Form No. 3377-332 Rev B Greensmaster® 3400 TriFlex™ Traction Unit Model No. 04520—Serial No. 313000001 and Up g014597 Register at www.Toro.com.
This product complies with all relevant European directives, for details please see the separate product specific Declaration of Conformity (DOC) sheet. WARNING CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. 1 g014685 Important: This engine is not equipped with a spark arrester muffler.
Contents Drive System Maintenance .........................................39 Adjusting the Transmission for Neutral .....................39 Adjusting the Transport Speed .................................39 Adjusting the Mowing Speed....................................39 Cooling System Maintenance ......................................40 Cleaning the Radiator Screen....................................40 Brake Maintenance ....................................................41 Adjusting the Brakes ..........
Preparation Safety • While mowing, always wear substantial footwear, long This machine meets or exceeds CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-2004 specifications in effect at the time of production when 37 lb (16.8 kg) of weight is added to the rear wheel. • Improper use or maintenance by the operator or owner can result in injury.
Maintenance and Storage • Stop the blades from rotating before crossing surfaces other than grass. • Keep all nuts, bolts and screws tight to be sure the • When using any attachments, never direct discharge of equipment is in safe working condition. material toward bystanders nor allow anyone near the machine while in operation. • Never store the equipment with fuel in the tank inside a building where fumes may reach an open flame or spark.
Use of this product for purposes other than its intended use could prove dangerous to user and bystanders. • If the engine stalls or loses headway and cannot make it Operation • When a person or pet appears unexpectedly in or near to the top of a slope, do not turn the machine around. Always back slowly, straight down the slope. the mowing area, stop mowing. Careless operation, combined with terrain angles, ricochets, or improperly positioned guards can lead to thrown object injuries.
Sound Power Level Hand-Arm Vibration Level This unit has a guaranteed sound power level of 98 dBA, which includes an Uncertainty Value (K) of 1 dBA. Measured vibration level for right hand = 0.31 m/s2 Measured vibration level for left hand = 0.49 m/s2 Sound power level was determined according to the procedures outlined in ISO 11094. Uncertainty Value (K) = 0.25 m/s2 Measured values were determined according to the procedures outlined in EN 836.
115-8156 1. Reel height 3. 8 Blade cutting unit 5. 14 Blade cutting unit 7. Fast 2. 5 Blade cutting unit 4. 11 Blade cutting unit 6. Reel speed 8. Slow 117–2718 115-8155 1. Warning—read the Operator's Manual, do not prime or use starting fluid. 121–5169 115-8203 1. Read the Operator's manual for fuse information. 2. Radiator fan—50 Amp 1. Slow 5. Reel position setting 2. Continuous variable setting 6. Lower and 10. Fast—use for engage the transport reels 7. Reel—backlapping 11.
Battery Symbols Some or all of these symbols are on your battery. 121–5172 1. Off 2. Headlights 1. Explosion hazard 6. Keep bystanders a safe distance from the battery. 2. No fire, open flames, or smoking. 7. Wear eye protection; explosive gases can cause blindness and other injuries. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection. 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 3. On 5. Read the Operator’s Manual.
121–2640 (Affix over part no. 121–2641 for CE*) * This safety decal includes a slope warning required on the machine for compliance to the European Lawn Mower Safety Standard EN836:1997. The conservative maximum slope angles indicated for operation of this machine are prescribed by and required by this standard. 1. Warning—read the Operator’s Manual, do not operate this machine unless you are trained. 4.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description Use Qty. 1 Roll bar Bolt (1/2 x 3-3/4 inches) Flange-nut (1/2 inch) 1 4 4 Install the roll bar. 2 Seat completion kit 1 Install the seat to the base. 3 Steering wheel Locknut (1-1/2 inches) Washer Steering wheel cap 1 1 1 1 Install the steering wheel. No parts required – Activate and charge the battery. No parts required – Install the oil cooler (optional).
1 2 Installing the Roll Bar Installing the Seat Parts needed for this procedure: Parts needed for this procedure: 1 1 Roll bar 4 Bolt (1/2 x 3-3/4 inches) 4 Flange-nut (1/2 inch) Seat completion kit Procedure Acquire your desired seat kit from your distributor and install it as directed in the instruction included with the kit. Procedure 1. Remove the top crate support from the crate. 3 2. Remove the roll bar from the crate. 3.
