Greensmaster® 3400 TriFlex® Traction Unit

Parts needed for this procedure:

1. Remove the top crate support from the crate.

2. Remove the roll bar from the crate.

3. Install the roll bar into the pockets on each side of the machine, using 4 bolts (1/2 x 3-3/4 inches) and 4 flange nuts (1/2 inch) as shown in Figure 3.

   

   Figure 3

   1. Roll bar
   2. Bolt (1/2 x 3-3/4 inches)
   3. Flange nut (1/2 inch)

4. Torque the fasteners to 136 to 149 N∙m (100 to 110 ft-lb).

Parts needed for this procedure:

Acquire your desired seat kit from your distributor and install it as directed in the instruction included with the kit.

Parts needed for this procedure:

1. Slide the steering wheel onto the steering shaft (Figure 4).

   

   Figure 4

   1. Steering wheel
   2. Washer
   3. Locknut
   4. Cap

2. Slide the washer onto the steering shaft (Figure 4).

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 4).

4. Install the cap to the steering wheel and secure it with 6 bolts (Figure 4).

Use only electrolyte (1.265 specific gravity) to fill the battery initially.

1. Remove the fasteners and battery clamp and lift out the battery.

   Important: Do not add electrolyte while the battery is in the machine. You could spill it, causing corrosion.

2. Clean the top of the battery and remove the vent caps (Figure 5).

   

   Figure 5

3. Carefully fill each cell with electrolyte until the plates are covered with about 6 mm (1/4 inch) of fluid (Figure 6).

   

   Figure 6

   1. Electrolyte

4. Allow approximately 20 to 30 minutes for the electrolyte to soak into the plates. Fill as necessary to bring the electrolyte to within about 6 mm (1/4 inch) of the bottom of the fill well (Figure 6).

5. Connect a 2 to 4 A battery charger to the battery posts. Charge the battery for at least 2 hours at 4 A or for at least 4 hours at 2 A until the specific gravity is 1.250 or higher and the temperature is at least 16°C (60°F) with all cells gassing freely.

   Warning

   Charging the battery produces gasses that can explode.

   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. When the battery is charged, disconnect the charger from the electrical outlet and battery posts.

   Note: After the battery has been activated, add only distilled water to replace normal loss, although maintenance-free batteries should not require water under normal operating conditions.

   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.

   • Do not allow metal tools to short between the battery terminals and metal parts of the tractor.

   Important: Failure to correctly activate the battery may result in battery gassing and/or premature battery failure.

7. Install the vent caps.

8. Place the battery on the battery tray and secure it with the battery clamp and fasteners removed previously.

9. Install the positive cable (red) to the positive (+) terminal and then the negative cable (black) to the negative (–) terminal of the battery and secure them with the bolts and nuts (Figure 7). Slide the rubber boot over the positive terminal to prevent a possible short from occurring.

Figure 7

1. Negative (-)
2. Positive (+)

If you are operating the machine in hot climates, where the ambient temperature is above 29° C (85° F), or using it for heavy-duty use (mowing other than greens, such as fairways or verticutting), install a Hydraulic Oil Cooler Kit, Part No. 119-1691.

Parts needed for this procedure:

Install the 6 grass-basket hooks onto the ends of the suspension-arm bars using the 12 flange bolts (Figure 8).

Figure 8

1. Flange bolt
2. Grass-basket hook
3. Suspension-arm bar

Parts needed for this procedure:

1. Setup the cutting units as described in the cutting unit Operator’s Manual.

2. Apply grease to the inside diameter of the drive coupler.

3. Install the cutting units as described in Installing the Cutting Units.

Parts needed for this 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.

Parts needed for this procedure:

If this machine will be used in the EU, affix the warning decal 133-2339 over English warning decal 133-2338.

Parts needed for this procedure:

This machine complies with EN ISO 5395:2013 when you equip it with the CE Guard Kit (Model No. 04442).

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.

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.

