Form No. 3427-163 Rev A Greensmaster® 3420 TriFlex® Traction Unit Model No. 04540—Serial No. 403421001 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.
Contents Safety ....................................................................... 4 General Safety................................................... 4 Safety and Instructional Decals .......................... 4 Setup ........................................................................ 9 1 Installing the Roll Bar ..................................... 10 2 Installing the Seat .......................................... 10 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...
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 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; wear a seatbelt; do not remove the rollover bar.
decal131-2046 131-2046 1. Double lights 3. Off 2. Single light decal136-8506 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.
decal106-6755 106-6755 decal136-8505 136-8505 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. Traction—Mow 2. Engine speed—Slow 8. Traction—Neutral 3. Lower and engage the reels. 9. Reel—Transport 4. Raise and disengage the reels. 10. Reel—Mow 5. Mow direction 11. Reel—Backlapping 6. Traction—Transport 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. No parts required – Activate and charge the battery.
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 11 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. 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. • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable.
8 Adding Rear Weight Parts needed for this procedure: 1 Weight Kit, Part No. 121-6665 (purchase separately) Note: This kit is not required for units with the 3 wheel drive kit installed. Procedure This unit complies with EN ISO 5395:2013 and ANSI B71.4-2017 when equipped with Weight Kit, Part No. 121-6665. Note: If the unit is equipped with a 3-Wheel Drive Kit, additional weight is not required to meet EN ISO 5395:2013 and ANSI B71.4-2017. g256064 Figure 9 4.
• Apply the CE warning decal (Part No. 136-8505) 11 over the existing warning decal (Part No. 136-8506). • Apply the CE mark decal to the frame under the Reducing the Tire Pressure front of the seat (Figure 10). 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). 12 g233420 Figure 10 1.
Product Overview g014603 Figure 13 1. Traction pedal—forward 3. Steering-arm-locking pedal 2. Taction pedal—reverse g014674 Figure 12 1. Engine 5. Steering wheel 2. Roll bar 6. Traction pedal 3. Control panel 7. Footrest 4. Seat 8. Cutting units Controls g005105 Traction Pedal Figure 14 The traction pedal (Figure 13) has 3 functions: to make the machine move forward, to move it backward, and to stop the machine.
Throttle Lever Ignition Switch 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. 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.
• 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 Lists the number of preheats and starts the machine has experienced. BACKLAP Turns backlapping ON/OFF (once ON you can turn backlapping Off with this setting or by turning off the ignition key).
8 0.600 9 0.750 10 0.925 3. Using the appropriate graph (Figure 18) for 5-, 8-, 11-, or 14-blade cutting units, determine the proper reel speed setting. Adjusting the Tap-off Delay The tap-off delay feature allows the cutting units to turn off without raising, and you may adjust it with the InfoCenter. The delay setting represents the maximum time for the raise/lower joystick to remain in the raise position to activate this feature. The factory default setting is 1 which disables this feature.
Seat-Adjusting Lever Fuel-Shutoff Valve 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. 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.
Specifications Note: Specifications and design are subject to change without notice. Width of cut Minimum ground clearance (at the machine centerline) g016588 151 cm (59.5 inches) 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 (46.9 inches) Overall length (with baskets) 249 cm (98.0 inches) Overall width 179 cm (70.6 inches) Overall height 205 cm (80.8 inches) Figure 22 1.
Fuel Specification Operation • Fuel tank capacity: 22.7 L (6 U.S. gallons) Note: Determine the left and right sides of the • Recommended Fuel: machine from the normal operating position. – 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.
Filling the Fuel Tank 1. During Operation Clean around the fuel-tank cap and remove it (Figure 23). During Operation Safety General Safety • The owner/operator can prevent and is responsible • • • g272992 Figure 23 1. Fuel-tank cap 2. • Add the specified fuel to the fuel tank until the level is 25 mm (1 inch) below the bottom of the filler neck. This space in the tank allows the fuel to expand. • • Important: Do not fill the fuel tank • completely full. 3. Install the cap.
• – 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. • Rollover Protection System (ROPS) Safety • • Do not remove any of the ROPS components from • • • • • the machine. Ensure that the seat belt is attached and that you can release it quickly in an emergency. Always wear your seat belt. Check carefully for overhead obstructions and do not contact them.
5. Turn the ignition key to the START position. Note: If fluid leaks continue to appear, contact Important: To prevent overheating of the your authorized Toro distributor for assistance and, if necessary, replacement parts. starter motor, do not engage the starter longer than 10 seconds. After 10 seconds of continuous cranking, wait 60 seconds before engaging the starter motor again. 6. Release the key when the engine starts and allow it to move to the ON position. 7.
Checking the Raise/Lower Mow Control Checking the Traction Pedal Perform the following system checks daily to ensure that the interlock system is operating correctly: 1. 2. Sit on the seat, move the traction pedal to the NEUTRAL position, move the functional-control lever to the NEUTRAL position, and engage the parking brake. Try to move the traction pedal forward or backward. The pedal should not move, which indicates that the interlock system is operating correctly.
Driving the Machine without Mowing units do; therefore, you should practice gaining the required timing necessary to minimize the cleanup mowing operation. • Ensure that the cutting units are fully raised. • Move the functional-control lever to the TRANSPORT 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. position.
Cutting the Periphery and Finishing the Job 1. Finish cutting the green by mowing the outer periphery. Change the direction of cutting from the previous mowing. 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. Note: Always keep weather and turf conditions in mind and be sure to change the direction of mowing from the previous cutting. 2.
Inspecting and Cleaning after Mowing After Operation After Operation Safety 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. General Safety • Shut off the engine, remove the key (if equipped), and wait for all movement to stop before you leave the operator’s position.
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). g270390 Figure 26 1. Tie-down loop (each side) 2. Rear tie-down loop g014627 Figure 27 1.
2. Before starting the engine, close the bypass valve by rotating it so that the slot is horizontal (Figure 27). Important: Do not start the engine when the bypass valve is open.
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 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 37). • 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 39). 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 40 1. Eccentric Figure 41 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 40). 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 42). • 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 46 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 49. 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 51). 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 53). 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 53).
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 55 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 (if equipped), 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).