4 Activating and Charging the Battery No Parts Required Procedure Use only electrolyte (1.265 Specific Gravity) to fill battery initially. Figure 6 1. Electrolyte 1. Remove the fasteners 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 1/4 inch (6 mm) of the bottom of the fill well (Figure 6). Important: Do not add electrolyte while the battery is in the machine.
WARNING 5 Battery terminals or metal tools could short against metal tractor components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. • When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the tractor. • Do not allow metal tools to short between the battery terminals and metal parts of the tractor.
3. If installing the center cutting unit, lift up on the foot rest and swing it up, allowing access to the center cutting unit position (Figure 10). 7 CAUTION Installing the Cutting Units The foot rest can pinch fingers if it falls into the closed position. Parts needed for this procedure: 1 Gauge bar 3 Cutting unit (model 04613, 04614, or 04615) 3 Grass Basket Keep your fingers clear of the area where the foot rest seats while it is open.
4 1 2 23 1 g01461 1 Figure 12 1. Suspension-arm bar 2. Cutting-unit bar 6. Close the latches down and around the cutting-unit bar and lock them in place (Figure 11). Note: A “click” can be heard and felt when the latches are properly locked in place. 7. Coat the spline shaft of the cutting unit motor with clean grease (Figure 13). 8.
Product Overview 8 Adding Rear Weight 4 2 3 Parts needed for this procedure: 1 5 Weight kit, 121–6665 (purchase separately) Note: This kit is not required for units with the 3 wheel drive kit installed. 1 6 7 Procedure This unit complies with the ANSI B71.4-2004 and EN 836 Standards when equipped with weight kit 121–6665. Note: If the unit is equipped with a three wheel drive kit additional weight is not required to meet ANSI B71.4-2004 and EN 836 standards.
2 3 1 1 4 2 3 9 7 g014603 5 Figure 15 1. Traction pedal—forward 8 6 g014599 Figure 17 3. Steering arm locking pedal 2. Taction pedal—reverse 1. Throttle control 6. Battery warning light 2. Raise/Lower Mow Control 7. Service indicator light 3. Functional control lever 8. Glow plug indicator light 4. Ignition switch 9. Water temperature light 5.
Engine Oil Pressure Light Parking Brake Lever The light (Figure 17) glows if the engine oil pressure drops below a safe level. Pull up on the brake lever (Figure 15) to set the parking brake. Disengage it by pushing it forward and down. Lock the parking brake any time you leave the machine. Water Temperature Light The light (Figure 17) glows and the engine automatically shuts down when the engine coolant temperature gets too high.
Fuel Shut-Off Valve Close the fuel shut-off valve (Figure 23), behind the seat and under the fuel tank, when storing or transporting the machine on a truck or trailer. 1 1 g014623 Figure 21 1. Reel speed control Seat Adjusting Lever The seat adjusting lever is located on the front, right corner of the seat (Figure 22), allowing you to adjust the seat fore and aft. g01462 6 Figure 23 1.
Specifications Operation Note: Specifications and design are subject to change without notice. Note: Determine the left and right sides of the machine from the normal operating position. Width of cut 59.5 inches (151 cm) Wheel tread 50.5 inches (128 cm) Think Safety First Wheel base 48.6 inches (123 cm) Overall length (w/baskets) 98.0 inches (249 cm) Please carefully read all of the safety instructions and symbols in the safety section.
Filling the Fuel Tank is necessary to permit venting when filling, which prevents oil from overrunning into breather. Use only clean, fresh diesel fuel or biodiesel fuels with low (<500 ppm) or ultra low (<15 ppm) sulfur content. The minimum cetane rating should be 40. Purchase fuel in quantities that can be used within 180 days to ensure fuel freshness. Fuel tank capacity: 6 U.S. gallons (22.7 l) Use summer grade diesel fuel (No.
1. Clean around the fuel tank cap (Figure 26). DANGER In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any fuel that spills. 1 • Do not fill the fuel tank completely full. Add fuel to the fuel tank until the level is 1 in. (25 mm) below the bottom of the filler neck. This empty space in the tank allows fuel to expand.
