Greensmaster® 3400 TriFlex® Traction Unit

• 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 23).

   

   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.

   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.

Important: Do not use brackish or reclaimed water to clean the machine.

Important: Do not use power-washing equipment to wash the machine. Power-washing equipment may damage the electrical system, loosen important decals, or wash away necessary grease at friction points. Avoid excessive use of water near the control panel, engine, and battery.

Important: Do not wash the machine with the engine running. Washing the machine with the engine running may result in internal engine damage.

After cleaning the machine, do 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 (Figure 26).

  

  Figure 26

  1. Tie-down loop (each side)
  2. Rear tie-down loop

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).

   

   Figure 27

   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 27).

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

• Check the air-cleaner body for damage which could cause an air leak; replace it if it is damaged. Check the whole intake system for leaks, damage, or loose hose clamps.

• Changing the air filter before it is necessary increases the chance of dirt entering the engine when the filter is removed.

• Ensure that the cover is seated correctly and seals with the air cleaner body.

1. Release the latches securing the air-cleaner cover to the air-cleaner body (Figure 28).

   

   Figure 28

   1. Air-cleaner body
   2. Air filter
   3. Air-cleaner cover

2. Remove the cover from the air-cleaner body.

3. Before removing the filter, use low pressure air (275 kPa (40 psi), clean and dry) to help remove large accumulations of debris packed between the outside of the primary filter and the canister. This cleaning process prevents debris getting 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. Remove and replace the primary filter, as follows:

   Important: Do not clean the used element.

   1. Inspect the new filter for shipping damage; do not use a damaged element.

   2. Carefully pull the old filter out of the filter body and discard it.

   3. 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.

      Important: Do not apply pressure to the flexible center of the filter.

5. Clean the dirt ejection port located in the removable cover. Remove the rubber outlet valve from the cover, clean the cavity and replace the outlet valve.

6. Install the cover orienting the rubber outlet valve in a downward position—between approximately 5 o’clock to 7 o’clock when viewed from the end.

7. Secure the latches (Figure 28).

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).

   

   Figure 33

   1. Fuel filter
   2. Drain plug

4. Tighten the plug after draining.

   Note: Because the accumulated water will be mixed with diesel fuel, drain the fuel filter into a suitable container and dispose of it properly.

1. Close the fuel-shutoff valve (Figure 34) below the fuel tank.

   

   Figure 34

   1. Fuel-shutoff valve

2. Clean the area where the filter canister mounts (Figure 35).

3. Place a drain pan under the fuel filter.

4. Open the filter drain plug (Figure 35).

   

   Figure 35

   1. Fuel filter/water separator canister
   2. Filter-drain plug

5. Unscrew the filter canister and dispose of it according to local regulations.

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.

Inspect the fuel lines for deterioration, damage, or loose connections.

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.

The battery cables must be tight on the terminals to provide good electrical contact.

1. Check the electrolyte level in the cells of the battery.

2. If needed, add distilled or demineralized water into the cell of the battery.

   Note: Only raise the electrolyte level to the bottom of the split ring inside each cell.

3. Clean the top of the battery by washing it periodically with a brush dipped in ammonia or bicarbonate of soda solution.

4. Flush the top surface of the battery with water after cleaning it.

   Important: Do not remove the fill caps while cleaning the battery.

If corrosion occurs at the terminals, disconnect the cables, negative (-) cable first, and scrape the clamps and terminals separately. Connect the cables, positive (+) cable first, and coat the terminals with petroleum jelly.

The fuses in the electrical system are located under the seat (Figure 36).

Figure 36

1. Start/run, Diagnostic lights, and glow—7.5 A
2. Reel engage, lift/lower, fan—7.5 A
3. Lift reel, E-reel enable, and over temp—7.5 A
4. No fuse
5. Lights and leak detector—15 A
6. Starter—15 A
7. Run—10 A
8. ECM logic and power—2 A

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).

