Form No. 3437-387 Rev A Greensmaster® 3400 TriFlex® Traction Unit Model No. 04520—Serial No. 405700000 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. Visit www.Toro.com for more information, including safety tips, training materials, accessory information, help finding a dealer, or to register your product.
Contents Electrical System Safety ................................... 37 Servicing the Battery......................................... 37 Locating the Fuses ........................................... 37 Drive System Maintenance .................................. 38 Checking the Tire Pressure............................... 38 Checking the Torque of the Wheel Nuts .............................................................. 38 Adjusting the Transmission for Neutral..............
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.
decal115-8203 decal119-9346 115-8203 1. Read the Operator's Manual for fuse information. 119-9346 1. Press the pedal to unlock. 2. Radiator fan—50 A 2. Read the Operator's Manual for more information. decal131-2046 131-2046 1. Double lights 3. Off 2. Single light decal133-8062 133-8062 decal115-8226 115-8226 1. Tipping hazard—read the Operator's Manual; wear a seatbelt; do not remove the roll bar.
decal136-8506 decal136-8505 136-8506 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.
decal139-6492 139-6492 1. Read the Operator’s Manual before performing maintenance. 2. Low hydraulic fluid level indicator 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. 139-2728) Clip decal (115-8156) Steering wheel Locknut (1-1/2 inches) Washer Steering-wheel cap 1 1 1 1 1 1 5 No parts required – Activate and charge the battery.
Description Use Qty. Declaration of Conformity Noise rating certificate 1 1 For CE compliance. 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 4 Bolt (1/2 x 3-3/4 inches) 4 Flange nut (1/2 inch) 1 Seat Kit (order separately; contact your authorized Toro distributor) Procedure Procedure 1. 2. 3.
4 Installing the Steering Wheel Parts needed for this procedure: g291701 Figure 4 Premium Seat (Model No. 04719) 1. Service decal 3. 2.5 cm (1 inch) 2. Clip decal 4. 16.5 cm (6.5 inches) 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 6). g010834 g291702 Figure 6 Figure 5 Standard Seat (Model No. 04508) 1. Clip decal 1. Steering wheel 3. Locknut 2. Washer 4. Cap 2. Service decal 11 2.
5 Activating and Charging the Battery No Parts Required Procedure g005080 Figure 7 Use only electrolyte (1.265 specific gravity) to fill the battery initially. 3. DANGER Carefully fill each cell with electrolyte until the plates are covered with about 6 mm (1/4 inch) of fluid (Figure 8). Battery electrolyte contains sulfuric acid, which can be fatal if consumed and causes severe burns. • Do not drink electrolyte and avoid contact with skin, eyes or clothing.
6. When the battery is charged, disconnect the charger from the electrical outlet and battery posts. 6 Note: After the battery has been activated, Installing the Oil Cooler add only distilled water to replace normal loss, although maintenance-free batteries should not require water under normal operating conditions. Optional Important: Failure to correctly activate the battery may result in battery gassing and/or premature battery failure. 7. Install the vent caps. 8.
7 8 Installing the Grass-Basket Hooks Installing the Cutting Units Parts needed for this procedure: Parts needed for this procedure: 6 Grass-basket hook 12 Flange bolts Procedure 1 Gauge bar 3 Cutting unit (obtain from your authorized Toro distributor) 3 Grass basket Procedure Install the 6 grass-basket hooks onto the ends of the suspension-arm bars using the 12 flange bolts (Figure 10). 1. Prepare the cutting units for installation; refer to your cutting unit Operator’s Manual. 2.
10 Installing the CE Guard Kit Parts needed for this procedure: 1 CE Guard Kit―Part No. 04442 (sold separately) g233420 Procedure Figure 11 Install the CE Guard Kit; refer to the CE Guard Kit for Greensmaster 3400 TriFlex Traction Unit Installation Instructions. 1. CE mark decal • Install the production year decal near the serial plate (Figure 12). 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 38). 13 Burnishing the Brakes g014674 Figure 13 No Parts Required 1. Engine 2. Roll bar 6. Traction pedal Procedure 3. Control panel 7. Footrest 4. Seat 8. Cutting units 5.
Steering-Arm-Locking Pedal Press the pedal (Figure 14) and raise or lower the steering arm for operator comfort, then, release the pedal to lock the arm in place. Throttle Lever Use the throttle lever (Figure 16) 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. Important: You cannot shut off the engine using the throttle lever. g014603 Figure 14 1. Traction pedal—forward 3.