Checking the Cooling System The capacity of the cooling system is approximately 4.9 quarts (4.6 l). Refer to Cleaning the Radiator Screen (page 40). 4 Figure 28 1 1. Reserve tank 2 3. If the coolant is low, remove the reserve tank cap and add a 50/50 mixture of water and permanent ethylene glycol antifreeze. Do not overfill. 3 g01461 3 Figure 27 1. Wing bolts 3. Reserve tank 2. Radiator screen 4. Radiator fill cap 4. Install the reserve tank cap.
High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46 Material Properties: Viscosity, ASTM D445 cSt @ 40°C 44 to 48 cSt @ 100°C 7.9 to 8.5 Viscosity Index ASTM D2270 140 to 160 Pour Point, ASTM D97 -34°F to -49°F Industry Specifications: Vickers I-286-S (Quality Level), Vickers M-2950-S (Quality Level), Denison HF-0 Important: The ISO VG 46 Multigrade fluid has been found to offer optimal performance in a wide range of temperature conditions.
Filling the Hydraulic Tank 1. Position the machine on a level surface. Make sure the machine has cooled down so the oil is cold. 2. Remove the cap from the reservoir (Figure 29). 1 1 2 g014720 Figure 30 1. Fuel filter 2. Drain plug g014719 Figure 29 Checking the Tire Pressure 1. Hydraulic reservoir cap The tires are over-inflated at the factory for shipping purposes. Reduce the pressure to the proper levels before starting the unit. 3.
Break-in Period two minutes. Turn the steering wheel to the left and right to check the steering response. Then shut the engine off (see Stopping in Starting and Stopping the Engine) and wait for all moving parts to stop. Check for oil leaks, loose parts and any other noticeable malfunctions. Refer to the Engine Manual supplied with the machine for oil change and maintenance procedures recommended during the break-in period. Only 8 hours of mowing operation is required for the break-in period.
Installing and Removing the Cutting Units 2. Sit on the seat, move the traction pedal to Neutral, move the functional control lever to Neutral, and engage the parking brake. Move the functional control lever to mow or transport and try to start the engine. The engine should not crank, which means that the interlock system is operating correctly. Correct the problem if it is not operating properly. Installing the Cutting Units 1.
4 1 2 23 1 g01461 1 Figure 33 1. Suspension-arm bar 2. Cutting-unit bar 4. Close the latches down and around the cutting-unit bar and lock them in place (Figure 32). Note: A “click” can be heard and felt when the latches are properly locked in place. 5. Coat the spline shaft of the cutting unit motor with clean grease (Figure 34). 6.
Removing the Cutting Units 5. Disconnect the latches from the cutting-unit bar. 1. Park the machine on a clean level surface, lower the cutting units to the ground until the suspension hydraulics are fully extended, stop the engine, and set the parking brake. 2. Push the motor retaining bar out of the slots on the motor towards the cutting unit and remove the motor from the cutting unit. 6. Roll the cutting unit out from under the suspension arm. 7.
imaginary sight line approximately 6 to 10 ft (1.8 to 3 m) ahead of the machine to the edge of the uncut portion of the green (Figure 39). Some find it useful to include the outer edge of the steering wheel as part of the sight line; i.e. keep the steering wheel edge aligned with a point that is always kept the same distance away from the front of the machine (Figure 39). 1 3 2 1 g014623 Figure 38 1. Reel speed control Note: You can increase or decrease the reel speed to compensate for turf conditions.
previous mowing. Always keep weather and turf conditions in mind and be sure to change the direction of mowing from the previous cutting. Replace the flag. damaged. If the machine must be moved a considerable distance, transport it on a truck or trailer. 1. Locate the bypass valve on the pump and rotate it so that the slot is vertical (Figure 40). At the end of the periphery cut, momentarily pull back on the raise/lower mow lever to shut the reels off without raising them.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval After the first hour Maintenance Procedure • Check the torque of the wheel nuts. After the first 8 hours • Check the torque of the wheel nuts. • Check the tension on the alternator belt. After the first 50 hours • Change the engine oil and filter. • Change the hydraulic oil filter. • Check the engine RPM (at idle and full throttle).
