Form No. 3450-100 Rev A Greensmaster® 3420 TriFlex® Traction Unit Model No. 04540—Serial No. 408000000 and Up Register at www.Toro.com.
Introduction This product complies with all relevant European directives; for details, please see the separate product specific Declaration of Conformity (DOC) sheet. This machine is a ride-on, reel-blade greens mower intended to be used by professional, hired operators in commercial applications. It is primarily designed for cutting grass on well-maintained turf. Using this product for purposes other than its intended use could prove dangerous to you and bystanders.
Maintenance ........................................................... 32 Maintenance Safety.......................................... 32 Recommended Maintenance Schedule(s) ........... 33 Daily Maintenance Checklist............................. 34 Lubrication .......................................................... 35 Greasing the Machine....................................... 35 Engine Maintenance ........................................... 35 Engine Safety .............................................
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.
decal119-9346 119-9346 1. Press the pedal to unlock. 2. Read the Operator's Manual for more information. decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. decal115-8226 115-8226 1. Tipping hazard—read the Operator's Manual; wear a seatbelt; do not remove the roll bar. 1. Explosion hazard 6. Keep bystanders away from the battery. 2. No fire, open flame, or smoking 7. Wear eye protection; explosive gases can cause blindness and other injuries. 3.
decal136-8506 decal136-8505 136-8506 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 away. 3. Cutting/dismemberment hazard of hand or foot—stay away from moving parts; keep all guards and shields in place. 6.
decal139-2728 139-2728 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.
decal139-6493 139-6493 1. Lower and engage the reels. 8. Reel—mow 2. Raise and disengage the reels. 9. Reel—backlap 3. Mow direction 4. Fast 10. Choke 11. Engine—start 5. Slow 12. Engine—run 6. Neutral 13. Engine—stop 7.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description Use Qty. Roll bar Bolt (1/2 x 3-3/4 inches) Flange nut (1/2 inch) 1 4 4 Install the roll bar. Seat Kit (order separately; contact your authorized Toro distributor) 1 Install the seat to the base. Service decal (Part No.
Media and Additional Parts Description Use Qty. Operator's Manual 1 Review the manual before operating the machine. Engine owner's manual 1 Use the manual to reference engine information. Declaration of Conformity Noise rating certificate 1 1 For CE compliance Ignition keys 2 Start the engine. 1 Installing the Roll Bar Parts needed for this procedure: 1 Roll bar 4 Bolt (1/2 x 3-3/4 inches) 4 Flange nut (1/2 inch) Procedure 1. Remove the top crate support from the crate. 2.
2 Installing the Seat Parts needed for this procedure: 1 Seat Kit (order separately; contact your authorized Toro distributor) Procedure Acquire your desired seat kit from your distributor and install it to the machine; refer to the kit Installation Instructions. g291701 Figure 4 Premium Seat (Model No. 04719) 3 1. Service decal 3. 2.5 cm (1 inch) 2. Clip decal 4. 16.5 cm (6.5 inches) Installing the Service and Clip Decals Parts needed for this procedure: 1 Service decal (Part No.
4 5 Installing the Steering Wheel Charging the Battery No Parts Required Parts needed for this procedure: 1 Steering wheel 1 Locknut (1-1/2 inches) 1 Washer 1 Steering-wheel cap Procedure Charge the battery; refer to Charging the Battery (page 40). 6 Procedure 1. Installing the Grass-Basket Hooks Slide the steering wheel onto the steering shaft (Figure 6).
7 8 Installing the Cutting Units Setting the Clip-Control Feature Parts needed for this procedure: 1 Gauge bar 3 Cutting unit (obtain from your authorized Toro distributor) 3 Grass basket 3 Electric-reel-motor counterweight 6 Capscrew 3 O-ring No Parts Required Procedure The machine has a clip-control feature that varies the speed of the reels with the speed of the machine to maintain a constant clip. This achieves a consistent, high quality-of-cut and a uniform after-cut appearance.
10 Installing the CE Guard Kit Parts needed for this procedure: 1 CE Guard Kit―Part No. 04443 (sold separately) Procedure g233420 Figure 10 Install the CE guard kit; refer to the CE Guard Kit for Greensmaster 3420 TriFlex Traction Unit Installation Instructions. 1. CE mark decal • Install the production year decal near the serial plate (Figure 11). 11 Installing the CE Decals Parts needed for this procedure: 1 Warning decal (Part No.
Product Overview 12 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 42). 13 Burnishing the Brakes g014674 Figure 12 No Parts Required 1. Engine 2. Roll bar 6. Traction pedal Procedure 3. Control panel 7. Footrest 4. Seat 8. Cutting units 5.
Throttle Lever The throttle lever (Figure 15) 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 shut off the engine using the throttle lever. g014603 Figure 13 1. Traction pedal—forward 3. Steering-arm-locking pedal 2. Taction pedal—reverse g315320 Figure 15 1. Raise/lower mow control 2. Functional-control lever 4. Throttle lever 5.
