Form No. 3422-479 Rev C Greensmaster® 3420 TriFlex® Traction Unit Model No. 04540—Serial No. 403099001 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.
Contents Safety ....................................................................... 4 General Safety ................................................... 4 Safety and Instructional Decals .......................... 5 Setup ...................................................................... 10 1 Installing the Roll Bar ......................................11 2 Installing the Seat ...........................................11 3 Installing the Steering Wheel..........................
Safety Inspecting the Fuel Lines and Connections.................................................. 40 Electrical System Maintenance ........................... 40 Electrical System Safety ................................... 40 Servicing the Battery......................................... 40 Locating the Fuses ........................................... 41 Jump-Starting the Machine............................... 42 Drive System Maintenance .................................. 42 Checking the Tire Pressure...
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 missing. decal119-9343 119-9343 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.
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. Tipping hazard—read the Operator's Manual; always wear a seat belt when operating; do not remove the rollover protection system (ROPS). decal131-2046 131-2046 1. Double lights 2. Single light 6 3.
decal119-9346 119-9346 1. Press the pedal to unlock. 2. Read the Operator's Manual for more information. decal136-8506 136-8506 decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 6. Keep bystanders a safe distance away from the battery. 2. No fire, open flame, or smoking 7. Wear eye protection; explosive gasses can cause blindness and other injuries. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection. 8.
decal106-6755 106-6755 decal136-8505 136-8505 Replaces Decal 136-8506 for CE Machines 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.
decal138-9695 138-9695 1. Engine speed—Fast 7. Reel speed—Neutral 2. Engine speed—Slow 8. Reel—Transport 3. Lower and engage the reels. 9. Reel—Mow 4. Raise and disengage the reels. 10. Reel—Backlapping 5. Reel speed—Fast 11. Move forward. 6. Reel speed—Slow decal132-9550 132-9550 1. Choke 3. Engine—run 2. Engine—start 4.
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 3300 Series Traction Unit (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 3 Installing the Seat Installing the Steering Wheel Parts needed for this procedure: 1 Seat-completion kit Parts needed for this procedure: Procedure Acquire your desired seat kit from your distributor and install it to the machine; refer to the kit Installation Instructions. 1 Steering wheel 1 Locknut (1-1/2 inches) 1 Washer 1 Steering-wheel cap Procedure 1. Slide the steering wheel onto the steering shaft (Figure 4). g010834 Figure 4 12 1. Steering wheel 3. Locknut 2. Washer 4.
4 Activating and Charging the Battery No Parts Required Procedure g032705 Use only electrolyte (1.265 specific gravity) to fill the battery initially. Figure 6 1. Electrolyte WARNING 4. Battery terminals or metal tools could short against metal machine components, causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. 5. • When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine.
secure them with the bolts and nuts (Figure 7). Slide the rubber boot over the positive terminal to prevent a possible short from occurring. 6 WARNING Installing the Grass-Basket Hooks Incorrect battery cable routing could damage the tractor and cables, causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Parts needed for this procedure: • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable.
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) g233420 Procedure 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 increase 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 g033079 Figure 15 1. Ignition switch 4. Throttle lever 2. Functional-control lever 3.
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 151 cm (59.5 inches) Wheel tread 128 cm (50.5 inches) Wheel base 123 cm (48.6 inches) Overall length (with baskets) 249 cm (98.0 inches) Overall width 179 cm (70.6 inches) Overall height 205 cm (80.
Fuel Specification • Fuel tank capacity: 22.7 L (6 U.S. gallons) • Recommended Fuel: – 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. 2-D) at temperatures above -7° C (20° F) and winter-grade (No. 1-D or No. 1-D/2-D blend) below that temperature.
4. • Keep your hands and feet away from the cutting Wipe up any spilled fuel. units. Keep clear of the discharge opening at all times. Performing Daily Maintenance • Look behind and down before backing up to be sure of a clear path. • Use care when approaching blind corners, shrubs, Service Interval: Before each use or daily trees, or other objects that may obscure your vision.
