Form No. 3427-136 Rev A Greensmaster® 3400 TriFlex® Traction Unit Model No. 04520—Serial No. 403420001 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. Visit www.Toro.com for more information, including safety tips, training materials, accessory information, help finding a dealer, or to register your product.
Contents Servicing the Battery......................................... 36 Locating the Fuses ........................................... 36 Drive System Maintenance .................................. 37 Checking the Tire Pressure............................... 37 Checking the Torque of the Wheel Nuts .............................................................. 37 Adjusting the Transmission for Neutral.............. 37 Adjusting the Transport Speed..........................
Safety • Do not operate the machine without all guards This machine has been designed in accordance with EN ISO 5395 and ANSI B71.4-2017 and meets these standards when you complete the setup procedures. • Keep bystanders and children out of the operating and other safety protective devices in place and functioning properly on the machine. area. Never allow children to operate the machine.
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.
decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. decal106-6755 106-6755 1. Engine coolant under pressure. 3. Warning—do not touch the hot surface. 1. Explosion hazard 6. Keep bystanders away from the battery. 2. Explosion hazard—read the Operator's Manual. 4. Warning—read the Operator's Manual. 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.
decal132-9549 132-9549 1. Read the Operator's Manual before servicing or performing maintenance. 2. Hydraulic-fluid level 4. Engine—start 3. Choke 6. Engine—stop 5. Engine—run decal138-9695 138-9695 1. Engine speed—Fast 7. Traction—Mow 2. Engine speed—Slow 8. Traction—Neutral 3. Lower and engage the reels. 9. Reel—Transport 4. Raise and disengage the reels. 10. Reel—Mow 5. Mow direction 11. Reel—Backlapping 6.
decal136-8505 136-8505 Note: This machine complies with the industry standard stability test in the static lateral and longitudinal tests with the maximum recommended slope indicated on the decal. Review the instructions for operating the machine on slopes in the Operator’s Manual as well as the conditions in which you would operate the machine to determine whether you can operate the machine in the conditions on that day and at that site.
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. 4 No parts required – Activate and charge the battery. 5 Oil Cooler Kit—Greensmaster 3400 Series Traction Unit (Part No.
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 to the machine; refer to the kit Installation Instructions. 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). 4 Activating and Charging the Battery g005080 Figure 5 3. No Parts Required Carefully fill each cell with electrolyte until the plates are covered with about 6 mm (1/4 inch) of fluid (Figure 6). Procedure Use only electrolyte (1.265 specific gravity) to fill the battery initially.
6. When the battery is charged, disconnect the charger from the electrical outlet and battery posts. 5 Note: After the battery has been activated, Installing the Oil Cooler add only distilled water to replace normal loss, although maintenance-free batteries should not require water under normal operating conditions. Optional Important: Failure to correctly activate the battery may result in battery gassing and/or premature battery failure. 7. Install the vent caps. 8.
6 7 Installing the Grass-Basket Hooks Installing the Cutting Units Parts needed for this procedure: Parts needed for this procedure: 6 Grass-basket hook 12 Flange bolts Procedure 1 Gauge bar 3 Cutting unit (obtain from your authorized Toro distributor) 3 Grass basket Procedure Install the 6 grass-basket hooks onto the ends of the suspension-arm bars using the 12 flange bolts (Figure 8). 1. Prepare the cutting units for installation; refer to your cutting unit Operator’s Manual. 2.
9 Installing the CE Guard Kit Parts needed for this procedure: 1 CE Guard Kit―Part No. 04442 (sold separately) g233420 Procedure Figure 9 Install the CE Guard Kit; refer to the CE Guard Kit for Greensmaster 3400 TriFlex Traction Unit Installation Instructions. 1. CE mark decal • Install the production year decal near the serial plate (Figure 10). 10 Installing the CE Decals Parts needed for this procedure: 1 Warning decal (Part No.