Wheel nut torque specification: 95 to 122 N∙m (70 to 90 ft-lb)

Note: To ensure even distribution, torque the wheel nuts in a X pattern.

If the machine creeps when the traction-control pedal is in the NEUTRAL position, adjust the neutral-return mechanism.

1. Ensure that the bypass valve is closed.

2. Lift the machine and support it at the frame so that 1 of the front wheels is off the floor.

   Note: If the machine is equipped with a 3-Wheel Drive Kit, also raise and block the rear wheel.

3. Start the engine, move the throttle to the SLOW position, and ensure that the front wheel that is off the floor is not rotating.

4. If the wheel is rotating, shut off the engine and proceed as follows:

   1. Loosen the nut securing the eccentric to the top of the hydrostat (Figure 37).

      

      Figure 37

      1. Eccentric
      2. Locknut

   2. Move the functional-control lever to the NEUTRAL position and the throttle to the SLOW position. Start the engine.

   3. 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 37). Verify the adjustment with the throttle in the SLOW and FAST position.

      Note: If the wheel still turns when the eccentric is at the maximum adjustment, contact your authorized Toro distributor or refer to the Service Manual for further adjustment.

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.

   

   Figure 39

   1. Jam nut
   2. Nut
   3. Trunnion bolt

3. Rotate the trunnion bolt clockwise to reduce the mowing speed and counterclockwise to increase the mowing speed.

4. Tighten the jam nut on the trunnion bolt and the nut on the pedal pivot to lock the adjustment (Figure 39). Check the adjustment and adjust as required.

To prevent the system from overheating, keep the radiator screen and radiator clean. Check and clean the screen and radiator daily or, if necessary, hourly. Clean these components more frequently in dusty, dirty conditions.

1. Remove the radiator screen (Figure 40).

   

   Figure 40

   1. Wing bolts
   2. Radiator screen
   3. Reserve tank
   4. Radiator cap

2. Working from the fan side of the radiator, blow out the radiator with compressed air.

3. Clean the screen and install it.

The capacity of the cooling system is approximately 4.6 L (4.9 US qt).

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.

1. Park the machine on a level surface.

2. Check the coolant level (Figure 40 and Figure 41).

   It should be between the lines on the reserve tank when the engine is cold.

   

   Figure 41

   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.

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.

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 Dealer or refer to the Service Manual for more information.

Note: Burnish the brakes annually; refer to Burnishing the Brakes.

Ensure that the belt is properly tensioned to ensure proper operation of the machine and prevent unnecessary wear.

1. 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.

2. Apply moderate thumb pressure to the belt between the pulleys (10 kg or 22 lb). The belt should deflect 7 to 9 mm (0.28 to 0.35 inch). If not, complete the following procedure to adjust the belt tension:

   

   Figure 42

   1. Alternator belt—apply pressure here
   2. Alternator
   3. Adjusting strap

   1. Loosen the bolts securing the alternator to the engine and adjusting strap.

   2. Inspect the belt for wear or damage and replace if it is worn.

   3. Using a lever placed between the alternator and the engine block, pull the alternator out to obtain the correct belt tension and tighten the bolts.

Important: Regardless of the hydraulic fluid type used, any machine used for mowing fairways, verticutting, or used during ambient temperatures above 29°C (85°F) should have the Oil Cooler Kit (Part No. 117-9314) installed.

Checking the Hydraulic-Fluid Level

Maintenance Service Interval	Maintenance Procedure
Before each use or daily	Check the hydraulic-fluid level.

The hydraulic-fluid reservoir is filled at the factory with high quality hydraulic fluid. Before operating the machine each day, check the level of the hydraulic fluid. Your machine has a dipstick or a white plastic window on the front of the hydraulic-fluid reservoir (behind the seat on the left side of the machine) that is used to check the hydraulic-fluid level. The fluid should be between the window lines or the dipstick marks; if not, add more appropriate fluid.

Refer to Figure 43 for this procedure.

Figure 43

1. Hydraulic-tank cap or dipstick location

1. Position the machine on a level surface.

   Note: Ensure that the machine has cooled down so that the fluid is cold.

