Form No. 3385-979 Rev B Greensmaster® 3420 TriFlex™ Traction Unit Model No. 04540—Serial No. 314004001 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. WARNING CALIFORNIA Proposition 65 Warning This product contains a chemical or chemicals known to the State of California to cause cancer, birth defects, or reproductive harm. Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. g014685 Figure 1 1.
Contents Storing the Battery ............................................ 43 Replacing the Fuses ......................................... 44 Jump Starting the Machine ............................... 44 Drive System Maintenance .................................. 45 Adjusting the Transmission for Neutral.............. 45 Adjusting the Transport Speed.......................... 45 Adjusting the Mowing Speed ............................ 46 Cooling System Maintenance ..............................
Safety ◊ lack of awareness of the effect of ground conditions, especially slopes. This machine meets or exceeds CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-2012 specifications in effect at the time of production when 16.8 kg (37 lb) of weight is added to the rear wheel. ◊ The owner/user can prevent and is responsible for accidents or injuries occurring to people, or property. Preparation Improper use or maintenance by the operator or owner can result in injury.
Rollover Protection System (ROPS) - Use and Maintenance • 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. Do not change the engine governor settings or overspeed the engine.
• Keep the nozzle in contact with the rim of the fuel • Keep hands and feet away from moving parts. If tank or container opening at all times until fueling is complete. possible, do not make adjustments with the engine running. • Charge batteries in an open well ventilated area, • Do not use a nozzle lock open device. • If fuel is spilled on clothing, change clothing away from spark and flames. Unplug charger before connecting or disconnecting from battery.
• • • • • • • • • • – 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. Raise the cutting units when driving from one work area to another.
Measured vibration level for left hand = 0.52 m/s2 Measured vibration level = 0.12 m/s2 Uncertainty Value (K) = 0.26 m/s2 Uncertainty Value (K) = 0.06 m/s2 Measured values were determined according to the procedures outlined in EN 836. Measured values were determined according to the procedures outlined in EN 836. Whole Body Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger.
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 decal121-6670 121–6670 1. Engage the reels. 2. Disengage the reels. decal115-8155 115-8155 1. Warning—read the Operator's Manual, do not prime or use starting fluid. decal117-2718 117–2718 decal115-8203 115-8203 1. Read the Operator's manual for fuse information. 2.
decal121-5169 121–5169 1. Throttle—slow 5. Functional control lever 2. Throttle—continuous variable setting 6. Lower the reels and engage. 3. Throttle—fast 7. Use for backlapping reels 4. Raise the reels 8. Neutral 9. Use for mowing 10. Use for transport decal121-5171 decalbatterysymbols 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. 6. Keep bystanders a safe distance from the battery. 2.
decal121-2641 decal121-2640 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.
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. 2. Remove the roll bar from the crate. 3.
3. Secure the steering wheel to the shaft with a jam nut 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 a screw (Figure 4). 4 Activating and Charging the Battery g001197 Figure 6 No Parts Required 1. Electrolyte Procedure 4. Use only electrolyte (1.265 specific gravity) to fill battery initially. 1. Remove the fasteners and battery clamp and lift out the battery.
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. g005098 Figure 7 • Do not allow metal tools to short between the battery terminals and metal parts of the tractor. 1. Negative (-) 2.
1. 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. Parts needed for this procedure: 1 Gauge bar 3 Cutting unit (model 04613, 04614, or 04615) 3 Cutting unit upper weight 6 Hex head screws 3 Grass Basket Disconnect the cutting unit power disconnect couplers; refer to Cutting Unit Power Disconnect Connectors (page 25).
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. g014611 Figure 13 1. Suspension-arm bar 2. Cutting-unit bar g014602 10. Figure 11 1. Footrest—closed 2. Footrest—open 8. Position the cutting unit under the suspension arm. 9.
8 Installing the CE Guard Kit Parts needed for this procedure: 1 CE Guard Kit―Part No. 04443 (sold separately) Procedure Install the CE guard kit; refer to the CE Guard Kit for Greensmaster 3420 TriFlex Traction Unit Installation Instructions. 9 g015525 Figure 14 1. Reel motor 3. Cavity 2. Spline shaft 4. Motor retaining bar Installing EU Decals Parts needed for this procedure: 13. Mount a grass basket onto the basket hooks on the suspension arm. 14.
Product Overview g014603 Figure 16 1. Traction pedal—forward 3. Steering arm locking pedal 2. Traction pedal—reverse 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 g005105 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.
Backlap Switch Note: The engine cannot be stopped by the use of the throttle control. The backlap switch is located under the plastic cover to the left of the seat. Use the backlap switch (Figure 19) in conjunction with the raise/lower mow control lever and the reel speed control for backlapping the reels. g017943 Figure 19 1. Backlap switch—backlap position g017975 Figure 18 1. Ignition switch 4. Throttle 2. Functional control lever 3. Raise/Lower Mow Control 5. InfoCenter 2.
• Coolant temperature—indicates the engine 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. • Engine oil pressure light—this icon appears if the engine oil pressure drops below a safe level. • Menu access/back button—press this button to access the InfoCenter menus. You can use it to back out of any menu you are currently using. • Down button—use this button to scroll down menus.
