Form No. 3380-291 Rev B Greensmaster® 3400 TriFlex™ Traction Unit Model No. 04520—Serial No. 314000001 and Up 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 This product contains a chemical or chemicals known to the State of California to cause cancer, birth defects, or reproductive harm. Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. g014685 Figure 1 1.
Contents Electrical System Maintenance ........................... 38 Servicing the Battery......................................... 38 Storing the Battery ............................................ 39 Locating the Fuses ........................................... 39 Drive System Maintenance .................................. 40 Adjusting the Transmission for Neutral.............. 40 Adjusting the Transport Speed.......................... 40 Adjusting the Mowing Speed ............................
Safety ◊ lack of awareness of the effect of ground conditions, especially slopes. ◊ The owner/user can prevent and is responsible for accidents or injuries occurring to himself or herself, other people, or property 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 16.8 kg (37 lb) of weight is added to the rear wheel.
Rollover Protection System (ROPS) - Use and Maintenance • When using any attachments, never direct • • • • • • • • • • • • • discharge of material toward bystanders nor allow anyone near the machine while in operation. Never operate the machine with damaged guards, shields, or without safety protective devices in place. Be sure all interlocks are attached, adjusted properly, and functioning properly. Do not change the engine governor settings or overspeed the engine.
• Keep the nozzle in contact with the rim of the fuel • Keep hands and feet away from moving parts. If tank or container opening at all times until fueling is complete. possible, do not make adjustments with the engine running. • Charge batteries in an open well ventilated area, • Do not use a nozzle lock open device. • If fuel is spilled on clothing, change clothing away from spark and flames. Unplug charger before connecting or disconnecting from battery.
Maintenance and Storage – Do not drive close to sand traps, ditches, creeks, or other hazards. • Make sure all hydraulic line connectors are tight – Reduce speed when making sharp turns. Avoid sudden stops and starts. and all hydraulic hoses and lines are in good condition before applying pressure to the system. – Watch out for traffic when near or crossing roads. Always yield the right-of-way.
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 = 0.22 m/s2 Measured vibration level for left hand = 0.24 m/s2 Uncertainty Value (K) = 0.24 m/s2 Sound power level was determined according to the procedures outlined in ISO 11094. Measured values were determined according to the procedures outlined in EN 836.
decal115-8156 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 decal117-2718 117–2718 decal115-8155 115-8155 1. Warning—read the Operator's Manual, do not prime or use starting fluid. decal121-5169 121–5169 decal115-8203 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.
decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. decal121-5172 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.
decal121-2640 121–2640 1. Warning—read the Operator’s Manual, do not operate this machine unless you are trained. 4. Tipping hazard—do not drive across slopes greater than 15 degrees or down slopes greater than 15 degrees. 2. Thrown object hazard—keep bystanders a safe distance from the machine 5. Warning—lock the parking brake, stop the engine and remove the ignition key before leaving the machine. 3.
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. 2. Remove the roll bar from the crate. 3.
3. Secure the steering wheel to the shaft with a jam nut and tighten it to 27 to 35 N-m (20 to 26 ft-lb) (Figure 4). 4. Install the cap to the steering wheel and secure it with a screw (Figure 4). 4 Activating and Charging the Battery g001197 Figure 6 No Parts Required 1. Electrolyte Procedure 4. Use only electrolyte (1.265 specific gravity) to fill battery initially. 1. Remove the fasteners and battery clamp and lift out the battery.
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. g005098 Figure 7 • Do not allow metal tools to short between the battery terminals and metal parts of the tractor. 1. Negative (-) 2.
g014596 Figure 9 g015492 Figure 8 1. Prop (not provided) 1. Flange bolt 2. Bedknife adjusting screw nut (2) 3. Suspension arm bar 2. Grass basket hook Note: All cutting units are shipped with the counter weight mounted to the right end and the motor mount and drive coupler mounted to the left end of the cutting unit. 7 Installing the Cutting Units 1. Apply grease to the inside diameter of the drive coupler. 2. The cutting unit is shipped without a front roller. Obtain a roller (Model No.