The traction pedal (Figure 10) has 3 functions: to make the machine move forward, to move it backward, and to stop the machine. Press the top of the pedal to move forward and the bottom of the pedal to move backward or to assist in stopping when moving forward. Also, allow the pedal to move to the neutral position to stop the machine. For operator comfort, do not rest the heel of your foot on reverse when operating forward (Figure 11).

Figure 10

1. Traction pedal—forward
2. Taction pedal—reverse
3. Steering-arm-locking pedal

Figure 11

Ground speeds are as follows:

• 3.2 to 8 km/h (2 to 5 mph) forward mowing speed

• 16 km/h (10 mph) maximum transport speed

• 4.0 km/h (2.5 mph) reverse speed

Press the pedal (Figure 10) and raise or lower the steering arm for operator comfort, then, release the pedal to lock the arm in place.

The throttle lever (Figure 12) allows you 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.

Note: You cannot stop the engine using the throttle lever.

Figure 12

1. Throttle lever
2. Raise/Lower mow control
3. Functional-control lever
4. Ignition switch
5. Engine-oil-pressure light
6. Battery-warning light
7. Service-indicator light
8. Glow-plug-indicator light
9. Water-temperature light

Moving the control (Figure 12) 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. During operation, you can stop the reels by pulling back on the control momentarily and releasing it. Start the reels by moving the control forward.

The functional-control lever (Figure 12) 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.

• REAR position—neutral and backlapping

• MIDDLE position—used for mowing operation

• FRONT position—used for transport operation

Insert the key into the switch (Figure 12) and turn it clockwise as far as possible 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 OFF position to shut off the engine.

The light (Figure 12) glows if the battery charge is low.

The light (Figure 12) glows if the engine-oil pressure drops below a safe level.

The light (Figure 12) glows and the engine automatically shuts down when the engine-coolant temperature gets too high. If the engine shuts down, you can start the engine and drive the machine for 10 seconds before it will shutdown again, allowing you to move the machine to a location where you can allow it to cool down.

The service-indicator light (Figure 12) illuminates when the machine sensors detect an issue with 1 of the systems of the machine. If this light illuminates, stop what you are doing and drive to a safe location where you or a service technician can diagnose the problem. For more information on diagnosing system issues using the service indicator light, refer to Diagnosing the Service Indicator Light.

When the glow-plug-indicator light (Figure 12) is lit, it indicates the glow plugs are on.

Note: The glow-plug-indicator light may illuminate for a short time after the engine has started; this is normal.

The hour meter (Figure 13) indicates the total hours the machine has operated. It starts to function whenever you rotate the ignition switch to the ON position.

Figure 13

1. Hour meter

Pull up on the brake lever (Figure 14) to set the parking brake. Disengage it by squeezing the release lever on the underside of the brake lever and lowering it down to the released position. Lock the parking brake any time you leave the machine.

Figure 14

1. Parking-brake lever
2. Release lever

The backlap lever is located under the plastic cover to the left of the seat. Use the backlap lever (Figure 15) in conjunction with the raise/lower mow control lever and the reel-speed control for backlapping the reels.

Figure 15

1. Backlap lever—mow position
2. Backlap lever—backlap position

The reel-speed control is located under the plastic cover to the left of the seat. Use the reel-speed control (Figure 16) to adjust the speed of the reels.

Figure 16

1. Reel-speed control

The seat-adjusting lever is located on the front, left corner of the seat (Figure 17), allowing you to adjust the seat forward and rearward.

Note: If you need additional adjustment on the seat, you can remove the 4 nuts securing the seat slide rails to the base and move the seat slide rails to the second set of mounting holes provided.

Figure 17

1. Seat-adjusting handle

Close the fuel-shutoff valve (Figure 18), behind the seat and under the fuel tank, when storing or transporting the machine on a truck or trailer.

Figure 18

1. Fuel shutoff (under the fuel tank)

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.

To best protect your investment and maintain optimal performance of your Toro equipment, count on Toro genuine parts. When it comes to reliability, Toro delivers replacement parts designed to the exact engineering specification of our equipment. For peace of mind, insist on Toro genuine parts.

• 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. Use of winter-grade fuel at lower temperatures provides lower flash point and cold flow characteristics which will ease starting and reduce fuel filter plugging.

