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Related Manuals for Toro 04540
Summary of Contents for Toro 04540
- Page 1 Form No. 3370-454 Rev B Greensmaster ® 3420 TriFlex™ Traction Unit Model No. 04540—Serial No. 311000001 and Up g014597 To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com. Original Instructions (EN)
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Page 2: Introduction
You are responsible for operating the product properly and safely. This manual also uses 2 words to highlight information. You may contact Toro directly at www.Toro.com for Important calls attention to special mechanical product and accessory information, help finding a dealer, information and Note emphasizes general information or to register your product. -
Page 3: Table Of Contents
Fuel Filter/Water Separator ........ 41 Safety ................4 Fuel Lines and Connections........ 41 Safe Operating Practices ........4 Electrical System Maintenance........ 42 Toro Mower Safety ..........6 Servicing the Battery........... 42 Sound Power Level..........7 Storing the Battery..........42 Sound Pressure Level ........... 7 Fuses.............. -
Page 4: Safety
Safety ◊ the type of machine is unsuitable for the task; ◊ lack of awareness of the effect of ground This machine meets or exceeds CEN standard conditions, especially slopes. EN 836:1997, ISO standard 5395:1990, and ANSI ◊ The owner/user can prevent and is B71.4-2004 specifications in effect at the time of responsible for accidents or injuries occurring production when 119 lb (54 kg) of weight is added... - Page 5 • Remember there is no such thing as a safe slope. • Reduce the throttle setting before stopping the Travel on grass slopes requires particular care. To engine and, if the engine is provided with a fuel guard against overturning: shut-off valve, turn the fuel off at the conclusion of mowing.
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Page 6: Toro Mower Safety
The following list contains safety information specific to and wait for the reels to stop spinning. Set the Toro products or other safety information that you must parking brake. Stop the engine and remove the key know that is not included in the ANSI standards. -
Page 7: Sound Power Level
Keep everyone away. • To ensure safety and accuracy, have an Authorized Toro Distributor check the maximum engine speed with a tachometer. Maximum governed engine speed should be 2900 RPM. • The engine must be shut off before checking the oil or adding oil to the crankcase. -
Page 8: Safety And Instructional Decals
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. 115-8155 1. Warning—read the Operator's Manual, do not prime or use starting fluid. - Page 9 117–2718 115-8201 1. Read the Operator's manual for fuse information. 117–9536 1. Warning—wear hearing protection. 2. Warning—read the Operator's Manual, do not operate this machine unless you are trained. 3. Cutting/dismemberment hazard of hand or foot, mower blade—stay away from moving parts; keep all guards and shields in place.
- Page 10 117–9537 Replaces 117–9536 for CE. * This safety decal includes a slope warning required on the machine for compliance to the European Lawn Mower Safety Standard EN836:1997. The conservative maximum slope angles indication for operation of this machine are prescribed by and required by this standard.
- Page 11 119-1657 1. Throttle—fast 4. Lower the reels and engage. 7. Use for transport 2. Throttle—continuous variable setting 5. Raise the reels 8. Use for mowing 3. Throttle—slow 6. Functional control lever 9. Neutral—Use for backlapping reels 119-1688 1. Choke (gasoline models 3.
- Page 12 119-9343 Battery Symbols 119-9346 Some or all of these symbols are on your battery. 1. Press pedal to unlock 2. Read the Operator's 1. Explosion hazard 6. Keep bystanders a safe Manual for more distance from the battery. information. 2. No fire, open flames, or 7.
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Page 13: Setup
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description Qty. Roll bar Bolt (1/2 x 3-3/4 inches) Install the roll bar. Flange-nut (1/2 inch) Seat completion kit Install the seat to the base. Steering wheel Locknut (1-1/2 inches) Install the steering wheel. -
Page 14: Installing The Roll Bar
Installing the Roll Bar Installing the Seat Parts needed for this procedure: Parts needed for this procedure: Roll bar Seat completion kit Bolt (1/2 x 3-3/4 inches) Procedure Flange-nut (1/2 inch) Acquire your desired seat kit from your distributor and Procedure install it as directed in the instruction included with the kit. -
Page 15: Activating And Charging The Battery
3. Secure the steering wheel to the shaft with a jam nut and tighten it to 20 to 26 ft-lb (27 to 35 N-m) (Figure 4). 4. Install the cap to the steering wheel and secure it with a screw (Figure 4). Activating and Charging the Battery Figure 6... -
Page 16: Installing The Grass Basket Hooks
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. -
Page 17: Installing The Cutting Units
Procedure Obtain a roller (Model No. 04625, 04626 or 04627) Note: When sharpening, setting the height-of-cut, from your local Toro Distributor. Install the roller or performing other maintenance procedures on the using the loose parts supplied with the cutting unit cutting units, store the cutting unit reel motors in the and installation instructions included with the roller. - Page 18 7. If installing the center cutting unit, lift up on the foot rest and swing it up, allowing access to the center cutting unit position (Figure 11). CAUTION The foot rest can pinch fingers if it falls into the closed position. Keep your fingers clear of the area where the foot rest seats while it is open.
