km/h (3.8 mph) 1. A brake adjustment rod is located at each side of the machine so that you can adjust the brakes equally. Loosen the jam nut on the trunnion bolt on the side of the traction pedal (Figure 43). 1. While moving forward in transport speed, press the brake pedal; both wheels should apply equally. CAUTION Testing the brakes in a confined area where others are present could cause injury.
Controls System Maintenance Important: Burnish the brakes annually; refer to the 8 Burnishing the Brakes (page 14) section. Adjusting the Cutting Unit Lift/Drop The cutting unit lift/drop circuit comes with a flow-control valve (Figure 45). This valve is preset at the factory at approximately 3 turns open, but you may need to adjust it to compensate for differences in hydraulic fluid temperatures, mowing speeds, etc.
Note: You should not need to rotate it more than 1/32 to 1/16 of a turn. 4. 5. Rotate the clevis until you attain the desired height (Figure 48). Test the adjustment and repeat step 3 as needed; when finished, tighten the jam nut. Adjusting the Lift Cylinders To regulate the height of the front-cutting units when in the raised (transport) position, you can adjust the front-lift cylinders. 1. Lower the cutting units to the ground. 2.
Hydraulic System Maintenance in consistently high ambient temperatures, 18°C (65°F) to 49°C (120°F), ISO VG 68 hydraulic fluid may offer improved performance. Premium Biodegradable Hydraulic Fluid-Mobil EAL EnviroSyn 46H Hydraulic System Safety Important: Mobil EAL EnviroSyn 46H is the only • Seek immediate medical attention if fluid is injected synthetic biodegradable fluid approved by Toro.
1. Clean the area around the left filter mounting area (Figure 50). Place a drain pan under the filter and remove the filter. g033486 Figure 50 1. Hydraulic filter Note: If you are not going to drain the hydraulic g229800 the fluid, disconnect and plug the hydraulic line going to the filter. Figure 49 1. Dipstick 4. Filler neck 2. Hydraulic fluid level (good—at or below the groove) 5. Dipstick hole 2.
Checking the Hydraulic Lines and Hoses Cutting Unit Maintenance Blade Safety WARNING Refer to and complete the procedure in Pre-Maintenance Safety (page 26). Hydraulic fluid escaping under pressure can penetrate skin and cause injury. A worn or damaged blade or bedknife can break, and a piece could be thrown toward you or bystanders, resulting in serious personal injury or death.
g229849 g014736 Figure 52 4. Tilt the operator’s seat forward and support it with the prop rod (Figure 53). g229880 Figure 54 1. Knob (reel-speed control) 3. Indicator arrow 2. Handle (backlap lever) Note: You can increase or decrease the reel speed to compensate for turf conditions. g229847 Figure 53 5. To adjust the reel speed by rotating the knob of the reel-speed control (Figure 54) until the indicator arrow are in line with the number that you determined in step 3.
Backlapping the Reels WARNING Contact with the reels or other moving parts can result in personal injury. • Keep your hands and clothing away from the reels or other moving parts. • Never attempt to turn the reels by hand or foot while the engine is running. g229849 1. Position the machine on a level surface, lower the cutting units, shut off the engine, remove the key, and set the parking brake. 2. Tilt the operator’s seat forward and support it with the prop rod (Figure 55). g229848 Figure 56 1.
10. Storage When finished, return the backlap lever to the F position, move the reel speed knob to the desired reel-speed setting, lower the seat, and wash all lapping compound off of the cutting units. Adjust cutting unit reel to bedknife as needed. To store the machine for an extended time, do the following steps: Important: If you do not return the backlap lever to the F position after backlapping, the cutting units will not raise or function properly. 1.
California Proposition 65 Warning Information What is this warning? You may see a product for sale that has a warning label like the following: WARNING: Cancer and Reproductive Harm—www.p65Warnings.ca.gov. What is Prop 65? Prop 65 applies to any company operating in California, selling products in California, or manufacturing products that may be sold in or brought into California.
The Toro Warranty A Two-Year Limited Warranty Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty statements for these products).