Product Overview 11 Reducing the Tire Pressure No Parts Required Procedure The tires are overinflated at the factory for shipping purposes. Reduce the pressure to the proper levels before starting the machine; refer to Checking the Tire Pressure (page 37). 12 Burnishing the Brakes g014674 Figure 11 No Parts Required 1. Engine 2. Roll bar 6. Traction pedal Procedure 3. Control panel 7. Footrest 4. Seat 8. Cutting units 5.
Steering-Arm-Locking Pedal Press the pedal (Figure 12) and raise or lower the steering arm for operator comfort, then, release the pedal to lock the arm in place. Throttle Lever The throttle lever (Figure 14) allows you to control the speed of the engine. Move the throttle lever toward the FAST position to increases the engine speed; move it toward the SLOW position to decrease the engine speed. Note: You cannot stop the engine using the throttle lever. g014603 Figure 12 1. Traction pedal—forward 3.
Functional Control Lever Hour Meter The functional control lever (Figure 14) provides 2 traction selections plus a NEUTRAL position. You can shift from mow to transport or transport to mow (not to neutral) while the machine is in motion; no damage will result. The hour meter (Figure 15) indicates the total hours the machine has operated. It starts to function whenever you rotate the ignition switch to the ON position.
Backlap Lever Seat-Adjusting Lever The backlap lever is located under the plastic cover to the left of the seat. Use the backlap lever (Figure 17) in conjunction with the raise/lower mow control lever and the reel-speed control for backlapping the reels. The seat-adjusting lever is located on the front, left corner of the seat (Figure 19), allowing you to adjust the seat forward and rearward.
Fuel-Shutoff Valve Specifications Close the fuel-shutoff valve (Figure 20), behind the seat and under the fuel tank, when storing or transporting the machine on a truck or trailer. Note: Specifications and design are subject to change without notice. Width of cut 151 cm (59.5 inches) Wheel tread (to the center of the tire) 128 cm (50.5 inches) Wheel tread (to the outside of the tire) 154 cm (60.5 inches) Minimum ground clearance (at the machine centerline) 11 cm (4.
Fuel Specification Operation • Fuel tank capacity: 22.7 L (6 U.S. gallons) Note: Determine the left and right sides of the • Recommended Fuel: machine from the normal operating position. – 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.
Filling the Fuel Tank 1. During Operation Clean around the fuel-tank cap and remove it (Figure 21). During Operation Safety General Safety • The owner/operator can prevent and is responsible • • • g272992 Figure 21 1. Fuel-tank cap 2. • Add the specified fuel to the fuel tank until the level is 25 mm (1 inch) below the bottom of the filler neck. This space in the tank allows the fuel to expand. • • Important: Do not fill the fuel tank • completely full. 3. Install the cap.
• – Wait for all movement to stop. Operate the machine only in good visibility and appropriate weather conditions. Do not operate the machine when there is the risk of lightning. • Rollover Protection System (ROPS) Safety • • Do not remove any of the ROPS components from • • • • • the machine. Ensure that the seat belt is attached and that you can release it quickly in an emergency. Always wear your seat belt. Check carefully for overhead obstructions and do not contact them.
5. Turn the ignition key to the START position. Note: If fluid leaks continue to appear, contact Important: To prevent overheating of the your authorized Toro distributor for assistance and, if necessary, replacement parts. starter motor, do not engage the starter longer than 10 seconds. After 10 seconds of continuous cranking, wait 60 seconds before engaging the starter motor again. 6. Release the key when the engine starts and allow it to move to the ON position. 7.
Checking the Raise/Lower Mow Control Checking the Traction Pedal Perform the following system checks daily to ensure that the interlock system is operating correctly: 1. 2. Sit on the seat, move the traction pedal to the NEUTRAL position, move the functional-control lever to the NEUTRAL position, and engage the parking brake. Try to move the traction pedal forward or backward. The pedal should not move, which indicates that the interlock system is operating correctly.
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. Note: This holds compaction to a minimum and leaves a neat, attractive pattern on the greens. 3. Push forward the raise/lower mow lever as the front edges of the grass baskets cross the outer edge of the green. Note: This procedure drops the cutting units to the turf and starts the reels.
