Form No. 3404-731 Rev C Greensmaster® 3420 TriFlex® Traction Unit Model No. 04540—Serial No. 316000001 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 Replacing the Fuel Filter/Water Separator ...................................................... 40 Inspecting the Fuel Lines and Connections.................................................. 41 Electrical System Maintenance ........................... 41 Servicing the Battery......................................... 41 Locating the Fuses ........................................... 42 Drive System Maintenance .................................. 42 Adjusting the Transmission for Neutral.............
Safety • Operate the machine only in good light, keeping This machine has been designed in accordance with EN ISO 5395:2013 and ANSI B71.4-2012 and meets these standards when the appropriate weight kit is added. • Be sure all drives are in neutral and the parking away from holes and hidden hazards. brake is engaged before the starting engine. Start the engine only from the operator's position. • Slow down and use extra care on hillsides. Turf conditions can affect the machine's stability.
• Keep the ROPS in safe operating condition by • • • This product is capable of amputating hands and feet and of throwing objects. Always follow all safety instructions to avoid serious injury or death. periodically thoroughly inspecting for damage and keeping all mounting fasteners tight. Replace a damaged ROPS. Do not repair or revise. Do not remove the ROPS. Any alterations to a ROPS must be approved by the manufacturer.
• Traverse slopes carefully. Do not start or stop Replacement parts and accessories made by other manufacturers could be dangerous, and such use could void the product warranty. suddenly when traveling uphill or downhill. • The operator must be skilled and trained in how to drive on hillsides. Failure to use caution on slopes or hills may cause loss of control and cause the machine to tip or roll, possibly resulting in personal injury or death.
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. 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.
decal119-9346 119-9346 1. Press pedal to unlock 2. Read the Operator's Manual for more information. decal132-9548 132-9548 7. Reel speed—neutral 1. Engine speed—fast 2. Engine speed—slow 8. Reel—transport 3. Lower and engage the reels 9. Reel—mow 4. Raise and disengage the reels 10. Reel—backlaping 5. Reel speed—fast 11. Move forward 6.
decal132-9550 132-9550 1. Choke 3. Engine—run 2. Engine—start 4. Engine—stop 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 gases can cause blindness and other injuries. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection. 8. Battery acid can cause blindness or severe burns. 9.
decal131-2046 131-2046 1. Double lights 3. Off 2. Single light decal133-2339 133-2339 Replaces Decal 133-2338 for CE Machines 1. Warning—read the Operator’s Manual, do not operate this machine unless you are trained. 4. Tipping hazard—do not drive across or down slopes greater than 15 degrees. 2. Warning—wear hearing protection. 5. Thrown object hazard—keep bystanders a safe distance away from the machine. 6.
decal119-9345 119-9345 11
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 4 5 6 7 8 9 10 11 12 13 Description Use Qty. Roll bar Bolt (1/2 x 3-3/4 inches) Flange-nut (1/2 inch) Seat Seat wire harness Steering wheel Locknut (1-1/2 inches) Washer Steering-wheel cap 1 4 4 1 1 1 1 1 1 No parts required – Activate and charge the battery. No parts required – Install the optional oil cooler.
Description Use Qty. Pre-delivery Inspection Sheet Noise rating certificate Certificate of compliance 1 1 1 Save for future reference Ignition keys 2 Start the engine. 1 2 Installing the Roll Bar Installing the Seat Parts needed for this procedure: Parts needed for this procedure: 1 Roll bar 1 Seat 4 Bolt (1/2 x 3-3/4 inches) 1 Seat wire harness 4 Flange-nut (1/2 inch) Procedure Procedure 1. Remove the top crate support from the crate. 2. Remove the roll bar from the crate. 3.
g014687 Figure 5 g193736 1. Steering wheel 3. Locknut 2. Washer 4. Cap 2. Slide the washer onto the steering shaft (Figure 5). 3. Secure the steering wheel to the shaft with a locknut and tighten it to 27 to 35 N∙m (20 to 26 ft-lb) (Figure 5). 4. Install the cap to the steering wheel and secure it with 6 bolts (Figure 5). Figure 4 1. Seat 2. Seat base 3. Washer 4. Bolt (5/16 x 3/4 inch) 4.
Important: Do not add electrolyte while the battery is in the machine. You could spill it, causing corrosion. 2. WARNING Charging the battery produces gasses that can explode. Clean the top of the battery and remove the vent caps (Figure 6). Never smoke near the battery and keep sparks and flames away from the battery. Important: If you do not charge the battery for at least the time specified above, you may reduce the life of the battery. 6.
WARNING 6 Incorrect battery cable routing could damage the tractor and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Installing the Grass-Basket Hooks • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. Parts needed for this procedure: • Always connect the positive (red) battery cable before connecting the negative (black) cable.