    Note: Use of summer-grade fuel above -7° C (20° F) will contribute toward longer fuel pump life and increased power compared to winter-grade fuel.

  • This machine can also use a biodiesel blended fuel of up to B20 (20% biodiesel, 80% petrodiesel). The petrodiesel portion should be low or ultra-low sulfur. Observe the following precautions:

    • The biodiesel portion of the fuel must meet specification ASTM D6751 or EN14214.

    • The blended fuel composition should meet ASTM D975 or EN590.

    • Painted surfaces may be damaged by biodiesel blends.

    • Use B5 (biodiesel content of 5%) or lesser blends in cold weather.

    • Monitor seals, hoses, gaskets in contact with fuel as they may be degraded over time.

    • Fuel filter plugging may be expected for a time after converting to biodiesel blends.

    • Contact your distributor if you wish for more information on biodiesel.

Your fuel tank has a sight glass (Figure 19) or a fuel gauge (Figure 20). Refer to these figures for this procedure.

Figure 19

Fuel tank—sight glass equipped

1. Fuel-tank cap
2. Sight glass

Figure 20

Fuel tank—fuel gauge equipped

1. Fuel gauge
2. Fuel-tank cap

1. Clean around the fuel-tank cap and remove it.

2. Fill the tank until the level is 6 to 13 mm (1/4 to 1/2 inch) below the bottom of the filler neck.

   Important: Do not overfill the tank. Use the sight glass or fuel gauge to check the amount of fuel in the tank.

3. Install the cap.

4. Wipe up any fuel that may have spilled.

Before starting the machine each day, perform the following procedures:

• Check the engine-oil level—refer to Checking the Engine Oil.

• Drain water from the fuel filter—refer to Draining Water from the Fuel Filter.

• Check the cooling system—refer to Cooling System Safety.

• Check the tire pressure—refer to Checking the Tire Pressure.

• Check the hydraulic-fluid level—refer to Checking the Hydraulic-Fluid Level.

• Check the reel-to-bedknife contact—refer to Checking the Reel-to-Bedknife Contact.

Refer to the engine manual supplied with the machine for oil change and maintenance procedures recommended during the break-in period.

Only 8 hours of mowing operation is required for the break-in period.

Since the first hours of operation are critical to future dependability of the machine, monitor its functions and 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.

Note: Inspect the areas beneath the mowers to be certain they are clear of debris.

The purpose of the safety-interlock system is to prevent operation of the machine where there is possible injury to the operator or damage to the machine.

The safety-interlock system prevents the engine from starting unless:

• The traction pedal is in the NEUTRAL position.

• The functional-control lever is in the NEUTRAL position.

The safety-interlock system prevents the machine from moving unless:

• The parking brake is disengaged.

• The operator is seated.

• The functional-control lever is in the MOW position or the TRANSPORT position.

The safety-interlock system prevents the reels from operating unless the functional-control lever is in the MOW position.

Perform the following system checks daily to ensure that the interlock system is operating correctly:

1. 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.

2. Try to press the traction pedal.

   The pedal should not press, which means that the interlock system is operating correctly. Correct the problem if it is not operating properly.

3. 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.

4. Move the functional-control lever to the MOW position or the TRANSPORT position and try to start the engine.

   The engine should not turnover or start, which means that the interlock system is operating correctly. Correct the problem if it is not operating properly.

5. 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.

6. Start the engine and move the functional-control lever to the MOW position or the TRANSPORT position.

   The engine should shut off, which means that the interlock system is operating correctly.

   Correct the problem if it is not operating properly.

7. 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.

8. Start the engine.

9. Release the parking brake, move the functional control lever to the MOW position, and rise from the seat.

   The engine should shut off, which means that the interlock system is operating correctly. Correct the problem if it is not operating properly.

10. 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.

11. Start the engine.

12. Move the raise/lower mow control forward to lower the cutting units. The cutting units should lower but not start rotating.

    If they start rotating, the interlock system is not operating correctly; correct the problem before operating the machine.