Daily Maintenance Checklist Duplicate this page for routine use. Maintenance Check Item For the week of: Mon. Tues. Wed. Thurs. Fri. Sat. Check the safety interlock operation. Check the instrument operation Check the brake operation. Check the fuel filter/water separator. Check the fuel level. Check the engine oil level. Clean the screen and radiator. Inspect the air filter. Check any unusual engine noises. Check the reel-to-bedknife adjustment. Check the hydraulic hoses for damage.
Engine Maintenance 4. Clean the dirt ejection port located in the removable cover. Remove the rubber outlet valve from the cover, clean the cavity and replace the outlet valve. Servicing the Air Cleaner 5. Install the cover orienting the rubber outlet valve in a downward position—between approximately 5:00 to 7:00 when viewed from the end. Service Interval: Every 200 hours • Check the air cleaner body for damage which could cause an air leak. Replace if damaged.
Fuel System Maintenance 3. Screw the filter on by hand until the gasket contacts the filter adapter, then tighten 1/2 to 3/4 turn further. Do not overtighten. 4. Add oil to the crankcase; refer to Checking the Engine Oil (page 21). Servicing the Fuel Filter/Water Separator 5. Dispose of the used oil properly. Service Interval: Every 800 hours 1. Close the fuel shut off valve (Figure 44) below the fuel tank. 1 g01462 6 Figure 44 1. Fuel shut-off valve 2.
Electrical System Maintenance Servicing the Battery WARNING 1 CALIFORNIA Proposition 65 Warning Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. 2 g014720 Figure 45 1. Fuel filter /water separator canister 2. Filter drain plug 5. Unscrew the filter canister and dispose of it according to local regulations. Voltage: 12 v, 530 Cold Cranking Amps 6.
2 WARNING Battery terminals or metal tools could short against metal tractor components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. • When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the tractor. • Do not allow metal tools to short between the battery terminals and metal parts of the tractor. WARNING 1 Incorrect battery cable routing could damage the tractor and cables causing sparks.
Adjusting the Transport Speed Drive System Maintenance The traction pedal is adjusted for maximum transport speed at the factory, but an adjustment may be required if the pedal reaches full stroke before it contacts the pedal stop, or if a decrease in transport speed is desired. Adjusting the Transmission for Neutral Press down on the traction pedal.
Cooling System Maintenance Cleaning the Radiator Screen To prevent the system from overheating, the radiator screen and radiator must be kept clean. Check and clean the screen and radiator daily or, if necessary, hourly. Clean these components more frequently in dusty, dirty conditions. 1. Remove the radiator screen (Figure 50). 2 4 1 3 g014625 Figure 49 1. Jam nut 2. Nut 3. Trunnion bolt 1 3.
Brake Maintenance Belt Maintenance Adjusting the Brakes Adjusting the Alternator Belt If the brake fails to hold the machine while parked, you can adjust the brakes using the bulkhead fitting near the brake drum; contact your Authorized Service Distributor or refer to the Service Manual for more information. Service Interval: After the first 8 hours Make sure the belt is properly tensioned to ensure proper operation of the machine and prevent unnecessary wear. 1.
Checking the Hydraulic Lines and Hoses Hydraulic System Maintenance WARNING Changing the Hydraulic Oil and Filter Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • Make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system.
Cutting Unit Maintenance Backlapping the Reels 1 WARNING Contact with the reels or other moving parts can result in personal injury. • Keep fingers, 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. 1. Position the machine on a level surface, lower the cutting units, stop the engine, engage the parking brake. g014623 Figure 54 2. Remove the plastic cover to the left side of the seat. 1. Reel speed control 3.
Diagnostics System Storage Diagnosing the Service Indicator Light If you wish to store the machine for a long period of time, the following steps should be performed prior to storage: 1. Remove accumulations of dirt and old grass clippings. Sharpen the reels and bedknives, if necessary; refer to the Cutting Unit Operator's Manual. Use a rust preventive on bedknives and reel blades. Grease and oil all lubrication points; refer to Lubrication.
Schematics g014737 Electrical Schematic (Rev.
G020720 Hydraulic Schematic (Rev.
Notes: 47
The Toro Total Coverage Guarantee A 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).