5. With the latches on the suspension-arm bar pointing up (i.e., open) (Figure 11), push the suspension arm down so that the bar fits over the bar across the top of the cutting unit (Figure 12). g014609 Figure 11 1. Latch—closed position 3. Latch—open position 2. Suspension-arm bar g014690 Figure 13 1. Reel motor 3. Cavity 2. Spline shaft 4. Motor retaining bar 9. Mount a grass basket onto the basket hooks on the suspension arm. 10. Repeat this procedure for the other cutting units.
Product Overview 8 Adding Rear Weight Parts needed for this procedure: 1 Weight kit, 121–6665 (purchase separately) Note: This kit is not required for units with the 3 wheel drive kit installed. 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. g014674 Figure 14 9 1.
g014603 Figure 15 1. Traction pedal—forward 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 Raise/Lower Mow Control Moving the control (Figure 17) forward during operation lowers the cutting units and starts the reels.
Battery Warning Light The light (Figure 17) glows if the battery charge is low. Engine Oil Pressure Light The light (Figure 17) glows if the engine oil pressure drops below a safe level. Water Temperature Light The light (Figure 17) glows and the engine automatically shuts down when the engine coolant temperature gets too high.
g014620 Figure 20 1. Backlap lever—mow position 2. Backlap lever—backlap position Reel Speed Control The reel speed control is located under the plastic cover to the left of the seat. Use the reel speed control (Figure 21) to adjust the rpm of the reels. g014628 Figure 22 1. Seat adjusting handle Fuel Shutoff Valve Close the fuel shutoff valve (Figure 23), behind the seat and under the fuel tank, when storing or transporting the machine on a truck or trailer. g014623 Figure 21 1.
Specifications Operation Note: Specifications and design are subject to Note: Determine the left and right sides of the machine from the normal operating position. change without notice. Width of cut 151 cm (59.5 inches) Wheel tread 128 cm (50.5 inches) Wheel base 123 cm (48.6 inches) Overall length (w/baskets) 249 cm (98.0 inches) Overall width 179 cm (70.62 inches) Overall height 205 cm (80.
Important: Check the level of oil every 8 Important: Make sure that the dipstick is removed while filling the engine with oil. When adding engine oil or filling oil, there must be clearance between the oil fill device and the oil fill hole in the valve cover as shown in Figure 24. This clearance is necessary to permit venting when filling, which prevents oil from overrunning into breather. operating hours or daily.
1. DANGER Clean around the fuel tank cap (Figure 26). 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. • Do not fill the fuel tank completely full. Add fuel to the fuel tank until the level is 25 mm (1 inch) 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 4.6 L (4.9 quarts). Refer to Cleaning the Radiator Screen (page 41). g008427 Figure 28 1. Reserve tank 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. 4. Install the reserve tank cap. g014613 Checking the Hydraulic Fluid Level Figure 27 1. Wing bolts 3. Reserve tank 2. Radiator screen 4.
Filling the Hydraulic Tank High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46 Material Properties: Viscosity, ASTM D445 cSt @ 40°C 44 to 50 cSt @ 100°C 7.9 to 8.5 Viscosity Index ASTM D2270 140 to 160 Pour Point, ASTM D97 -34°F to -49°F 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).
Break-in Period 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. 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.
6. Allow the engine to warm up for a few minutes before operating. Perform the following system checks daily to be sure the interlock system is operating correctly: Important: When the engine is started for the first time, or after an overhaul of the engine, operate the machine in forward and reverse for one to two minutes. Turn the steering wheel to the left and right to check the steering response.