Functional Control Lever Hour Meter The functional control lever (Figure 16) provides 2 traction selections plus a NEUTRAL position. You can shift from mow to transport or transport to mow (not to neutral) while the machine is in motion; no damage will result. The hour meter (Figure 17) indicates the total hours the machine has operated. It starts to function whenever you rotate the ignition switch to the ON position.
Backlap Lever Seat-Adjusting Lever The backlap lever is located under the plastic cover to the left of the seat. Use the backlap lever (Figure 19) in conjunction with the raise/lower mow control lever and the reel-speed control for backlapping the reels. The seat-adjusting lever is located on the front, left corner of the seat (Figure 21), allowing you to adjust the seat forward and rearward.
Fuel-Shutoff Valve Specifications Close the fuel-shutoff valve (Figure 22), behind the seat and under the fuel tank, when storing or transporting the machine on a truck or trailer. Note: Specifications and design are subject to change without notice. Width of cut 151 cm (59.5 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) Minimum ground clearance (at the machine centerline) 11 cm (4.
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.
• • Use extreme caution when operating the machine – 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. 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.
4. 5. 6. 7. to use the FAST throttle-lever position for this check. A fast throttle setting may not be required after the break-in period. Insert the key into the switch and rotate it to the ON position. Hold it in the ON position until the glow-plug-indicator light goes off (approximately 6 seconds). Turn the ignition key to the START position. Note: If fluid leaks continue to appear, contact your authorized Toro distributor for assistance and, if necessary, replacement parts.
The safety-interlock system prevents the reels from operating unless the functional-control lever is in the MOW position. The engine should shut off, which indicates that the interlock system is operating correctly. Correct the problem if it is not operating properly. Checking the Traction Pedal Checking the Raise/Lower Mow Control Perform the following system checks daily to ensure that the interlock system is operating correctly: 1. 2.
which quickly lines the machine up for your next pass. to lay down and therefore be difficult to trap between the reel blades and the bedknife. Cutting the Green 1. Approach the green with the functional-control lever in the MOW position and the throttle at full speed. 2. Start on 1 edge of the green so that you can use the ribbon procedure of cutting. Note: This holds compaction to a minimum and leaves a neat, attractive pattern on the greens. 3.
After Operation damage to the turf may result. Stopping the machine on a wet green may leave marks or indentations from the wheels. After Operation Safety Cutting the Periphery and Finishing the Job 1. General Safety Finish cutting the green by mowing the outer periphery. Change the direction of cutting from the previous mowing. • 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 Hauling the Machine 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. • Use a full-width ramp for loading the machine into • Use care when loading or unloading the machine into a trailer or a truck. a trailer or a truck.
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.
Engine Maintenance into the intake when you remove the primary filter. Engine Safety Important: Avoid using high-pressure air that could force dirt through the filter into the intake tract. • Shut off the engine before checking the oil or adding oil to the crankcase. Do not change the governor speed or overspeed the engine. • 4. Remove and replace the primary filter, as follows: Important: Do not clean the used element. Servicing the Air Cleaner A.
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. 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. 1. Position the machine on a level surface. 2. Remove the dipstick and wipe it with a clean rag (Figure 30). Important: Remove the dipstick while filling the engine with oil.
Fuel System Maintenance Draining Water from the Fuel Filter Service Interval: Before each use or daily g014754 Figure 31 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 33). 1. Drain plug 2. Remove the oil filter (Figure 32). Apply a light coat of clean oil to the new filter gasket. g014720 Figure 33 1. Fuel filter 4.
Replacing the Fuel Filter/Water Separator 6. Screw the filter on by hand until the gasket contacts the filter adapter, then tighten 1/2 to 3/4 turn further. Service Interval: Every 500 hours 7. Ensure that the filter-drain plug is closed. Open the fuel-shutoff valve. 1. Close the fuel-shutoff valve (Figure 34) below the fuel tank. Inspecting the Fuel Lines and Connections Service Interval: Every 2 years Inspect the fuel lines for deterioration, damage, or loose connections. g014626 Figure 34 1.
Electrical System Maintenance 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. Electrical System Safety • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. • Disconnect the battery before repairing the machine. Disconnect the negative terminal first and the positive last. Connect the positive terminal first and the negative last.