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Page 19: Adding Rear Weight
Installing EU Decals Parts needed for this procedure: Warning decal 117-9537 Procedure If this machine will be used in the EU, affix the warning decal 117-9537 over warning decal 117-9536. Figure 14 1. Reel motor 3. Cavity 4. Motor retaining bar 2. -
Page 20: Product Overview
Product Overview g014603 Figure 16 1. Traction pedal—forward 3. Steering arm locking pedal 2. Taction pedal—reverse g014674 Figure 15 1. Engine 5. Steering wheel 2. Roll bar 6. Traction pedal 3. Control panel 7. Foot rest 4. Seat 8. Reels with grass baskets Controls Figure 17 Traction Pedal... - Page 21 Battery Warning Light Note: The engine cannot be stopped by the use of the throttle control. The light (Figure 18) glows if the battery charge is low. Engine Oil Pressure Light The light (Figure 18) glows if the engine oil pressure drops below a safe level.
- Page 22 Figure 21 1. Backlap switch—backlap 2. Backlap switch—mow position position Reel Speed Control The reel speed control is located under the plastic g014600 cover to the left of the seat. Use the reel speed control Figure 19 (Figure 22) to adjust the RPM of the reels. 1.
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Page 23: Specifications
Cutting Unit Power Disconnect Couplers Before installing, removing, or working on the cutting units, disconnect the cutting units from the power supply by separating the cutting unit power disconnect couplers (Figure 25), located as the base of the rollover bar on the left side of the traction unit. -
Page 24: Attachments/Accessories
Contact your Authorized Service Dealer or Distributor or go to Think Safety First www.Toro.com for a list of all approved attachments and accessories. Please carefully read all of the safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury. -
Page 25: Filling The Fuel Tank
2. Remove the dipstick and wipe it with a clean rag (Figure 27). Push the dipstick into the tube and make sure it is seated fully. Remove the dipstick from the tube and check the level of oil. If the oil level is low, remove the filler cap from the valve cover and slowly add enough oil to raise the level to the Full mark on the dipstick. - Page 26 DANGER DANGER Under certain conditions, diesel fuel and fuel In certain conditions, fuel is extremely flammable vapors are highly flammable and explosive. A fire and highly explosive. A fire or explosion from fuel or explosion from fuel can burn you and others and can burn you and others and can damage property.
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Page 27: Checking The Cooling System
The cooling system is filled 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. CAUTION If the engine has been running, the pressurized, hot coolant can escape and cause burns. - Page 28 Important: Regardless of hydraulic fluid type Toro Premium All Season Hydraulic Fluid (Available in 5 used, any machine used for mowing fairways, gallon pails or 55 gallon drums. See parts catalog or Toro verticutting or used during ambient temperatures distributor for part numbers.) above 85°F (29°C) should have Oil Cooler Kit, Part...
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Page 29: Draining Water From The Fuel Filter
Checking the Torque of the before puncturing. Ensure the pour spout and funnel are clean. Wheel Nuts 4. Install the reservoir cap. Wipe up any fluid that may have spilled. WARNING Important: Check level of hydraulic fluid Failure to maintain proper torque of the wheel nuts before engine is first started and daily thereafter. -
Page 30: Starting And Stopping The Machine
as indicated by their smell. An adjustment to the brakes 2. Rotate the starter key to Off to shut the engine may be required after break-in; refer to Adjusting the off. Remove the key from the switch to prevent Brakes. accidental starting. -
Page 31: Installing And Removing The Cutting Units
Installing and Removing the control lever to mow or transport and try to start the engine. The engine should not crank, which means Cutting Units that the interlock system is operating correctly. Correct the problem if it is not operating properly. Installing the Cutting Units 3. - Page 32 g014609 Figure 35 1. Latch—closed position 3. Latch—open position 2. Suspension-arm bar Figure 37 1. Reel motor 3. Cavity 4. Motor retaining bar 2. Spline shaft 8. Mount a grass basket onto the basket hooks on the suspension arm. 9. Repeat this procedure for the other cutting units. 10.