Cutting the Periphery and Finishing the Job 1. After Operation Finish cutting the green by mowing the outer periphery. Change the direction of cutting from the previous mowing. After Operation Safety General Safety Note: Use the throttle lever to adjust the machine speed when you cut the periphery. This will match the clip to the green and may reduce triplex ring. • Shut off the engine, remove the key (if equipped), and wait for all movement to stop before you leave the operator’s position.
Inspecting and Cleaning after Mowing Hauling the Machine 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. • Use a full-width ramp for loading the machine into • Use care when loading or unloading the machine into a trailer or a truck. a trailer or a truck.
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 25). g014627 Figure 25 1. Bypass valve-slot shown in closed (horizontal) position 2.
Maintenance CAUTION 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.
Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first hour • Torque the wheel nuts. After the first 8 hours • Check the tension on the alternator belt. After the first 10 hours • Torque the wheel nuts. After the first 50 hours • Change the engine oil and filter. • Check the engine speed (at idle and full throttle). Before each use or daily • Inspect the seat belt(s) for wear, cuts, and other damage.
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.
Engine Maintenance into the intake when you remove the primary filter. Engine Safety Important: Avoid using high-pressure air that could force dirt through the filter into the intake tract. • Shut off the engine before checking the oil or adding oil to the crankcase. Do not change the governor speed or overspeed the engine. • 4. Remove and replace the primary filter, as follows: Important: Do not clean the used element. Servicing the Air Cleaner A.
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. 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. 1. Position the machine on a level surface. 2. Remove the dipstick and wipe it with a clean rag (Figure 28). Important: Remove the dipstick while filling the engine with oil.
Fuel System Maintenance Draining Water from the Fuel Filter Service Interval: Before each use or daily g014754 Figure 29 1. Park 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 31). 1. Drain plug 2. Remove the oil filter (Figure 30). Apply a light coat of clean oil to the new filter gasket. g014720 Figure 31 1. Fuel filter 4.
Replacing the Fuel Filter/Water Separator 6. Screw the filter on by hand until the gasket contacts the filter adapter, then tighten 1/2 to 3/4 turn further. Service Interval: Every 500 hours 7. Ensure that the filter-drain plug is closed. Open the fuel-shutoff valve. 1. Close the fuel-shutoff valve (Figure 32) below the fuel tank. Inspecting the Fuel Lines and Connections Service Interval: Every 2 years Inspect the fuel lines for deterioration, damage, or loose connections. g014626 Figure 32 1.
Electrical System Maintenance 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. Electrical System Safety • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. • 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.
Drive System Maintenance Checking the Tire Pressure Service Interval: Before each use or daily Vary the tire pressure for all 3 wheels, depending upon your turf conditions, from a minimum of 83 to a maximum of 110 kPa (12 psi to 16 psi). Checking the Torque of the Wheel Nuts g014616 Figure 35 Service Interval: After the first hour 1. Eccentric 2. Locknut After the first 10 hours Every 200 hours WARNING Failure to maintain proper torque of the wheel nuts could result in personal injury.
Adjusting the Mowing Speed The mow speed is set to 3.8 mph at the factory. You can adjust the forward moving speed from 0 to 8 km/h (0 to 5 mph). 1. Loosen the jam nut on the trunnion bolt (Figure 37). 2. Loosen the nut securing the lock and mow brackets on the pedal pivot. g015494 Figure 36 1. Pedal stop 1. Put the functional-control lever in the TRANSPORT position and loosen the locknut securing the pedal stop to the floor plate (Figure 36). 2.
Cooling System Maintenance 3. Checking the Engine-Coolant Level Cooling System Safety The capacity of the cooling system is approximately 4.6 L (4.9 US qt). • Swallowing engine coolant can cause poisoning; keep out of reach from children and pets. Fill the cooling system 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.