2. Check the fluid level according to the tank on your machine:

   • If your tank has a sight window, check the oil level there and proceed to step 5.

   • If your tank does not have a sight window, locate the dipstick on the top of the hydraulic tank and proceed to step 3.

3. Remove the dipstick and wipe it with a clean rag, then screw the dipstick back into the tank.

4. Remove the dipstick and check the fluid level. If the fluid is between the marks on the dipstick, the level is sufficient. If the level is not between the marks, more fluid is needed.

5. Remove the cap or dipstick (depending on your machine) from the hydraulic fluid tank and slowly fill the tank with the appropriate high-quality hydraulic fluid until the level is between the 2 lines on the sight window or 2 marks on the dipstick.

6. Install the cap or dipstick and wipe up any fluid that may have spilled.

   Important: Check the level of the hydraulic fluid before the engine is first started and daily thereafter.

Check the hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration. Make all necessary repairs before operating.

Note: When sharpening, setting the height of cut, or performing other maintenance procedures on the cutting units, store the cutting unit reel motors in the storage location on the front of the suspension arms to prevent damage to them.

Important: Do not raise the suspension to the transport position when the reel motors are in the holders in the machine frame. Damage to the motors or hoses could result.

Important: Whenever you need to tip the cutting unit, prop up the rear of the cutting unit to ensure that the nuts on the bedbar adjusting screws are not resting on the work surface (Figure 45).

Figure 45

1. Prop (not provided)
2. Bedbar-adjusting-screw nut (2)

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.

1. Park the machine on a level surface, lower the cutting units, shut off the engine, remove the key, and engage the parking brake.

2. Remove the plastic cover to the left side of the seat.

3. Make initial reel to bedknife adjustments appropriate for backlapping on all cutting units which are to be backlapped; refer to the Cutting Unit Operator’s Manual.

   Danger

   Changing the engine speed while backlapping may cause the reels to stall.

   • Never change the engine speed while backlapping.

   • Backlap only at idle engine speed.

4. Start the engine and run at low idle speed.

5. Rotate the backlap lever to the REVERSE (R) position (Figure 52).

   

   Figure 52

   1. Backlap lever—FORWARD position
   2. Backlap lever—REVERSE position

6. Rotate the reel-speed control to setting 1 (Figure 53).

   

   Figure 53

   1. Reel-speed control

7. With the functional-control lever in the NEUTRAL position, move the raise/lower mow control forward to start the backlapping operation on the designated reels.

8. Apply lapping compound with a long-handled brush. Never use a short-handled brush.

9. If the reels stall or become erratic while backlapping, select a higher reel speed setting until the speed stabilizes, then return the reel speed to setting 1 or to your desired speed.

10. To make an adjustment to the cutting units while backlapping, turn the reels off by moving the raise/lower mow control rearward and shut off the engine. After completing adjustments, repeat steps 4 through 8.

11. Repeat the procedure for all cutting units you want to backlap.

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.

To achieve a consistent, high-quality cut and a uniform after-cut appearance, you must correctly set the reel speed control (located on the manifold block under the cover to the left of the seat). Adjust the reel speed control as follows:

1. Select the height of cut at which the cutting units are set.

2. Choose the desired ground speed best suites conditions.

3. Use the table that follows to determine the reel-speed setting for your 5-, 8-, 11-, or 14-blade cutting units; refer to Reel Speed Table.

4. Adjust the reel speed by rotating the knob (Figure 53) until the indicator arrows are in line with the number you determined in step 3.

   Note: You can increase or decrease the reel speed to compensate for turf conditions.

Reel Speed Table

The service indicator light illuminates in the event of a fault in the machine. When this light is on, you can access the computer codes to diagnose the problem by entering diagnostic mode. In diagnostic mode, the service indicator light flashes a number of times, giving you the error code that you or your authorized Toro distributor can use to identify the problem.

Note: You cannot start the engine in diagnostic mode.