Form No. 3417-544 Rev A Greensmaster® 3400 TriFlex® Traction Unit Model No. 04520—Serial No. 400000000 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. g228077 Figure 1 1.
Contents Checking the Torque of the Wheel Nuts .............................................................. 33 Adjusting the Transmission for Neutral.............. 33 Adjusting the Transport Speed.......................... 34 Adjusting the Mowing Speed ............................ 35 Cooling System Maintenance .............................. 35 Cooling System Safety ..................................... 35 Cleaning the Radiator Screen ........................... 35 Checking the Engine-Coolant Level.......
Safety • Do not operate the machine without all guards This machine has been designed in accordance with EN ISO 5395:2013 and ANSI B71.4-2017 and meets these standards when the appropriate weight kit is added. • • General Safety • This product is capable of amputating hands and feet and of throwing objects. Always follow all safety instructions to avoid serious personal injury. and other safety protective devices in place and working on the machine. Keep clear of any discharge opening.
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 decal115-8155 115-8155 1. Warning—read the Operator's Manual, do not prime or use starting fluid. decal115-8203 115-8203 1. Read the Operator's Manual for fuse information. decal115-8226 115-8226 2. Radiator fan—50 A 1.
decal117-2718 117–2718 decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. decal131-2046 131-2046 1. Double lights 3. Off 1. Explosion hazard 6. Keep bystanders a safe distance away from the battery. 2. No fire, open flame, 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.
decal132-9548 132-9548 1. Engine speed—fast 7. Reel speed—neutral 2. Engine speed—slow 8. Reel—transport 9. Reel—mow 3. Lower and engage the reels 4. Raise and disengage the reels 10. Reel—backlaping 5. Reel speed—fast 11. Move forward 6. Reel speed—slow decal132-9549 132-9549 4. Engine—start 1. Read the Operator's Manual before servicing or performing maintenance. 2. Hydraulic fluid level 5. Engine—run 3. Choke 6.
decal133-2338 decal133-2339 133-2338 1. Warning—read the Operator’s Manual, do not operate this machine unless you are trained. 4. Tipping hazard—slow the machine before turning, do not turn at high speeds. 2. Warning—wear hearing protection. 5. Thrown object hazard—keep bystanders a safe distance away from the machine. 6. Warning—lock the parking brake, shut off 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 optional oil cooler.
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 locknut 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 6 bolts (Figure 4). 3. Carefully fill each cell with electrolyte until the plates are covered with about 6 mm (1/4 inch) of fluid (Figure 6). 4 Activating and Charging the Battery No Parts Required g032705 Figure 6 Procedure 1. Electrolyte Use only electrolyte (1.265 specific gravity) to fill the battery initially. 4.
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.
6 Installing the Grass-Basket Hooks Grass-basket hook 12 Flange bolts Apply grease to the inside diameter of the drive coupler. 3. Install the cutting units as described in Installing the Cutting Units (page 40). 8 Parts needed for this procedure: 6 2. Adding Rear Weight Parts needed for this procedure: Procedure 1 Install the 6 grass-basket hooks onto the ends of the suspension-arm bars using the 12 flange bolts (Figure 8). Weight Kit, Part No.
Product Overview 10 Installing the CE Guard Kit EU Only Parts needed for this procedure: 1 CE Guard Kit (Model No. 04442—purchase separately) Procedure This machine complies with EN ISO 5395:2013 when you equip it with the CE Guard Kit (Model No. 04442). 11 g014674 Figure 9 Reducing the Tire Pressure 1. Engine No Parts Required 5. Steering wheel 2. Roll bar 6. Traction pedal 3. Control panel 7. Foot rest 4. Seat 8.
Note: You cannot stop the engine using the throttle lever. g014603 Figure 10 1. Traction pedal—forward g032816 Figure 12 3. Steering-arm-locking pedal 1. Throttle lever 2. Taction pedal—reverse 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.
the key counterclockwise to the OFF position to shut off the engine. Battery-Warning Light The light (Figure 12) glows if the battery charge is low. Engine-Oil-Pressure Light The light (Figure 12) glows if the engine-oil pressure drops below a safe level. Water-Temperature Light The light (Figure 12) glows and the engine automatically shuts down when the engine-coolant temperature gets too high.
in conjunction with the raise/lower mow control lever and the reel-speed control for backlapping the reels. g014620 Figure 15 1. Backlap lever—mow position 2. Backlap lever—backlap position g193737 Figure 17 1. Seat-adjusting handle 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 16) to adjust the speed of the reels.