7 9 Installing the Cutting Units Adding Rear Weight Parts needed for this procedure: 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 1 Weight kit – Part No. 119-7129 (purchase separately) Procedure This unit complies with the ANSI B71.4-2012 and EN ISO 5395:2013 Standards when equipped with the Weight Kit (Part No. 119-7129). Procedure 10 1.
Product Overview 12 Reducing the Tire Pressure No Parts Required Procedure The tires are over-inflated at the factory for shipping purposes. Reduce the pressure to the proper levels before starting the machine. Refer to Checking the Tire Pressure (page 29). 13 Burnishing the Brakes g014674 Figure 10 No Parts Required 1. Engine 2. Roll bar 6. Traction pedal Procedure 3. Control panel 7. Footrest 4. Seat 8.
g033079 Figure 13 g014603 Figure 11 1. Traction pedal—forward 3. Steering arm locking pedal 1. Ignition switch 4. Throttle lever 2. Functional-control lever 3. Raise/Lower mow control 5. InfoCenter 2. Traction pedal—reverse Raise/Lower Mow Control Moving the control (Figure 13) forward during operation lowers the cutting units and starts the reels. Pull back on the control to stop the reels and raise the cutting units.
it down to its released position. Lock the parking brake any time you leave the machine. g017973 Figure 15 g027863 Figure 14 1. Parking-brake lever 2. Release lever 1. Battery voltage 6. Hour meter 2. Power light/fault indicator 7. Right button 3. Engine speed (rpm)/status 8. Down button 4. Fault log 9. Menu access/back button 5.
• FUNCTIONAL CONTROL STATUS —transport mode is SERVICE indicated by a rabbit and mow mode is indicated by a turtle. • ENGINE OIL PRESSURE light—this icon appears if 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.
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. 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.
Note: If you need additional adjustment on the seat, you can remove the 4 bolts securing the seat to the base and move the seat to the second set of mounting holes provided. g014736 Figure 17 4. To set the reel speed, on the InfoCenter open the Main Menu and scroll down to SETTINGS. 5. In the SETTINGS menu, scroll down to REEL SPEED and use the ± button to set the reel speed to the desired number. g193737 Figure 18 1.
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 oil level before and after starting the engine the first time. Note: Determine the left and right sides of the machine from the normal operating position. Use high-quality engine oil that meets the following specifications: • API Classification Level Required: CH–4, CI–4 or higher. • Preferred oil: SAE 10W–30 • Alternate oil: SAE 15W–40 Think Safety First Carefully read all safety instructions and symbols in the safety section.
Filling the Fuel Tank 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. Fuel tank capacity: 22.7 L (6 U.S. gallons) 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.
1. DANGER Clean around the fuel-tank cap (Figure 24). 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.
Checking the Cooling System The capacity of the cooling system is approximately 4.6 L (4.9 US qt). Keep the radiator screen clean; refer to Cleaning the Radiator Screen (page 44). g008427 Figure 26 1. Reserve tank 3. If the coolant is low, remove the reserve tank cap and add a 50/50 mixture of water and permanent ethylene glycol antifreeze. Do not overfill. 4. Install the reserve-tank cap. g014613 Figure 25 1. Wing bolts 3. Reserve tank 2. Radiator screen 4.
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 Important: The ISO VG 46 Multigrade fluid has been found to offer optimal performance in a wide range of temperature conditions.
Checking the Torque of the Wheel Nuts glow-plug-indicator light goes off (approximately 6 seconds). 5. Important: To prevent overheating of the 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. WARNING Failure to maintain proper torque of the wheel nuts could result in personal injury.
• The traction pedal is in the NEUTRAL position. • The functional-control lever is in the NEUTRAL The engine should shut off, which means that the interlock system is operating correctly. Correct the problem if it is not operating properly. position. The safety-interlock system prevents the machine from moving unless: • The parking brake is off. • The operator is seated. • The functional-control lever is in the MOW position or the TRANSPORT position.
Installing the Electrical Counterweights Secure the electrical counterweight to the existing counterweight with 2 capscrews as shown in Figure 29. g014602 Figure 30 1. Footrest—closed 3. 4. 2. Footrest—open Position the cutting unit under the center suspension arm. With the latches on the suspension-arm bar pointing up (i.e., open) (Figure 31), push the suspension arm down so that the bar fits over the bar across the top of the cutting unit (Figure 32). g036342 Figure 29 1. Cap screw (2) 3.
5. Removing the Cutting Units Close the latches down and around the cutting-unit bar and lock them in place (Figure 31). 1. Note: You will hear a click and feel when the latches are properly locked in place. 6. 7. Disconnect the cutting unit power disconnect couplers; refer to Cutting Unit Power Disconnect Connectors (page 24). CAUTION Coat the spline shaft of the cutting unit motor with clean grease (Figure 33).