Installing and Removing the Cutting Units Installing the Cutting Units 1. Lift up on the foot rest and swing it open, allowing access to the center cutting unit position (Figure 31). CAUTION The foot rest can pinch fingers if it falls into the closed position. Keep your fingers clear of the area where the foot rest seats while it is open. g014611 Figure 33 1. Suspension-arm bar 4. 2. Cutting-unit bar Close the latches down and around the cutting-unit bar and lock them in place (Figure 32).
Removing the Cutting Units 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. g014605 Figure 35 1. Reel motor 3. g014690 2. Motor retaining bar Move the motor to the storage location on the front of the suspension arm (Figure 36). Figure 34 1.
4. Open the latches on the suspension-arm bar of the cutting unit you are removing (Figure 32). 5. Disconnect the latches from the cutting-unit bar. 6. Roll the cutting unit out from under the suspension arm. 7. Repeat steps 2 through 6 for the other cutting units as required.
3. Important: The machine should never be Overlap a minimal amount with the previous cut on return passes. To assist in maintaining a straight line across the green and keep the machine an equal distance from the edge of the previous cut, establish an imaginary sight line approximately 1.8 to 3 m (6 to 10 ft) 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.
After cleaning, it is recommended the machine be inspected for possible hydraulic fluid leaks and damage or wear to hydraulic and mechanical components. The cutting units should be checked for sharpness. Also, lubricate the traction pedal and brake shaft assembly with SAE 30W oil or spray lubricant to deter corrosion and help keep the machine performing satisfactorily during the next mowing operation. Towing the Machine In case of an emergency the machine can be towed for a short distance (less than 0.
Maintenance Note: Looking for an Electrical Schematic or Hydraulic Schematic for your machine? Download a free copy of the schematic by visiting www.Toro.com and searching for your machine from the Manuals link on the home page. 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.
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 checking the sealing end of the filter and the body. Do not use a damaged element. Insert the new filter by applying pressure to the outer rim of the element to seat it in the canister. Do not apply pressure to the flexible center of the filter. Servicing the Air Cleaner Service Interval: Every 200 hours 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. 5.
Fuel System Maintenance Servicing the Fuel Filter/Water Separator Service Interval: Every 800 hours 1. Close the fuel shut off valve (Figure 44) below the fuel tank. g014615 Figure 43 1. Oil filter 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 22). 5. Dispose of the used oil properly. g014626 Figure 44 1. Fuel shut-off valve 37 2.
Electrical System Maintenance Servicing the Battery WARNING 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. 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. 6.
Locating the Fuses 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. The fuses in the machine’s electrical system are located under the seat (Figure 46). • 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.
Drive System Maintenance Adjusting the Transport Speed Adjusting the Transmission for Neutral 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. If the machine creeps when the traction control pedal is in the neutral position, the neutral return mechanism must be adjusted. 1.
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). g014625 Figure 49 1. Jam nut 2. Nut 3. Trunnion bolt 3. Rotate the trunnion bolt clockwise to reduce the mowing speed and counterclockwise to increase the mowing speed. 4.
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.
Hydraulic System Maintenance Stop the machine, recheck the fluid level and replenish as required. 6. Dispose of the oil and filter properly. Checking the Hydraulic Lines and Hoses Changing the Hydraulic Oil and Filter Service Interval: After the first 50 hours WARNING Every 800 hours Hydraulic fluid escaping under pressure can penetrate skin and cause injury. If the oil becomes contaminated, contact your local Toro distributor because the system must be flushed.
Cutting Unit Maintenance Backlapping the Reels 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. 2. Remove the plastic cover to the left side of the seat. 3.
Diagnostics System Note: The system stores only the three most recent fault codes. For a list of error codes, refer to your Authorized Distributor or the Service Manual. Diagnosing the Service Indicator Light The service indicator light illuminates in the event of a fault in the machine. When this light is on, you can access the computer codes to diagnose the problem by entering diagnostic mode.
Storage 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. 2. Block up the wheels to remove any weight on the tires. 3.
Notes:
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).