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 (48.5 inches) Overall length (w/baskets) Overall width Overall height Net Weight w/reels (11 Blade) Before Operation Safety 249 cm (98 inches) General Safety 179 cm (70.
Filling the Fuel Tank • Fuel tank capacity: 22.7 L (6 U.S. gallons) • Recommended Fuel: – For best results, 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. – Use summer-grade diesel fuel (No. 2-D) at temperatures above -7° C (20° F) and winter-grade (No. 1-D or No. 1-D/2-D blend) below that temperature.
Performing Daily Maintenance • Stop the cutting units whenever you are not • Before starting the machine each day, perform the following procedures: • Check the engine-oil level—refer to Checking the Engine Oil (page 29). • Drain water from the fuel filter—refer to Draining Water from the Fuel Filter (page 31). • Check the cooling system—refer to Cooling System Safety (page 35). • Check the tire pressure—refer to Checking the Tire Pressure (page 33).
Starting the Engine slopes are safe for machine operation. Always use common sense and good judgement when performing this survey. Important: Do not use ether or other types of starting fluid. • Slopes are a major factor related to loss-of-control Note: You may need to bleed the fuel system before and tip-over accidents, which can result in severe injury or death. Operating the machine on any slope requires extra caution.
3. Close the fuel shut-off valve before storing the machine. The engine should not turnover or start, which means that the interlock system is operating correctly. Correct the problem if it is not operating properly. Checking the Safety-Interlock System CAUTION If the safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. • Do not tamper with the interlock switches.
Mowing in the opposite direction, then turn it in the direction of the uncut portion; i.e., if intending to turn right, first swing slightly left, then right. Before mowing greens, find a clear area and practice starting and stopping the machine, raising and lowering the cutting units, turning, etc. Note: This helps to get the machine more quickly aligned for the next pass. Try to make as short of a turn as possible except during warmer weather when a wider arc minimizes the turf bruising.
water pressure does not contaminate and damage the seals and bearings. Do not wash a warm engine or electrical connections with water. reels, then drive off the green. When all the cutting units are off of the green, raise them. Note: This minimizes grass clumps left on the green. 10. Replace the flag. 11. Empty the grass baskets of all clippings before transporting to the next green.
Towing the Machine In case of an emergency, you can tow the machine for up to 0.4 km (1/4 mile). Important: Do not tow the machine faster than 3 to 5 km/h (2 to 3 mph) to avoid damaging the drive system. If you must move the machine more than 0.4 km (1/4 mile), 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 22). g014627 Figure 22 1. Bypass valve-slot shown in closed (horizontal) position 2.
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.
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/empty the fuel filter/water separator. Check the fuel level. Check the hydraulic-fluid 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.
Pre-Maintenance Procedures Engine Maintenance Engine Safety • Shut off the engine before checking the oil or Pre-Maintenance Safety adding oil to the crankcase. Do not change the governor speed or overspeed the engine. • • Before adjusting, cleaning, repairing, or leaving the machine, do the following: – Park the machine on a level surface. Servicing the Air Cleaner – Move the throttle switch to the low-idle position.
checking. If the oil level is at or below the Add mark on the dipstick, add oil to bring the oil level to the FULL mark. Do not overfill. into the intake when you remove the primary filter. Important: Avoid using high pressure air which could force dirt through the filter into the intake tract. 4. Important: Keep the engine oil level between the upper and lower limits on the oil gauge; the engine may fail if you run it with too much or too little oil. Remove and replace the primary filter, as follows:.
g014754 Figure 26 g014618 1. Drain plug Figure 25 1. Filler cap 2. Dipstick 3. Push the dipstick into the tube and make sure it is seated fully. 4. Remove the dipstick from the tube and check the level of oil. 2. Remove the oil filter (Figure 27). Apply a light coat of clean oil to the new filter gasket. Note: If the oil level is low, remove the filler cap from the valve cover and slowly add enough oil to raise the level to the FULL mark on the dipstick.
Replacing the Fuel Filter/Water Separator Fuel System Maintenance Service Interval: Every 800 hours Draining Water from the Fuel Filter 1. Close the fuel-shutoff valve (Figure 29) below the fuel tank. Service Interval: Before each use or daily 1. Position the machine on a level surface and shut off the engine. 2. Place a drain pan under the fuel filter. 3. Open the drain plug on the fuel filter approximately one turn and drain any accumulated water (Figure 28). g014626 Figure 29 1.
