Form No. 3377-360 Rev A Greensmaster® 3420 TriFlex™ Traction Unit Model No. 04540—Serial No. 313000001 and Up g014597 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 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 Jump Starting the Machine.......................................40 Drive System Maintenance .........................................41 Adjusting the Transmission for Neutral .....................41 Adjusting the Transport Speed .................................41 Adjusting the Mowing Speed....................................42 Cooling System Maintenance ......................................42 Cleaning the Radiator Screen....................................42 Brake Maintenance ...................
Preparation Safety • While mowing, always wear substantial footwear, long 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 37 lb (16.8 kg) of weight is added to the rear wheel. • Improper use or maintenance by the operator or owner can result in injury.
Maintenance and Storage • Stop the blades from rotating before crossing surfaces other than grass. • Keep all nuts, bolts and screws tight to be sure the • 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.
• Always wear substantial shoes. Do not operate the • Always use the seat belt with the ROPS when operating machine while wearing sandals, tennis shoes, or sneakers. Wearing safety shoes and long pants is advisable and required by some local ordinances and insurance regulations. the machine. • 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.
Sound Pressure Level Measured vibration level for left hand = 0.52 m/s2 This unit has a sound pressure level at the operator’s ear of 84 dBA, which includes an Uncertainty Value (K) of 1 dBA. Uncertainty Value (K) = 0.26 m/s2 Measured values were determined according to the procedures outlined in EN 836. Sound pressure level was determined according to the procedures outlined in EN 836. Whole Body Measured vibration level = 0.12 m/s2 Vibration Level Uncertainty Value (K) = 0.
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 121–6670 1. Engage the reels. 2. Disengage the reels. 115-8155 1. Warning—read the Operator's Manual, do not prime or use starting fluid. 117–2718 115-8203 1. Read the Operator's manual for fuse information. 2.
121–5169 1. Throttle—slow 5. Functional control lever 2. Throttle—continuous variable setting 6. Lower the reels and engage. 9. Use for mowing 3. Throttle—fast 7. Use for backlapping reels 4. Raise the reels 8. Neutral 121–5171 1. Choke 3. Engine run 2. Engine—start 4. Engine—stop Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 6. Keep bystanders a safe distance from the battery. 2. No fire, open flames, or smoking. 7.
121–2641 1. Warning—read the Operator’s Manual, do not operate this machine unless you are trained. 4. Tipping hazard—slow machine before turning, do not turn at high speeds. 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. 121–2640 3. Cutting/dismemberment hazard of hand or foot, mower blade—stay away from moving parts; keep all guards and shields in place. 1.
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 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. 3 2. Remove the roll bar from the crate. 3.
4 Activating and Charging the Battery No Parts Required Procedure Use only electrolyte (1.265 Specific Gravity) to fill battery initially. Figure 6 1. Electrolyte 1. Remove the fasteners and battery clamp and lift out the battery. 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). Important: Do not add electrolyte while the battery is in the machine.
WARNING 5 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.
2 on the front of the suspension arms to prevent damage to them. 3 Important: Do not raise the suspension to the transport position when the reel motors are in the holders in the machine frame. Damage to the motors or hoses could result. Important: Whenever the cutting unit has to be tipped to expose bedknife/reel, prop up rear of cutting unit to make sure nuts on back end of bedbar adjusting screws are not resting on work surface (Figure 9). 1 g016294 Figure 10 2 2 1.
9. With the latches on the suspension-arm bar pointing up (i.e., open) (Figure 12), push the suspension arm down so that the bar fits over the bar across the top of the cutting unit (Figure 13). 1 2 3 g014609 Figure 12 1. Latch—closed position 3. Latch—open position 2. Suspension-arm bar 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. 1 15.
Product Overview 8 Installing EU Decals 4 2 3 Parts needed for this procedure: 1 5 Warning decal 121–2640 1 6 Procedure 7 If this machine will be used in the EU, affix the warning decal 121–2640 over warning decal 121–2641. 8 g014674 Figure 15 1. Engine 5. Steering wheel 2. Roll bar 6. Traction pedal 3. Control panel 7. Foot rest 4. Seat 8.
Note: The engine cannot be stopped by the use of the throttle control. 1 3 4 2 2 3 1 g014603 Figure 16 1. Traction pedal—forward 5 3. Steering arm locking pedal G017975 2. Traction pedal—reverse Figure 18 1. Ignition switch 4. Throttle 2. Functional control lever 3. Raise/Lower Mow Control 5. InfoCenter Raise/Lower Mow Control Moving the control (Figure 18) forward during operation lowers the cutting units and starts the reels.
conjunction with the raise/lower mow control lever and the reel speed control for backlapping the reels. 1 1200 170 100 1 C2 n/min 7.5 C2 7.5 2 7.5 7.5 15 7.5 10 2 15 7.5 10 2 52.2V 240 10,000.0 1600 3 n/min 2 G017943 G017947 Figure 19 1. Backlap switch—backlap position Figure 21 2. Backlap switch—mow position 1. Functional control status 3. PTO speed 2. Functional control status • Engine RPM/status—indicates the engine RPM.
Main Menu Settings Menu Item Description Menu Item Description Faults The Faults menu contains a list of the recent machine faults. Refer to the Service Manual or your Authorized Toro Distributor for more information on the Faults menu and the information contained there. Units Controls the units used on the InfoCenter. The menu choices are English or Metric. Language Controls the language used on the InfoCenter. LCD Backlight Controls the brightness of the LCD display.