Service 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 Reel Speed Controls the reel speed. Backlap rpm Controls the backlap rpm speed. About Lists the number of preheats and starts the machine has experienced. Menu Item Description Model Lists the model number of the machine. SN Lists the serial number of the machine.
Machine Configuration Passcode the raise position to activate this feature. The factory default setting is 1 which disables this feature. Increment Number Delay Time (Seconds) 1 Off 2 0.050 3 0.100 4 0.150 5 0.200 6 0.250 7 0.300 8 0.350 9 0.400 10 0.450 There are 5 operating configuration settings that are adjustable within the setting menu of the InfoCenter: Raise and lower delay, tap-off delay, reel speed, and backlap speed.
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. g014628 Figure 24 1. Seat adjusting lever g014610 Note: Before lifting the seat, slide it to the furthest Figure 23 back position and move the steering arm fully forward.
Cutting Unit Power Disconnect Connectors Attachments/Accessories A selection of Toro approved attachments and accessories is 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.
Operation Important: Make sure that the dipstick is removed while filling the engine with oil. When adding engine oil or filling oil, there must be clearance between the oil fill device and the oil fill hole in the valve cover as shown in Figure 27. This clearance 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.
Important: Check the level of oil every 8 petrodiesel portion should be low or ultra low sulfur. Observe the following precautions: operating hours or daily. Change the oil and filter initially after the first 50 hours of operation, thereafter change the oil and the filter every 150 hours. However, change the oil more frequently when the engine is operated in extremely dusty or dirty conditions. 5. • The biodiesel portion of the fuel must meet specification ASTM D6751 or EN14214.
DANGER 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. • Do not fill the fuel tank completely full. Add fuel to the fuel tank until the level is 25 mm (1 inch) below the bottom of the filler neck. This empty space in the tank allows fuel to expand.
g008427 Figure 31 1. Reserve tank g014613 Figure 30 1. Wing bolts 3. Reserve tank 2. Radiator screen 4. Radiator fill cap 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. • Do not open the radiator cap when the engine is running. Check the coolant level (Figure 31). It should be between the lines on the reserve tank when the engine is cold.
Viscosity, ASTM D445 cSt @ 40°C 44 to 50 cSt @ 100°C 7.9 to 8.5 140 to 160 Viscosity Index ASTM D2270 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, Vickers 35 VQ 25 (Eaton ATS373-C) Important: The ISO VG 46 Multigrade fluid has been found to offer optimal performance in a wide range of temperature conditions.
Draining Water from the Fuel Filter Checking the Reel-to-Bedknife Contact Service Interval: Before each use or daily 1. Position the machine on a level surface and stop 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). Tighten the plug after draining. Each day before operating the machine, check the reel-to-bedknife contact, regardless if the quality of cut had previously been acceptable.
Starting and Stopping the Machine Checking the Safety Interlock System Note: Inspect the areas beneath the mowers to be CAUTION certain they are clear of debris. If the safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. Starting the Machine Important: Do not use ether or other types of starting fluid. • Do not tamper with the interlock switches.
4. 5. lever to mow or transport. The engine should kill, which means that the interlock system is operating correctly. Correct the problem if it is not operating properly. Installing and Removing the Cutting Units 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. Release the parking brake, move the functional control lever to mow, and rise from the seat.
g014609 Figure 36 1. Latch—closed position 3. Latch—open position 2. Suspension-arm bar g015525 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 25). g014611 Figure 37 1. Suspension-arm bar 5. 2.
5. Open the latches on the suspension-arm bar of the cutting unit you are removing (Figure 36). 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 Connectors (page 25). g015522 Figure 39 1. Reel motor 4. 2.
At the end of the periphery cut, momentarily pull back on the raise/lower mow lever to shut the reels off without raising them. Continue moving forward until the reel stops rotating, then, drive off the green and 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.
considerable distance, 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 42). g014627 Figure 42 1. Bypass valve—slot shown in closed (horizontal) position 2. Before starting the engine, close the bypass valve by rotating it so that the slot is horizontal (Figure 42). Do not start the engine when the valve is open.
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.
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. Install the cover orienting the rubber outlet valve in a downward position—between approximately 5:00 to 7:00 when viewed from the end. 6.
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. 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. 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.
Replacing the Fuses The fuses are located under the seat (Figure 49). g002735 Figure 50 1. Alternate positive battery post 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.
Drive System Maintenance Adjusting the Transport Speed Adjusting the Transmission for Neutral 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. If the machine creeps when the traction control pedal is in the neutral position, the neutral return mechanism must be adjusted. 1.
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). 2. Loosen the nut securing the lock and mow brackets on the pedal pivot. 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.
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 Stop the machine, recheck the fluid level and replenish as required. 6. Dispose of the oil and filter properly. Checking the Hydraulic Lines and Hoses Changing the Hydraulic Oil and Filter Service Interval: After the first 50 hours WARNING Every 800 hours 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 10. If the reels stall or become erratic while backlapping, select a higher reel speed setting until the speed stabilizes. Backlapping the Reels 11. To make an adjustment to the cutting units while backlapping, turn the reels off by moving the Raise/Lower Mow control rearward and stop the engine. After completing adjustments, repeat steps 4 through 9. 12. Repeat the procedure for all cutting units you want to backlap. 13.
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 (page 40). 2. Block up the wheels to remove any weight on the tires. 3.
Notes:
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).