6. Screw the filter on by hand until the gasket contacts the filter adapter, then tighten 1/2 to 3/4 turn further. 7. Ensure that the filter-drain plug is closed. Open the fuel-shutoff valve. Electrical System Maintenance Electrical System Safety Inspecting the Fuel Lines and Connections • Disconnect the battery before repairing the Service Interval: Every 2 years • Charge the battery in an open, well-ventilated machine. Disconnect the negative terminal first and the positive last.
Drive System Maintenance with water after cleaning it. Do not remove the fill caps while cleaning the battery. The battery cables must be tight on the terminals to provide good electrical contact. Checking the Tire Pressure WARNING Incorrect battery cable routing could damage the tractor and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable.
g014616 g015494 Figure 32 1. Eccentric Figure 33 2. Locknut B. Move the functional-control lever to the NEUTRAL position and the throttle to the SLOW position. Start the engine. C. Rotate the eccentric until creep does not occur in either direction. When the wheel stops rotating, tighten the nut locking the eccentric and the adjustment (Figure 32). Verify the adjustment with the throttle in the SLOW and FAST position. 1.
Adjusting the Mowing Speed Cooling System Maintenance The mow speed is set to 3.8 mph at the factory. Cooling System Safety The forward moving speed can be adjusted from 0 to 8 km/h (0 to 5 mph). 1. Loosen the jam nut on the trunnion bolt (Figure 34). 2. Loosen the nut securing the lock and mow brackets on the pedal pivot. • Swallowing engine coolant can cause poisoning; keep out of reach from children and pets.
Brake Maintenance Checking the Engine-Coolant Level Adjusting the Brakes The capacity of the cooling system is approximately 4.6 L (4.9 US qt). 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. Fill the cooling system with a 50/50 solution of water and permanent ethylene glycol antifreeze.
Belt Maintenance Hydraulic System Maintenance Adjusting the Alternator Belt Hydraulic System Safety • Ensure that all hydraulic-fluid hoses and Service Interval: After the first 8 hours Ensure that the belt is properly tensioned to ensure proper operation of the machine and prevent unnecessary wear. 1. Shut off the engine, set the parking brake, and remove the ignition key. 2. Apply moderate thumb pressure to the belt between the pulleys (10 kg or 22 lb). The belt should deflect 7 to 9 mm (0.28 to 0.
Filling the Hydraulic Tank High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46 Refer to Figure 38 for this procedure. Material Properties: Viscosity, ASTM D445 cSt @ 40°C 44 to 48 cSt @ 100°C 7.9 to 8.
Changing the Hydraulic Fluid and Filter Checking the Hydraulic Lines and Hoses Service Interval: After the first 50 hours WARNING Every 800 hours Hydraulic fluid escaping under pressure can penetrate skin and cause injury. If the fluid becomes contaminated, have your Toro distributor flush the system. Contaminated fluid looks milky or black when compared to clean fluid. 1.
Installing the Cutting Units Cutting Unit Maintenance 1. Cutting Unit Safety A worn or damaged blade or bed-knife can break, and a piece could be thrown at you or bystanders, resulting in serious personal injury or death. Lift up on the foot rest and swing it open, allowing access to the center cutting unit position (Figure 41). CAUTION The foot rest can pinch fingers if it falls into the closed position. • Inspect the blades and bed-knives periodically for excessive wear or damage.
g014611 Figure 43 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 42). Note: You can hear a click and feel when the latches are properly locked in place. 5. Coat the spline shaft of the cutting unit motor with clean grease (Figure 44). 6.
Checking the Reel-to-Bedknife Contact Each day before operating the machine, check the reel-to-bedknife contact, regardless if the quality of cut had previously been acceptable. There must be light contact across the full length of the reel and bedknife; refer to the Cutting Unit Operator’s Manual.
Backlapping the Reels WARNING Contact with the reels or other moving parts can result in personal injury. • Keep your 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. g014623 1. Position the machine on a level surface, lower the cutting units, shut off the engine, and engage the parking brake. 2. Remove the plastic cover to the left side of the seat. 3.
Diagnostics System 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. In diagnostic mode, the service indicator light flashes a number of times, giving you the error code that you or your distributor can use to identify the problem. Note: You cannot start the engine in diagnostic mode.
Storage 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. If you wish to store the machine for a long period of time, the following steps should be performed prior to storage: 45 1. Remove accumulations of dirt and old grass clippings. Sharpen the blades and bedknives, if necessary; refer to the Cutting Unit Operator's Manual. Use a rust preventive on bedknives and blades.
Notes:
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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).