Drive System Maintenance 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). Checking the Torque of the Wheel Nuts g014616 Figure 37 Service Interval: After the first hour 1. Eccentric 2. Locknut After the first 10 hours Every 200 hours WARNING Failure to maintain proper torque of the wheel nuts could result in personal injury.
Adjusting the Mowing Speed The mow speed is set to 3.8 mph at the factory. You can adjust the forward moving speed from 0 to 8 km/h (0 to 5 mph). 1. Loosen the jam nut on the trunnion bolt (Figure 39). 2. Loosen the nut securing the lock and mow brackets on the pedal pivot. g015494 Figure 38 1. Pedal stop 1. Put the functional-control lever in the TRANSPORT position and loosen the locknut securing the pedal stop to the floor plate (Figure 38). 2.
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 Burnishing the Brakes Adjusting the Alternator Belt Service Interval: Yearly Firmly apply the brakes and drive the machine at mowing speed until the brakes are hot, as indicated by their smell. You may need to adjust the brakes after the break-in period; refer to Adjusting the Brakes (page 41). 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.
Hydraulic System Maintenance products only from reputable manufacturers who will stand behind their recommendation. High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46 Hydraulic System Safety Material Properties: • Seek immediate medical attention if fluid is injected Viscosity, ASTM D445 into skin. Injected fluid must be surgically removed within a few hours by a doctor.
Changing the Hydraulic Fluid and Filter 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. g014719 Figure 43 1.
Cutting Unit Maintenance and Checking the Hydraulic-Fluid Level (page 42). 4. 5. Start the machine and run it at idle for 3 to 5 minutes to circulate the fluid and remove any air trapped in the system. Shut off the engine and check the fluid level. Blade Safety 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. Dispose of the fluid and filter properly.
g014609 Figure 47 1. Latch—closed position g014596 Figure 45 3. Latch—open position 2. Suspension-arm bar 2. Bedbar-adjusting-screw nut (2) 1. Prop (not provided) Installing the Cutting Units 1. Lift up on the footrest and swing it open, allowing access to the center cutting unit position (Figure 46). CAUTION The footrest can pinch fingers if it falls into the closed position. Keep your fingers clear of the area where the footrest seats while it is open. g014611 Figure 48 1.
g014605 Figure 50 1. Reel motor 3. 2. Motor-retaining bar Move the motor to the storage location on the front of the suspension arm (Figure 51). g014690 Figure 49 1. Reel motor 3. Cavity 2. Spline shaft 4. Motor-retaining bar g014608 Figure 51 Note: When sharpening, setting the height 7. Mount a grass basket onto the basket hooks on the suspension arm. 8. Repeat this procedure for the other cutting units.
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. Backlapping the Reels g014620 Figure 52 1. Backlap lever—FORWARD position WARNING Contact with the reels or other moving parts can result in personal injury. 6.
12. When finished, return the backlap levers to the FORWARD (F) position, replace the cover, and wash all lapping compound off of the cutting units. Adjust cutting unit reel to bedknife as needed. Move the cutting unit reel speed control to the desired mowing position. Important: If the backlap lever is not returned to the FORWARD (F) position after backlapping, the cutting units will not raise or function properly.
Reel Speed Table Reel Speed Table Height of Cut 5-blade cutting unit 11-blade cutting unit 8-blade cutting unit 14-blade cutting unit Ground Speed 6.1 km/h (3.8 mph) 8.0 km/h (5.0 mph) 6.1 km/h (3.8 mph) 8.0 km/h (5.0 mph) 6.1 km/h (3.8 mph) 8.0 km/h (5.0 mph) 6.1 km/h (3.8 mph) Reel speed setting 1.6 mm (0.062 inch) *N/R *N/R 9 *N/R 9 *N/R 9 2.4 mm (0.094 inch) *N/R *N/R 9 *N/R 9 *N/R 9 3.2 mm (0.125 inch) *N/R *N/R 9 *N/R 9 *N/R *N/R 4.0 mm (0.
2. Move the functional-control lever to the TRANSPORT position. Storage 3. Ensure that the backlap lever is set to the FORWARD (F) position. Storage Safety 4. Get off the seat. • Shut off the machine, remove the key, and wait 5. Hold the raise/lower mow control in the RAISED position. 6. Turn the ignition switch to the RUN position. 7. Count the codes as they begin to flash (you may release the raise/lower mow control once they begin flashing).
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