Form No. 3370-454 Rev B Greensmaster® 3420 TriFlex™ Traction Unit Model No. 04540—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 Servicing the Air Cleaner .................................... 39 Changing the Engine Oil and Filter ..................... 40 Fuel System Maintenance ....................................... 41 Fuel Filter/Water Separator ................................ 41 Fuel Lines and Connections................................ 41 Electrical System Maintenance................................ 42 Servicing the Battery........................................... 42 Storing the Battery...............................
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 119 lb (54 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.
• Using the machine demands attention. To prevent loss of control: – Do not drive close to sand traps, ditches, creeks, or other hazards. – Reduce speed when making sharp turns. Avoid sudden stops and starts. – Watch out for traffic when near or crossing roads. Always yield the right-of-way. – Apply the service brakes when going downhill to keep forward speed slow and to maintain control of the machine. • Shut the engine off before emptying the baskets.
Vibration Level • Keep your body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not your hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. • Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved by stopping the engine and lowering the cutting units and attachments to the ground.
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.
117–2718 115-8201 1. Read the Operator's manual for fuse information. 117–9536 1. Warning—wear hearing protection. 2. Warning—read the Operator's Manual, do not operate this machine unless you are trained. 3. Cutting/dismemberment hazard of hand or foot, mower blade—stay away from moving parts; keep all guards and shields in place. 4. Tipping hazard—slow machine before turning, do not turn at high speeds. 115-8203 1. Read the Operator's manual for fuse information. 5.
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 conservative 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 119-1688 119-1658 1. Read the Operator's Manual before performing any maintenance. 2. Leak detector warning light. 11 1. Choke (gasoline models only) 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.
1. Disconnect the cutting unit power disconnect couplers; refer to Cutting Unit Power Disconnect Couplers (page 23). 6 CAUTION Installing the Cutting Units If you do not disconnect the power to the cutting units, someone could accidentally start the cutting unit, causing serious injury to hands and feet.
7. 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 11). 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. 2 Figure 13 1. Suspension-arm bar 2. Cutting-unit bar g014602 1 10. Close the latches down and around the cutting-unit bar and lock them in place (Figure 12). Figure 11 1. Footrest—closed 2.
8 Installing EU Decals Parts needed for this procedure: 1 Warning decal 117-9537 Procedure If this machine will be used in the EU, affix the warning decal 117-9537 over warning decal 117-9536. Figure 14 1. Reel motor 3. Cavity 2. Spline shaft 4. Motor retaining bar 13. Mount a grass basket onto the basket hooks on the suspension arm. 14. Repeat this procedure for the other cutting units. 15. Connect the cutting unit power disconnect couplers; refer to Cutting Unit Power Disconnect Couplers (page 23).
Product Overview 1 4 2 5 2 3 3 1 6 7 g014603 Figure 16 1. Traction pedal—forward 3. Steering arm locking pedal 2. Taction pedal—reverse 8 g014674 Figure 15 1. Engine 5. Steering wheel 2. Roll bar 6. Traction pedal 3. Control panel 7. Foot rest 4. Seat 8. Reels with grass baskets Controls Figure 17 Traction Pedal The traction pedal (Figure 16) has three functions: to make the machine move forward, to move it backward, and to stop the machine.
Battery Warning Light Note: The engine cannot be stopped by the use of the throttle control. 2 3 1 The light (Figure 18) glows if the battery charge is low. Engine Oil Pressure Light 4 The light (Figure 18) glows if the engine oil pressure drops below a safe level. Water Temperature Light The light (Figure 18) glows and the engine automatically shuts down when the engine coolant temperature gets too high.
Figure 21 1. Backlap switch—backlap position 2. Backlap switch—mow position Reel Speed Control 1 The reel speed control is located under the plastic cover to the left of the seat. Use the reel speed control (Figure 22) to adjust the RPM of the reels. g014600 Figure 19 1. Hour meter Parking Brake Lever Pull up on the brake lever (Figure 16) to set the parking brake. Disengage it by pushing it forward and down. Set the parking brake any time you leave the machine. Figure 22 1.
Cutting Unit Power Disconnect Couplers Before installing, removing, or working on the cutting units, disconnect the cutting units from the power supply by separating the cutting unit power disconnect couplers (Figure 25), located as the base of the rollover bar on the left side of the traction unit. Connect the couplers together before operating the machine. 1 g014628 Figure 23 1.
Attachments/Accessories Operation A selection of Toro approved attachments and accessories are available for use with the machine to enhance and expand its capabilities. Contact your Authorized Service Dealer or Distributor or go to www.Toro.com for a list of all approved attachments and accessories. Note: Determine the left and right sides of the machine from the normal operating position. Think Safety First Please carefully read all of the safety instructions and symbols in the safety section.