The factory default setting is 6 (375 ms) and is optimized for a 3.8 MPH mow speed. Increment Number Delay Time (Seconds) 1 0.100 2 0.150 3 0.200 4 0.250 5 0.300 6 0.375 7 0.475 8 0.600 9 0.750 10 0.925 g014736 Figure 22 4. To set the reel speed, on the InfoCenter open the Main Menu and scroll down to Settings. Tap-off Delay 5. In the Settings menu scroll down to Reel Speed and use the ± button to set the reel speed to the desired number.
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. 1 g014628 Figure 24 1. Seat adjusting lever g01461 0 Figure 23 Note: Before lifting the seat, slide it to the furthest back position and move the steering arm fully forward.
Cutting Unit Power Disconnect Connectors its capabilities. Contact your Authorized Service Dealer or Distributor or go to www.Toro.com for a list of all approved attachments and accessories. Before installing, removing, or working on the cutting units, disconnect the cutting units from the power supply by separating the cutting unit power disconnect connectors (Figure 26), located at the base of the rollover bar on the left side of the traction unit.
Operation is necessary to permit venting when filling, which prevents oil from overrunning into breather. 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. Knowing this information could help you or bystanders avoid injury. The use of protective equipment, such as but not limited to, for eyes, ears, feet, and head is recommended.
Filling the Fuel Tank • Fuel filter plugging may be expected for a time after converting to biodiesel blends. 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. • Contact your distributor if you wish for more information on biodiesel DANGER In certain conditions, fuel is extremely flammable and highly explosive.
the coolant at the beginning of each day before starting the engine. CAUTION If the engine has been running, the pressurized, hot coolant can escape and cause burns. 1 • 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. Check the coolant level (Figure 31). It should be between the lines on the reserve tank when the engine is cold. g014612 Figure 29 1.
Filling the Hydraulic Tank Toro Premium All Season Hydraulic Fluid (Available in 5 gallon pails or 55 gallon drums. See parts catalog or Toro distributor for part numbers.) 1. Position the machine on a level surface. Make sure the machine has cooled down so the oil is cold. Alternate fluids: If the Toro fluid is not available, other fluids may be used provided they meet all the following material properties and industry specifications. We do not recommend the use of synthetic fluid.
Draining Water from the Fuel Filter Checking the Reel-to-Bedknife Contact Service Interval: Before each use or daily 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 Adjusting the Reel to Bedknife in the Cutting Unit Operator’s Manual. 1. Position the machine on a level surface and stop the engine. 2.
2. Remove your foot from the traction pedal and make sure the pedal is in the neutral position. The safety interlock system prevents the engine from starting unless: 3. Move the throttle lever to the Slow position. • The traction pedal is in neutral. 4. Insert the key into the switch and rotate it to On. Hold it in the On position until the glow plug indicator light goes off (approximately 6 seconds). • The functional control lever is in neutral.
Installing and Removing the Cutting Units 1 2 3 Installing the Cutting Units 1. Disconnect the cutting unit power disconnect couplers; refer to Cutting Unit Power Disconnect Connectors (page 23). g014609 Figure 36 CAUTION 1. Latch—closed position 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. 3. Latch—open position 2.
Figure 39 1. Reel motor 2. Motor retaining bar 4. Move the motor to the storage location on the front of the suspension arm (Figure 40). Figure 38 1. Reel motor 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 Connectors (page 23). Removing the Cutting Units 1.
7. Roll the cutting unit out from under the suspension arm. 3 8. Repeat steps 3 through 7 for the other cutting units as required. 2 1 9. Connect the cutting unit power disconnect couplers; refer to Cutting Unit Power Disconnect Connectors (page 23). Training Period Before mowing greens with the machine, it is recommended that you find a clear area and practice starting and stopping, raising and lowering the cutting units, turning, etc.
raise the reels (This will help prevent dribbling grass onto the green while raising the reels). 7. Empty the grass baskets of all clippings before transporting to the next green. Heavy wet clippings place an undue strain on the baskets and will add unnecessary weight to the machine, thereby increasing the load on the engine, hydraulic system, brakes, etc. 1 Transport Operation Make sure the cutting units are in the full up position. Move the functional control lever to the transport position.
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.
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. 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. 5. Install the cover orienting the rubber outlet valve in a downward position—between approximately 5:00 to 7:00 when viewed from the end. 4. Add oil to the crankcase; refer to (page ). 5.
Fuel System Maintenance Fuel Filter/Water Separator Service Interval: Every 800 hours Servicing the Filter 1. Close the fuel shut off valve (Figure 47) below the fuel tank. 1 2 g014720 Figure 48 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.
Fuses The fuses in the machine’s electrical system are located under the seat (Figure 49). 2 Figure 50 1. Alternate positive battery post 1 g014617 Figure 49 1. Fuses 2. 50 A fuse for radiator fan (behind parts illustrated) Fuse Layout Starter 10A Run 10A Lights Leak Detector 15 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.
Adjusting the Mowing Speed Cooling System Maintenance The machine is adjusted at the factory, but speed may be varied if desired. 1. Loosen the jam nut on the trunnion bolt (Figure 53). Cleaning the Radiator Screen 2. Loosen the nut securing the lock and mow brackets on the pedal pivot. 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.
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.
Checking the Hydraulic Lines and Hoses Hydraulic System Maintenance WARNING Changing the Hydraulic Oil and Filter Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • Make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system.
Cutting Unit Maintenance Raise/Lower Mow control rearward and stop the engine. After completing adjustments, repeat steps 4 through 9. Backlapping the Reels 12. Repeat the procedure for all cutting units you want to backlap. WARNING 13. When finished, return the backlap switch 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.
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 Electric Reel Schematic (Rev.
G015569 Electrical Schematic (Rev.
G020719 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).