Brake Maintenance Belt Maintenance Burnishing the Brakes Adjusting the Alternator Belt Service Interval: Yearly Firmly apply the brakes and drive the machine at mowing speed until the brakes are hot, as indicated by their smell. You may need to adjust the brakes after the break-in period; refer to Adjusting the Brakes (page 40). 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.
Hydraulic System Maintenance products only from reputable manufacturers who will stand behind their recommendation. High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46 Hydraulic System Safety Material Properties: • Seek immediate medical attention if fluid is injected Viscosity, ASTM D445 into skin. Injected fluid must be surgically removed within a few hours by a doctor.
Changing the Hydraulic Fluid and Filter Service Interval: Every 800 hours—If you are not using the recommended hydraulic fluid or have ever filled the reservoir with an alternative fluid, change the hydraulic fluid, filter, and tank breather. Every 1,000 hours—If you are using the recommended hydraulic fluid, change the hydraulic-fluid filter. g014719 Figure 41 Every 2,000 hours—If you are using the recommended hydraulic fluid, change the hydraulic fluid. 1. Hydraulic-tank cap or dipstick location 1.
3. Fill the hydraulic reservoir with hydraulic fluid; refer to Hydraulic Fluid Specifications (page 41) and Hydraulic Fluid Specifications (page 41). Cutting Unit Maintenance 4. Start the machine and run it at idle for 3 to 5 minutes to circulate the fluid and remove any air trapped in the system. Shut off the engine and check the fluid level. Blade Safety 5.
g014609 Figure 45 1. Latch—closed position g014596 Figure 43 3. Latch—open position 2. Suspension-arm bar 2. Bedbar-adjusting-screw nut (2) 1. Prop (not provided) Installing the Cutting Units 1. Lift up on the footrest and swing it open, allowing access to the center cutting unit position (Figure 44). CAUTION The footrest can pinch fingers if it falls into the closed position. Keep your fingers clear of the area where the footrest seats while it is open. g014611 Figure 46 1.
g014605 Figure 48 1. Reel motor 3. 2. Motor-retaining bar Move the motor to the storage location on the front of the suspension arm (Figure 49). g014690 Figure 47 1. Reel motor 3. Cavity 2. Spline shaft 4. Motor-retaining bar g014608 Figure 49 Note: When sharpening, setting the height 7. Mount a grass basket onto the basket hooks on the suspension arm. 8. Repeat this procedure for the other cutting units.
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 g014620 Figure 50 1. Backlap lever—FORWARD position WARNING Contact with the reels or other moving parts can result in personal injury. 6.
12. When finished, return the backlap levers to the FORWARD (F) position, replace the cover, and wash all lapping compound off of the cutting units. Adjust cutting unit reel to bedknife as needed. Move the cutting unit reel speed control to the desired mowing position. Important: If the backlap lever is not returned to the FORWARD (F) position after backlapping, the cutting units will not raise or function properly.
Reel Speed Table Reel Speed Table Height of Cut 5-blade cutting unit 11-blade cutting unit 8-blade cutting unit 14-blade cutting unit Ground Speed 6.1 km/h (3.8 mph) 8.0 km/h (5.0 mph) 6.1 km/h (3.8 mph) 8.0 km/h (5.0 mph) 6.1 km/h (3.8 mph) 8.0 km/h (5.0 mph) 6.1 km/h (3.8 mph) Reel speed setting 1.6 mm (0.062 inch) *N/R *N/R 9 *N/R 9 *N/R 9 2.4 mm (0.094 inch) *N/R *N/R 9 *N/R 9 *N/R 9 3.2 mm (0.125 inch) *N/R *N/R 9 *N/R 9 *N/R *N/R 4.0 mm (0.
2. Move the functional-control lever to the TRANSPORT position. Storage 3. Ensure that the backlap lever is set to the FORWARD (F) position. Storage Safety 4. Get off the seat. • Shut off the machine, remove the key (if equipped), 5. Hold the raise/lower mow control in the RAISED position. 6. Turn the ignition switch to the RUN position. 7. Count the codes as they begin to flash (you may release the raise/lower mow control once they begin flashing).
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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).