• Evaluate the site conditions to determine if the • performance closely so that minor difficulties, which could lead to major problems, are noted and can be corrected. Inspect the machine frequently during break-in for signs of oil leakage, loose fasteners, or any other malfunction. slope is safe for machine operation, including surveying the site. Always use common sense and good judgment when performing this survey. Review the slope instructions, listed below, for operating the machine on slopes.
Checking the Machine after Checking the Safety-Interlock System Starting the Engine 1. Move the throttle lever to the FAST position. 2. Move the raise/lower mow control lever forward momentarily. Service Interval: Before each use or daily CAUTION If the safety interlock switches are disconnected or damaged the machine could operate unexpectedly, causing personal injury. • Do not tamper with the interlock switches.
2. 3. 4. Move the functional-control lever to the MOW position or the TRANSPORT position and try to start the engine. Driving the Machine without Mowing The engine should not turnover or start, 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 position.
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.
Towing the Machine Inspecting and Cleaning after Mowing In case of an emergency, you can tow the machine for up to 0.4 km (1/4 mile). 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 tow the machine faster than 3 to 5 km/h (2 to 3 mph) to avoid damaging the drive system.
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.Exmark.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. • Change the hydraulic-fluid 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 29).
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 33 g014618 1. Drain plug Figure 32 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 34). 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 800 hours Draining Water from the Fuel Filter 1. Close the fuel-shutoff valve (Figure 36) 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 35). g014626 Figure 36 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 Inspecting the Fuel Lines and Connections • Disconnect the battery before repairing the Service Interval: Every 2 years • Charge the battery in an open, well-ventilated machine. Disconnect the negative terminal first and the positive last.
Locating the Fuses 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. The fuses in the electrical system are located under the seat (Figure 38). • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. • Always connect the positive (red) battery cable before connecting the negative (black) cable.
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 40). 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 g015494 Figure 41 1. Eccentric Figure 42 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 41). 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 43). • 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 into skin. Injected fluid must be surgically removed within a few hours by a doctor. Ensure that the belt is properly tensioned to ensure proper operation of the machine and prevent unnecessary wear. 1.
High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46 Material Properties: Viscosity, ASTM D445 cSt @ 40°C 44 to 50 cSt @ 100°C 7.9 to 8.5 Viscosity Index ASTM D2270 140 to 160 Pour Point, ASTM D97 -34°F to -49°F Industry Specifications: Vickers I-286-S (Quality Level), Vickers M-2950-S (Quality Level), Denison HF-0 g014719 Important: The ISO VG 46 Multigrade fluid has Figure 47 been found to offer optimal performance in a wide range of temperature conditions.
Changing the Hydraulic Fluid and Filter Checking the Hydraulic Lines and Hoses Service Interval: After the first 50 hours Check the hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration. Make all necessary repairs before operating. Every 800 hours Hydraulic Fluid Capacity: 25.7 L (6.8 US gallons) If the fluid becomes contaminated, have your authorized Toro distributor flush the system.
Cutting Unit Maintenance Installing the Electrical Counterweights Blade Safety Secure the electrical counterweight to the existing counterweight with 2 capscrews as shown in Figure 50. Refer to and complete the procedure in Maintenance Safety (page 33). 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.
5. Close the latches down and around the cutting-unit bar and lock them in place (Figure 52). 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 54). 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 54).
Removing the Cutting Units 1. Disconnect the cutting unit power disconnect couplers; refer to Cutting Unit Power Disconnect Connectors (page 23). 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 56 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 23). Connect them when finished.
Storage If you wish to store the machine for a long period of time, the following steps should be performed prior to storage: 1. Always shut off the engine, remove the key (if equipped), wait for all moving parts to stop, and allow the machine to cool before adjusting, cleaning, storing, or repairing the machine. 2. Remove accumulations of dirt and old grass clippings. Sharpen the blades and bedknives, if necessary; refer to the cutting unit Operator's Manual.
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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).