Ignition Switch Insert the key into the switch (Figure 15) and turn it clockwise to the START position to start the engine. Release the key as soon as the engine starts; the key moves to the ON position. Turn the key counterclockwise to the STOP position to shut off the engine. Parking Brake Lever Pull the brake lever (Figure 16) to engage the parking brake. Disengage it by squeezing the release lever on the underside of the brake lever and lowering it to the released position.
• COOLANT TEMPERATURE —indicates the engine SERVICE coolant temperature in either °C or °F. • FUNCTIONAL CONTROL STATUS —transport mode is indicated by a rabbit and mow mode is indicated by a turtle. Menu Item Description HOURS Lists the total number of hours that the machine, engine, reels, backlap, and fan have been on, as well as the number of hours the machine has been transported and overheated. COUNTS Lists the number of preheats and starts the machine has experienced.
LOWER DELAY Controls the lower delay for the center cutting unit. TAPOFF DELAY Controls the tap-off delay. REEL SPEED Controls the reel speed. BACKLAP Controls the backlap rpm speed. RPM CLIP CONTROL Turns the automatic clip-control feature ON/OFF. BLADE COUNT Set the number of blades in each reel. This setting is only necessary if CLIP CONTROL is set to ON. CLIP (FOC) Sets the desired clip. This setting is only necessary if CLIP CONTROL is set to ON. 7 0.475 8 0.600 9 0.750 10 0.
3. Seat-Adjusting Lever Using the appropriate graph (Figure 18) for 5-, 8-, 11-, or 14-blade cutting units, determine the proper reel speed setting. The seat-adjusting lever is located on the front, left corner of the seat (Figure 20), allowing you to adjust the seat forward and rearward. Note: If you need to adjust the seat more, you can remove the 4 nuts that secure the seat slide rails to the base and move the seat slide rails to the second set of mounting holes provided. g014736 Figure 19 4.
Fuel-Shutoff Valve Close the fuel-shutoff valve (Figure 21), behind the seat and under the fuel tank, when storing or transporting the machine on a truck or trailer. g016588 Figure 22 1. Cutting unit power disconnect connector CAUTION 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. g014626 Figure 21 Always separate the cutting unit power disconnect connectors before working on the cutting units. 1.
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 Minimum ground clearance (at the machine centerline) 151 cm (59.5 inches) Before Operation 11 cm (4.5 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) Wheel base 119 cm (46.
Filling the Fuel Tank Fuel Specification 1. • Fuel tank capacity: 22.7 L (6 U.S. gallons) • Recommended Fuel: Clean around the fuel-tank cap and remove it (Figure 23). – 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.
During Operation During Operation Safety • General Safety – Engage the parking brake. – Shut off the engine and remove the key. – 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. • The owner/operator can prevent and is responsible • • • • • • • • • • • • • • • • Rollover Protection System (ROPS) Safety for accidents that may cause personal injury or property damage.
• Use extreme caution when operating the machine • • • glow-plug-indicator light goes off (approximately 6 seconds). near drop-offs, ditches, embankments, water hazards, or other hazards. The machine could suddenly roll over if a wheel goes over the edge or the edge caves in. Establish a safety area between the machine and any hazard. Identify hazards at the base of the slope. If there are hazards, mow the slope with a pedestrian-controlled machine.
check. A fast throttle setting may not be required after the break-in period. The safety-interlock system prevents the reels from operating unless the functional-control lever is in the MOW position. Note: If fluid leaks continue to appear, contact your authorized Toro distributor for assistance and, if necessary, replacement parts. Checking the Traction Pedal Important: A trace of fluid on the motor or wheel seals is normal. Seals require a small amount of lubrication to perform properly.
Driving the Machine without Mowing The engine should shut off, which indicates that the interlock system is operating correctly. Correct the problem if it is not operating properly. • Ensure that the cutting units are fully raised. • Move the functional-control lever to the TRANSPORT Checking the Raise/Lower Mow Control 1. position. Use the brakes to slow the machine while going down steep hills to avoid loss of control.
gaining the required timing necessary to minimize the cleanup mowing operation. Note: The delay in raising and lowering the center cutting unit depends on hydraulic fluid temperature. Cold hydraulic fluid results in a longer delay. As the fluid temperature increases, the delay time becomes shorter. 4. Overlap a minimal amount with the previous cut on return passes.
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. • Engage the parking brake, shut off the engine, remove the key, and wait for all movement to stop before you leave the operator’s position.
Inspecting and Cleaning after Mowing 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. Important: Do not use brackish or reclaimed water to clean the machine. Important: Do not use power-washing equipment to wash the machine.
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 27). g014627 Figure 27 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.
Lubrication Engine Maintenance Greasing the Machine Engine Safety • Shut off the engine before checking the oil or Service Interval: Every 400 hours • Lubricate the grease fitting with No. 2 lithium grease. 1. adding oil to the crankcase. Do not change the governor speed or overspeed the engine. Wipe the grease fitting clean so that you do not force foreign matter into the bearing or bushing (Figure 28).