Note: This holds compaction to a minimum and leaves a neat, attractive pattern on the greens. 3. Actuate the raise/lower mow lever as the front edges of the grass baskets cross the outer edge of the green. Note: This procedure drops the cutting units to the turf and starts the reels. Important: The No. 1 cutting unit reel is g036124 Figure 35 delayed; therefore, you should practice to gain the required timing necessary to minimize the cleanup mowing operation.
weight to the machine, thereby increasing the load on the engine, hydraulic system, brakes, etc. Inspecting and Cleaning after Mowing After mowing, thoroughly wash the machine with a garden hose without a nozzle so that excessive water pressure will not contaminate and damage the seals and bearings. Never wash a warm engine or electrical connections with water.
Towing the Machine In case of an emergency, you can tow the machine less than 0.4 km (1/4 mile); however, Toro does not recommend this as standard procedure. Important: Do not tow the machine faster than 3 to 5 km/h (2 to 3 mph) because it may damage the drive system. If the machine must be moved further 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 37). g014627 Figure 37 1.
Maintenance 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. Important: Refer to your engine owner’s manual for additional maintenance procedures. CAUTION If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders.
Daily Maintenance Checklist Duplicate this page for routine use. Maintenance Check Item For the week of: Mon. Tues. Wed. Thurs. Fri. Check the safety interlock operation. Check the instrument operation Check the leak detector alarm. Check the brake operation. Check the fuel level. Check the hydraulic fluid level. Check the engine oil level. Clean the engine air cooling fins. Inspect the air filter pre-cleaner. Check any unusual engine noises. Check the reel-to-bedknife adjustment.
Engine Maintenance Important: Do not clean the used element. Servicing the Air Cleaner A. Inspect the new filter for shipping damage; do not use a damaged element. B. Carefully pull the old filter out of the filter body and discard it. C. Insert the new filter by applying pressure to the outer rim of the element to seat it in the canister, checking the sealing end of the filter and the body.
Fuel System Maintenance Replacing the Fuel Filter/Water Separator Service Interval: Every 800 hours 1. Close the fuel-shutoff valve (Figure 41) below the fuel tank. g014615 Figure 40 1. Oil filter 3. Screw the filter on by hand until the gasket contacts the filter adapter, then tighten 1/2 to 3/4 turn further. Do not overtighten. 4. Add oil to the crankcase; refer to Checking the Engine Oil (page 25). 5. Dispose of the used oil properly. g014626 Figure 41 1. Fuel-shutoff valve 40 2.
Electrical System Maintenance Servicing the Battery Properly maintain the battery electrolyte and keep the top of the battery clean. Store the machine in a cool place to prevent the battery from running down. Check the electrolyte level every 50 operating hours or, if machine is in storage, every 30 days. g014720 DANGER Figure 42 1. Fuel filter /water separator canister Battery electrolyte contains sulfuric acid, which is lethal if consumed and causes severe burns. 2. Filter-drain plug 5.
Drive System Maintenance WARNING CALIFORNIA Proposition 65 Warning Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. Adjusting the Transmission for Neutral If the machine creeps when the traction-control pedal is in the NEUTRAL position, adjust the neutral-return mechanism. 1.
Reducing the Transport Speed or refer to the Service Manual for further adjustment. Adjusting the Transport Speed Obtaining the Maximum Transport Speed 1. Press down on the traction pedal and loosen the locknut securing the pedal stop to the floor plate. 2. Loosen the pedal stop until you obtain the desired transport speed. 3. Tighten the locknut securing the pedal stop.
Cooling System Maintenance 3. Checking the Engine-Coolant Level Cooling System Safety The capacity of the cooling system is approximately 4.6 L (4.9 US qt). • Swallowing engine coolant can cause poisoning; keep out of reach from children and pets. 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.
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 Ensure that the belt is properly tensioned to ensure proper operation of the machine and prevent unnecessary wear.
Checking the Hydraulic Lines and Hoses Hydraulic System Maintenance WARNING Changing the Hydraulic Fluid and Filter Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • Ensure that all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system. Service Interval: After the first 50 hours Every 800 hours If the oil becomes contaminated, have your Toro distributor flush the system.
Cutting Unit Maintenance position to return the machine to forward cutting operation. 15. Backlapping the Reels WARNING Contact with the reels or other moving parts can result in personal injury. • Keep your hands and clothing away from the reels or other moving parts. • Never attempt to turn the reels by hand or foot while the engine is running. 1. Position the machine on a level surface, lower the cutting units, stop the engine, engage the parking brake. 2.
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 blades and bedknives, if necessary; refer to the Cutting Unit Operator's Manual. Use a rust preventive on bedknives and blades. Grease and oil all lubrication points. 2. Block up the wheels to remove any weight on the tires. 3.
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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).
