Form No. 3366-522 Rev C Greensmaster® 3400 TriFlex™ Traction Unit Model No. 04520—Serial No. 311000001 and Up g014597 To register your product or download an Operator's Manual or Parts Catalog at no charge, go to 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 Changing the Engine Oil and Filter ..................... 37 Fuel System Maintenance ....................................... 38 Fuel Filter/Water Separator ................................ 38 Fuel Lines and Connections................................ 39 Electrical System Maintenance................................ 39 Servicing the Battery........................................... 39 Storing the Battery.............................................. 40 Fuses..........................................
Safety ◊ the type of machine is unsuitable for the task; ◊ 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 70 lb (31.7 kg) of weight is added to the rear wheel.
• Remember there is no such thing as a safe slope. Travel on grass slopes requires particular care. To guard against overturning: – do not stop or start suddenly when going up or downhill; – machine speeds should be kept low on slopes and during tight turns; – stay alert for humps and hollows and other hidden hazards; – never mow across the face of the slope, unless the mower is designed for this purpose. • Stay alert for holes in the terrain and other hidden hazards.
• Clean grass and debris from cutting units, drives, mufflers, and engine to help prevent fires. Clean up oil or fuel spillage. • Use jack stands to support components when required. • Carefully release pressure from components with stored energy. • Disconnect battery before making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last. • Use care when checking the reels. Wrap the reels or wear gloves, and use caution when servicing them.
Sound Pressure Level parking brake. Stop the engine and remove the key from the ignition switch. • Whenever the machine is left unattended, make sure the cutting units are fully raised, the reels are not spinning, the key is removed from the ignition switch, and the parking brake is set. This unit has a sound pressure level at the operator’s ear of 84 dBA, which includes an Uncertainty Value (K) of 1 dBA. Sound pressure level was determined according to the procedures outlined in EN 836.
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. 115-8155 1. Warning—read the Operator's Manual, do not prime or use starting fluid. 115-8156 1. Reel height 3. 8 Blade cutting unit 5. 14 Blade cutting unit 7. Slow 2. 5 Blade cutting unit 4. 11 Blade cutting unit 6. Reel speed 8.
117–9536 1. Warning—wear hearing protection. 2. Warning—read the Operator's Manual, do not operate this machine unless you are trained. 115-8201 3. Cutting/dismemberment hazard of hand or foot, mower blade—stay away from moving parts; keep all guards and shields in place. 1. Read the Operator's manual for fuse information. 4. Tipping hazard—slow machine before turning, do not turn at high speeds. 5. Thrown object hazard—keep bystanders a safe distance from the machine. 6.
117–9537 Replaces 117–9536 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 maximum slope angles indication for operation of this machine are prescribed by and required by this standard. 1. Warning—wear hearing protection. 2. Warning—read the Operator's Manual, do not operate this machine unless you are trained. 3.
9-1657 1. Throttle—fast 4. Lower the reels and engage. 7. Use for transport 2. Throttle—continuous variable setting 5. Raise the reels 8. Use for mowing 3. Throttle—slow 6. Functional control lever 9. Neutral—Use for backlapping reels 119-1658 1. Read the Operator's Manual before performing any maintenance. 2. Oil pressure warning light. 119-1688 1. Choke 3. Engine—preheat, On 2. Engine—start 4.
119-9343 Battery Symbols Some or all of these symbols are on your battery. 119-9346 1. Press pedal to unlock 2. Read the Operator's Manual for more information. 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.
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.
1 2 Installing the Roll Bar Installing the Seat Parts needed for this procedure: Parts needed for this procedure: 1 Roll bar 4 Bolt (1/2 x 3-3/4 inches) 4 Flange-nut (1/2 inch) 1 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.
3. Secure the steering wheel to the shaft with a jam nut and tighten it to 20 to 26 ft-lb (27 to 35 N-m) (Figure 4). 4. Install the cap to the steering wheel and secure it with a screw (Figure 4). 4 Activating and Charging the Battery Figure 6 1. Electrolyte No Parts Required 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).
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. Figure 7 1. Negative (-) 2.
2 2 1 g014596 Figure 9 Figure 8 1. Prop (not provided) 1. Flange bolt 3. Suspension arm bar 2. Bedknife adjusting screw nut (2) 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. 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.
down so that the bar fits over the bar across the top of the cutting unit (Figure 12). 1 2 3 4 23 g014609 Figure 11 1. Latch—closed position 1 3. Latch—open position 2. Suspension-arm bar 1 2 g014690 Figure 13 g01461 1 1. Reel motor 3. Cavity 2. Spline shaft 4. Motor retaining bar Figure 12 1. Suspension-arm bar 2. Cutting-unit bar 9. Mount a grass basket onto the basket hooks on the suspension arm. 10. Repeat this procedure for the other cutting units. 6.
Product Overview 9 Installing EU Decals 4 2 3 Parts needed for this procedure: 1 5 Warning decal 117-9537 1 6 Procedure 7 If this machine will be used in the EU, affix the warning decal 117-9537 over English warning decal 117-9536. 8 g014674 Figure 14 1. Engine 5. Steering wheel 2. Roll bar 6. Traction pedal 3. Control panel 7. Foot rest 4. Seat 8.
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.
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.
1 2 1 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 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.