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 that 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.
g014754 Figure 32 g014618 1. Drain plug Figure 31 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 oil level 2. Remove the oil filter (Figure 33). 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 500 hours Draining Water from the Fuel Filter 1. Close the fuel-shutoff valve (Figure 35) below the fuel tank. Service Interval: Before each use or daily 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 34). g014626 Figure 35 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 • Disconnect the battery before repairing the Inspecting the Fuel Lines and Connections machine. Disconnect the negative terminal first and the positive last. Connect the positive terminal first and the negative last.
g253380 g253379 Figure 37 1. Negative battery cable 2. Figure 38 2. Positive battery cable 1. Positive battery cable Lift the insulator and remove the positive battery cable from the battery post (Figure 37). 2. Connecting the Battery 2. Negative battery cable Connect the negative cable to the battery and tighten the battery-clamp nut (Figure 38). Charging the Battery WARNING WARNING Incorrect battery cable routing could damage the machine and cables causing sparks.
Locating the Fuses The fuses in the electrical system are located under the seat (Figure 40). g339469 Figure 39 1. Bolt 2. Washer 3. Retainer 3. 4. Nut 5. Radiator 6. Rear of the machine Connect a 2 to 4 A battery charger to the battery posts. Charge the battery for at least 2 hours at 4 A or for at least 4 hours at 2 A until the specific gravity is 1.250 or higher and the temperature is at least 16°C (60°F) with all cells gassing freely.
Jump-Starting the Machine Drive System Maintenance If you need to jump start the machine, you can use the alternate-positive post (located on the starter solenoid) instead of the positive battery post (Figure 42). 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).
g014616 g340662 Figure 43 1. Eccentric Figure 44 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 43). 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 You can adjust the forward moving speed from 0 to 8 km/h (0 to 5 mph). 1. 2. • Swallowing engine coolant can cause poisoning; keep out of reach from children and pets. Loosen the jam nut on the trunnion bolt (Figure 45). • Discharge of hot, pressurized coolant or touching a hot radiator and surrounding parts can cause severe burns.
Brake Maintenance Checking the Engine-Coolant Level Burnishing the Brakes The capacity of the cooling system is approximately 4.6 L (4.9 US qt). Service Interval: Yearly 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. Firmly apply the brakes and drive the machine at mowing speed until the brakes are hot, as indicated by their smell.
Belt Maintenance Hydraulic System Maintenance Adjusting the Alternator Belt Hydraulic System Safety • Seek immediate medical attention if fluid is injected 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. 2. • Park the machine on a level surface, shut off the engine, engage the parking brake, remove the key, and wait for all moving parts to stop.
High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46 Material Properties: Viscosity, ASTM D445 cSt @ 40°C (104°F) 44 to 48 140 or higher Viscosity Index ASTM D2270 Pour Point, ASTM D97 -37°C to -45°C (-34°F to -49°F) Industry Specifications: Eaton Vickers 694 (I-286-S, M-2950-S/35VQ25 or M-2952-S) g014719 Figure 49 Note: Many hydraulic fluids are almost colorless, making it difficult to spot leaks. A red dye additive for the hydraulic fluid is available in 20 ml (0.
Changing the Hydraulic Fluid and Filter and Checking the Hydraulic-Fluid Level (page 47). 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. Every 2,000 hours—If you are using the recommended hydraulic fluid, change the hydraulic fluid. 5.
Cutting Unit Maintenance Installing the Electrical Counterweights Blade Safety Secure the electrical counterweight to the existing counterweight with 2 capscrews as shown in Figure 52. A worn or damaged blade or bedknife can break, and a piece could be thrown toward you or bystanders, resulting in serious personal injury or death. • Inspect the blades and bedknives periodically for excessive wear or damage. • Use care when checking the blades. Wear gloves and use caution when servicing them.
5. Close the latches down and around the cutting-unit bar and lock them in place (Figure 54). Note: You can hear a click and feel when the latches are properly locked in place. g014602 6. Coat the spline shaft of the cutting unit motor with clean grease (Figure 56). 7. Insert the motor into the left side of the cutting unit (as viewed from the operator's position) and pull the motor retaining bar on the cutting unit toward the motor until you hear a click from both sides of the motor (Figure 56).
Removing the Cutting Units 1. Disconnect the cutting unit power disconnect couplers; refer to Cutting Unit Power Disconnect Connectors (page 21). CAUTION 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. g036124 Figure 58 Always separate the cutting unit power disconnect couplers before working on the cutting units. 2. 3.
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. Before checking the reels, disconnect the cutting unit power disconnect couplers; refer to Cutting Unit Power Disconnect Connectors (page 21). Connect them when finished.
Storage Storage Safety • Shut off the machine, remove the key, and wait for all movement to stop before you leave the operator’s position. Allow the machine to cool before adjusting, servicing, cleaning, or storing it. • Do not store the machine or fuel container where there is an open flame, spark, or pilot light, such as on a water heater or other appliance.
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The Toro Warranty Two-Year or 1,500 Hours Limited Warranty Conditions and Products Covered Parts 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 2 years or 1,500 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).