2. Remove the dipstick and wipe it with a clean rag (Figure 27). 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: of hydraulic oil. Order part no. 44-2500 from your 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.
Checking the Torque of the Wheel Nuts before puncturing. Ensure the pour spout and funnel are clean. 4. Install the reservoir cap. Wipe up any fluid that may have spilled. WARNING Important: Check level of hydraulic fluid before engine is first started and daily thereafter. Failure to maintain proper torque of the wheel nuts could result in personal injury. Torque the wheel nuts to 70 to 90 ft-lb (95 to 122 N-m) after 1-4 hours of operation and again after 10 hours of operation.
2. Rotate the starter key to Off to shut the engine off. Remove the key from the switch to prevent accidental starting. as indicated by their smell. An adjustment to the brakes may be required after break-in; refer to Adjusting the Brakes. 3. Close the fuel shut-off valves before storing the machine. Starting and Stopping the Machine Checking the Safety Interlock System Note: Inspect the areas beneath the mowers to be certain they are clear of debris.
Installing and Removing the Cutting Units 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 3. Sit on the seat, move the traction pedal to Neutral, move the functional control lever to Neutral, and engage the parking brake. Start the engine and move the functional control lever to mow or transport.
1 2 3 g014609 Figure 35 1. Latch—closed position 3. Latch—open position 2. Suspension-arm bar Figure 37 3. Cavity 2. Spline shaft 4. Motor retaining bar 8. Mount a grass basket onto the basket hooks on the suspension arm. 9. Repeat this procedure for the other cutting units. 10. Connect the cutting unit power disconnect couplers; refer to Cutting Unit Power Disconnect Couplers (page 23). Figure 36 1. Suspension-arm bar 1. Reel motor 2. Cutting-unit bar Removing the Cutting Units 1.
6. Disconnect the latches from the cutting-unit bar. 7. Roll the cutting unit out from under the suspension arm. 8. Repeat steps 3 through 7 for the other cutting units as required. 9. Connect the cutting unit power disconnect couplers; refer to Cutting Unit Power Disconnect Couplers (page 23). Figure 38 1. Reel motor Setting the Reel Speed 2.
Figure 41 1. Reel speed control Figure 42 Note: You can increase or decrease the reel speed to compensate for turf conditions. Preparing the Machine for Mowing 1. Alignment strip 3. Cut grass on right 2. Approximately 5 inches (12.7 cm) 4. Keep focal spot 6-10 ft (1.8-3 m) ahead of the machine. Training Period To assist in aligning the machine for successive cutting passes, it is suggested the following be done to the No. 2 and No.
Important: Familiarize yourself with the fact that the No. 1 cutting unit reel is delayed and therefore, you should practice to try to gain the required timing necessary to minimize the cleanup mowing operation. getting the machine more quickly aligned for the next pass. Follow the same procedure for turning in the opposite direction. It is a good practice to try to make as short of a turn as possible. However, turn in a wider arc during warmer weather to minimize the possibility of bruising the turf. 3.
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.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. CAUTION If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition. 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.
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.
Lubrication Engine Maintenance Greasing the Generator Belt Tensioner 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. Check the whole intake system for leaks, damage or loose hose clamps. • Service the air cleaner filter before 200 hours if the engine performance suffers due to extremely dusty, dirty conditions.
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. 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 Fuel Filter/Water Separator Service Interval: Every 800 hours Servicing the Filter 1. Close the fuel shut off valve (Figure 49) below the fuel tank. 1 2 g014720 Figure 50 1. Fuel filter /water separator canister 2. Filter drain plug 5. Unscrew the filter canister and dispose of it according to local regulations. 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. Make sure the filter drain plug is closed.
Electrical System Maintenance 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. Servicing the Battery • When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the tractor.
2 Figure 52 1. Alternate positive battery post 1 g014617 Figure 51 1. Fuses 2. 50 A fuse for radiator fan (behind parts illustrated) Fuse Layout Lights Leak Detector 15 A Starter 15 A Run 10 A Lift Reel E-Reel Enable Over Temp 7.5 A Reel Engage Lift/Lower Fan 7.5 A Start/Run Diag. Lights Glow 7.
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 56). 2 1 3 4 g014625 Figure 55 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 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.
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 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. Figure 60 1. Position the machine on a level surface, lower the cutting units, stop the engine, engage the parking brake. 1. Reel speed control 2. Remove the plastic cover to the left side of the seat. 7.
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 g015568 Hydraulic Schematic (Rev.
G015569 Electrical Schematic (Rev.
Electric Reel Schematic (Rev.
Notes: 54
Notes: 55
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).