Ensure that the cutting units are fully raised. Move the functional-control lever to the TRANSPORT position. Use the brakes to slow the machine while going down steep hills to avoid loss of control. Always approach rough areas at a reduced speed and cross severe undulations carefully. Familiarize yourself with the width of the machine. Do not attempt to pass between objects that are close together so that costly damage and down time can be prevented.

Before mowing greens, find a clear area and practice starting and stopping the machine, raising and lowering the cutting units, turning, etc.

Inspect the green for debris, remove the flag from the cup, and determine the best direction to mow. Base the direction to mow on the previous mowing direction. Always mow in an alternate pattern from the previous mowing so that the grass blades are less apt to lay down and therefore be difficult to trap between the reel blades and the bedknife.

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. 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 delayed; therefore, you should practice to gain the required timing necessary to minimize the cleanup mowing operation.

4. Overlap a minimal amount with the previous cut on return passes.

   Note: To assist in maintaining a straight line across the green and keep the machine an equal distance from the edge of the previous cut, establish an imaginary sight line approximately 1.8 to 3 m (6 to 10 ft) ahead of the machine to the edge of the uncut portion of the green (Figure 21). Some find it useful to include the outer edge of the steering wheel as part of the sight line; i.e., keep the steering wheel edge aligned with a point that is always kept the same distance away from the front of the machine.

5. As the front edges of the baskets cross the edge of the green, move the raise/lower mow lever rearward and hold it until all the cutting units have risen. This stops the reels and lifts the cutting units.

   Note: It is important to time this step correctly so that you do not cut into the fringe area yet cut as much of the green as possible to minimize the amount of grass left to mow around the outer periphery.

6. To cut down on operating time and ease lineup for the next pass, momentarily turn the machine in the opposite direction, then turn it in the direction of the uncut portion; i.e., if intending to turn right, first swing slightly left, then right.

   Note: This helps to get the machine more quickly aligned for the next pass. Try to make as short of a turn as possible except during warmer weather when a wider arc minimizes the turf bruising.

   

   Figure 21

   1. Alignment strip
   2. Approximately 12.7 cm (5 inches)
   3. Cut grass on the left
   4. Keep a focal spot 2 to 3 m (6 to 10 ft) ahead of the machine.

   Note: The steering wheel does not return to its original position after you complete a turn.

   Important: Never stop the machine on a green with the cutting unit reels operating as damage to the turf may result. Stopping the machine on a wet green may leave marks or indentations from the wheels.

7. If the leak detector alarm (if equipped on your model) sounds or you notice an oil leak while cutting on a green, immediately raise the cutting units, drive directly off the green, and stop the machine in an area away from the green. Determine the cause of the leak and correct the problem.

8. Finish cutting the green by mowing the outer periphery. Be sure to change the direction of cutting from the previous mowing.

   Note: Always keep weather and turf conditions in mind and be sure to change the direction of mowing from the previous cutting.

9. When finished mowing the outer periphery, tap the raise/lower mow lever rearward to stop the reels, then drive off the green. When all the cutting units are off of the green, raise them.

   Note: This minimizes grass clumps left on the green.

10. Replace the flag.

11. Empty the grass baskets of all clippings before transporting to the next green.

    Note: Heavy wet clippings place an undue strain on the baskets and add unnecessary weight to the machine, thereby increasing the load on the engine, hydraulic system, brakes, etc.

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 electrical connections with water.

After cleaning, inspect the machine for possible hydraulic fluid leaks, damage or wear to hydraulic and mechanical components, and the cutting units for sharpness. Also, lubricate the brake-shaft assembly with SAE 30 oil or spray lubricant to deter corrosion and help keep the machine performing satisfactorily during the next mowing operation.

• Use care when loading or unloading the machine into a trailer or a truck.

• Use full-width ramps for loading the machine into a trailer or a truck. Do not exceed a 15° angle between the ramp and the trailer or truck.

• Tie the machine down securely using straps, chains, cable, or ropes. Both front and rear straps should be directed down and outward from 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 22).

   

   Figure 22

   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 22). Do not start the engine when the valve is open.