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. Use 4 bolts (1/2 x 3-3/4 inches) and 4 flange nuts (1/2 inch) to install the roll bar into the ROPS brackets on each side of the machine as shown in Figure 3.

   

   Figure 3

   1. Roll bar
   2. Bolt (1/2 x 3-3/4 inches)
   3. ROPS bracket
   4. 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 to the machine; refer to the kit Installation Instructions.

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.

   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 (+)

Parts needed for this procedure:

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 the optional 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. Prepare the cutting units for installation; refer to your cutting unit Operator’s Manual.

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

3. Install the cutting units; refer to 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:

Install the CE Guard Kit; refer to the CE Guard Kit for Greensmaster 3400 TriFlex Traction Unit Installation Instructions.

Parts needed for this procedure:

If you use this machine in a country that complies to CE standards, perform the following steps after you install the guard kit to the machine:

• Apply the CE warning decal (Part No. 136-8505) over the existing warning decal (Part No. 136-8506).

• Apply the CE mark decal to the frame under the front of the seat (Figure 9).

  

  Figure 9

  1. CE mark decal

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.

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 11) 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 your comfort, do not rest the heal of your foot on the reverse pad of the traction pedal when you are driving the machine forward. (Figure 12).

Figure 11

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

Figure 12

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

The throttle lever (Figure 13) 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 13

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 13) forward during cutting operation lowers the cutting units and starts the reels. Pull back on the control to stop the reels and raise the cutting units. To stop the reels without raising the cutting units, pull back on the control momentarily and releasing it. Start the reels by moving the control forward.

The functional control lever (Figure 13) 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 position; use when backlapping the reels

• MIDDLE position—use when cutting grass

• FRONT position—use when driving the machine between job sites

Insert the key into the switch (Figure 13) 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. Turn the key counterclockwise to the STOP position to shut off the engine.

The light (Figure 13) glows if the battery charge is low.

The light (Figure 13) glows if the engine-oil pressure drops below a safe level.

The light (Figure 13) 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 13) 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 13) 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 14) indicates the total hours the machine has operated. It starts to function whenever you rotate the ignition switch to the ON position.

Figure 14

1. Hour meter

Pull the brake lever (Figure 15) to engage the parking brake. Disengage it by squeezing the release lever on the underside of the brake lever and lowering it to the released position. Engage the parking brake whenever you leave the machine.

Figure 15

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 16) in conjunction with the raise/lower mow control lever and the reel-speed control for backlapping the reels.

Figure 16

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 17) to adjust the speed of the reels.

Figure 17

1. Reel-speed control

The seat-adjusting lever is located on the front, left corner of the seat (Figure 18), 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 18

1. Seat-adjusting handle

Close the fuel-shutoff valve (Figure 19), behind the seat and under the fuel tank, when storing or transporting the machine on a truck or trailer.

Figure 19

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. Using winter-grade fuel at lower temperatures provides lower flash point and cold flow characteristics that will ease starting and reduce fuel filter plugging.

    Note: Using 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 authorized Toro distributor for more information on biodiesel.

1. Clean around the fuel-tank cap and remove it (Figure 20 or Figure 21).

   

   Figure 20

   Machines with a fuel tank sight gauge.

   1. Fuel tank sight gauge
   2. Fuel-tank cap
   

   Figure 21

   Machines with a fuel gauge.

   1. Fuel gauge
   2. 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. Watch the fuel level in the sight gauge or fuel gauge when you are filling the tank.

   Important: Do not fill the fuel tank completely full.

3. Install the cap.

   Note: You will hear a click sound when the cap is secure.

4. Wipe up any spilled fuel.

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 Maintenance.

• 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 Owner’s Manual supplied with the machine for oil change and maintenance procedures recommended during the break-in period.

Only 8 hours of 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.

Important: Do not use ether or other types of starting fluid.

Note: You may need to bleed the fuel system before starting the engine if any of the following situations have occurred:

• Initial start up of a new engine

• The engine has ceased running due to lack of fuel.

• Maintenance has been performed upon fuel system components; ie. filter replaced, etc.

Refer to your engine owner’s manual.

1. Sit on the seat, lock the parking brake, disengage the raise/lower mow control and move the functional-control lever to the NEUTRAL position.

2. Remove your foot from the traction pedal and make sure the pedal is in the NEUTRAL position.

3. Move the throttle lever to the SLOW position.

4. 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).

5. Turn the ignition key to the START position.

   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.

6. Release the key when the engine starts and allow it to move to the ON position.

7. Allow the engine to warm up for a few minutes before operating.

   Important: When starting the engine for the first time or after an overhaul of the engine, operate the machine in forward and reverse for 1 to 2 minutes. Turn the steering wheel to the left and right to check the steering response. Then shut the engine off and wait for all moving parts to stop; refer to Shutting Off the Engine. Check for oil leaks, loose parts and any other noticeable malfunctions.

1. Move the throttle lever to the FAST position.

2. Move the raise/lower mow control lever forward momentarily.

   The cutting units should lower and all the reels should rotate.

   Note: The function lever should be in the middle (mow) position for the reels run when lowering the cutting units

3. Move the raise/lower mow control lever rearward.

   The cutting reels should stop rotating and the cutting units should raise to the full transport position.

4. Engage the brake to keep the machine from moving, and operate the traction pedal through the forward and reverse positions.

5. Continue the above procedure for 1 or 2 minutes. Move the functional-control lever to the NEUTRAL position, engage the parking brake, and shut off the engine.

6. Check for fluid leaks and tighten the hydraulic fittings if any leaks are found.

   Note: When the machine is new and the bearings and reels are tight, it is necessary to use the FAST throttle-lever position for this check. A fast throttle setting may not be required after the break-in period.

   Note: If fluid leaks continue to appear, contact your authorized Toro distributor for assistance and, if necessary, replacement parts.

   Important: A trace of fluid on the motor or wheel seals is normal. Seals require a small amount of lubrication to perform properly.

1. Move the throttle lever to the SLOW position, pull back the raise/lower mow control, and move the functional-control lever to the NEUTRAL position.

2. Rotate the ignition key to the OFF position to shut off the engine. Remove the key from the switch to prevent accidental starting.

3. Close the fuel shut-off valve before storing the machine.

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

• You are seated in the operator's seat.

• 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.

• 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 to prevent costly damage and downtime.

Important: 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.

Before mowing greens, find a clear area and practice performing basic machine functions (e.g., starting and stopping the machine, raising and lowering the cutting units, and turning).

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.

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.

After cleaning the machine, perform the following:

• Inspect the machine for possible hydraulic fluid leaks, damage or wear to hydraulic and mechanical components.

• Inspect the cutting units for sharpness.

• 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 a full-width ramp for loading the machine into a trailer or a 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 24).

   

   Figure 24

   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 24).

   Important: Do not start the engine when the bypass valve is open.