Specifications Operation Note: Specifications and design are subject to change without notice. Width of cut 59.5 inches (151 cm) Wheel tread 50.5 inches (128 cm) Wheel base 48.6 inches (123 cm) Overall length (w/baskets) 98.0 inches (249 cm) Overall width 70.62 inches (179 cm) Overall height 80.83 inches (205 cm) Net Weight w/reels (11 Blade) Note: Determine the left and right sides of the machine from the normal operating position.
2. Remove the dipstick and wipe it with a clean rag (Figure 25). Push the dipstick into the tube and make sure it is seated fully. Remove the dipstick from the tube and check the level of oil. 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. Add the oil slowly and check the level often during this process. Do not overfill.
DANGER DANGER Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage. 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.
The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol antifreeze. Check the level of the coolant at the beginning of each day before starting the engine. CAUTION 1 If the engine has been running, the pressurized, hot coolant can escape and cause burns. • Do not open the radiator cap when the engine is running. • Use a rag when opening the radiator cap, and open the cap slowly to allow steam to escape. 1. Park the machine on a level surface. 2.
hydraulic fluid. Check the level of the hydraulic fluid before the engine is first started and daily thereafter. The recommended replacement fluid is as follows: authorized Toro distributor. This red dye is not recommended for use with biodegradable fluids. Important: Regardless of hydraulic fluid type used, any machine used for mowing fairways, verticutting or used during ambient temperatures above 85°F (29°C) should have Oil Cooler Kit, Part No. 117-9314, installed.
Note: Because the accumulated water will be mixed with diesel fuel, drain the fuel filter into a suitable container and dispose of it properly. refer to Adjusting the Reel to Bedknife in the Cutting Unit Operator’s Manual. 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.
cranking, wait 60 seconds before engaging the starter motor again. The safety interlock system prevents the reels from operating unless the functional control lever is in the Mow position. 6. Allow the engine to warm up for a few minutes before operating.
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 1 The foot rest can pinch fingers if it falls into the closed position. 2 Keep your fingers clear of the area where the foot rest seats while it is open. g01461 1 2 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).
4 23 2 1 1 g014605 Figure 35 1. Reel motor 2. Motor retaining bar 3. Move the motor to the storage location on the front of the suspension arm (Figure 36). g014690 g014608 Figure 34 1. Reel motor 3. Cavity 2. Spline shaft 4. Motor retaining bar Figure 36 Note: When sharpening, setting the height-of-cut, or performing other maintenance procedures on the cutting units, store the cutting unit reel motors in the storage location on the front of the suspension arms to prevent damage to them. 7.
Setting the Reel Speed Note: You can increase or decrease the reel speed to compensate for turf conditions. To achieve a consistent, high quality–of–cut and a uniform after cut appearance, it is important that the reel speed control (located on the manifold block under the cover to the left of the seat) be correctly set. Preparing the Machine for Mowing Adjust the reel speed control as follows: 1. Select the height-of-cut at which the cutting units are set. 2.
mowing so that the grass blades will be less apt to lay down and therefore be difficult to trap between the reel blades and bedknife. Mowing Procedures 1. Approach the green with the shift selector in the No. 1 position. Start on one edge of the green so that the ribbon procedure of cutting may be used. This holds compaction to a minimum and leaves a neat, attractive pattern on the greens. 2. Actuate the mow pedal as the front edge of the grass baskets cross the outer edge of the green.
Note: At the end of the periphery cut, momentarily pull back on the raise/lower mow lever to shut the reels off without raising them. Continue moving forward until the reel stops rotating, then, drive off the green and raise the reels (This will help prevent dribbling grass onto the green while raising the reels). 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 41). 7.
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 possibility of damage to the filter media. Inspect the new filter for shipping damage, 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 • Check the air cleaner body for damage which could cause an air leak. Replace if damaged.
Fuel System Maintenance Fuel Filter/Water Separator Service Interval: Every 800 hours Servicing the Filter 1. Close the fuel shut off valve (Figure 45) below the fuel tank. 1 g014615 Figure 44 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. 1 4. Add oil to the crankcase; refer to Checking the Engine Oil (page 23). 5. Dispose of the used oil and filter properly. g01462 6 Figure 45 1.
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 46 1. Fuel filter /water separator canister 2. Filter drain plug 5. Unscrew the filter canister and dispose of it according to local regulations.
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 51). 2 1 3 4 g014625 Figure 50 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.
Brake Maintenance Belt Maintenance Adjusting the Brakes Adjusting the Alternator Belt Service Interval: Yearly—Burnish the brakes. Service Interval: After the first 8 hours 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.
Hydraulic System Maintenance 5. Stop the machine, recheck the fluid level and replenish as required. Changing the Hydraulic Oil and Filter Checking the Hydraulic Lines and Hoses 6. Dispose of the oil and filter properly. Service Interval: After the first 50 hours Every 800 hours WARNING 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 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 55 1. Reel speed control 2. Remove the plastic cover to the left side of the seat. 3.
Diagnostics System – If the code is 123, the blink pattern will be ############_### Diagnosing the Service Indicator Light • If there are more than one fault, the tens place of the next fault will begin after a pause after the ones place of the first fault. Note: The system stores only the three most recent fault codes. The service indicator light illuminates in the event of a fault in the machine.
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; refer to Lubrication. 2. Block up the wheels to remove any weight on the tires. 3.
Schematics g014737 Electrical Schematic (Rev.
Hydraulic Schematic (Rev.
Notes: 50
Notes: 51
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).