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Page 33: Setting The Reel Speed
6. Disconnect the latches from the cutting-unit bar. 7. Roll the cutting unit out from under the suspension arm. 8. Repeat steps 3 through 7 for the other cutting units as required. 9. Connect the cutting unit power disconnect couplers; refer to Cutting Unit Power Disconnect Couplers (page 23). -
Page 34: Preparing The Machine For Mowing
Figure 41 1. Reel speed control Figure 42 1. Alignment strip 3. Cut grass on right Note: You can increase or decrease the reel speed 2. Approximately 5 inches 4. Keep focal spot 6-10 ft (12.7 cm) (1.8-3 m) ahead of the to compensate for turf conditions. -
Page 35: Transport Operation
Important: Familiarize yourself with the fact getting the machine more quickly aligned for the that the No. 1 cutting unit reel is delayed and next pass. Follow the same procedure for turning in therefore, you should practice to try to gain the opposite direction. -
Page 36: Towing The Machine
In case of an emergency the machine can be towed for a short distance (less than 1/4 mile (0.4 km)). However, Toro does not recommend this as standard procedure. Important: Do not tow the machine faster than 2-3 MPH (3-5 km/h) because the drive system may be damaged. -
Page 37: Maintenance
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. CAUTION If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition. Recommended Maintenance Schedule(s) Maintenance Service Maintenance Procedure... -
Page 38: Daily Maintenance Checklist
Daily Maintenance Checklist Duplicate this page for routine use. Maintenance Check Item For the week of: Mon. Tues. Wed. Thurs. Fri. Sat. Sun. Check the safety interlock operation. Check the instrument operation Check the brake operation. Check the fuel filter/water separator. -
Page 39: Lubrication
Lubrication Engine Maintenance Servicing the Air Cleaner Greasing the Generator Belt Tensioner Service Interval: Every 200 hours • Check the air cleaner body for damage which could Service Interval: Every 400 hours cause an air leak. Replace if damaged. Check the whole intake system for leaks, damage or loose hose Lubricate the grease fitting regularly with No. -
Page 40: Changing The Engine Oil And Filter
new filter for shipping damage, checking the sealing end of the filter and the body. Do not use a damaged element. Insert the new filter by applying pressure to the outer rim of the element to seat it in the canister. Do not apply pressure to the flexible center of the filter. -
Page 41: Fuel System Maintenance
Fuel System Maintenance Fuel Filter/Water Separator Service Interval: Every 800 hours Servicing the Filter 1. Close the fuel shut off valve (Figure 49) below the fuel tank. g014720 Figure 50 1. Fuel filter /water separator 2. Filter drain plug canister 5. -
Page 42: Electrical System Maintenance
Electrical System WARNING Maintenance Battery terminals or metal tools could short against metal tractor components causing sparks. Sparks can cause the battery gasses to explode, resulting Servicing the Battery in personal injury. • When removing or installing the battery, do not allow the battery terminals to touch any metal WARNING parts of the tractor. -
Page 43: Jump Starting The Machine
Figure 52 1. Alternate positive battery post g014617 Figure 51 1. Fuses 2. 50 A fuse for radiator fan (behind parts illustrated) Fuse Layout Lift Reel E-Reel Enable Over Temp 7.5 A Reel Engage Lights Lift/Lower Leak Detector 15 A 7.5 A Start/Run Starter... -
Page 44: Drive System Maintenance
Adjusting the Transport Speed Drive System Maintenance The traction pedal is adjusted for maximum transport speed at the factory, but an adjustment may be required if the pedal reaches full stroke before it contacts the Adjusting the Transmission pedal stop, or if a decrease in transport speed is desired. for Neutral Press down on the traction pedal. -
Page 45: Cooling System Maintenance
Cooling System Maintenance Cleaning the Radiator Screen To prevent the system from overheating, the radiator screen and radiator must be kept clean. Check and clean the screen and radiator daily or, if necessary, hourly. Clean these components more frequently in dusty, dirty conditions. -
Page 46: Brake Maintenance
Brake Maintenance Belt Maintenance Adjusting the Brakes Adjusting the Alternator Belt If the brake fails to hold the machine while parked, you Service Interval: After the first 8 hours can adjust the brakes using the bulkhead fitting near the Make sure the belt is properly tensioned to ensure proper brake drum;... -
Page 47: Hydraulic System Maintenance
Hydraulic fluid escaping under pressure can If the oil becomes contaminated, contact your local penetrate skin and cause injury. Toro distributor because the system must be flushed. • Make sure all hydraulic fluid hoses and lines are Contaminated oil looks milky or black when compared in good condition and all hydraulic connections to clean oil. -
Page 48: Cutting Unit Maintenance
Cutting Unit Maintenance Backlapping the Reels WARNING Contact with the reels or other moving parts can result in personal injury. • Keep fingers, hands, and clothing away from the reels or other moving parts. • Never attempt to turn the reels by hand or foot while the engine is running. -
Page 49: Diagnostics System
Diagnostics System – If the code is 123, the blink pattern will be ############_### • If there are more than one fault, the tens place of Diagnosing the Service the next fault will begin after a pause after the ones Indicator Light place of the first fault. -
Page 50: Storage
Storage If you wish to store the machine for a long period of time, the following steps should be performed prior to storage: 1. Remove accumulations of dirt and old grass clippings. Sharpen the reels and bedknives, if necessary; refer to the Cutting Unit Operator's Manual. -
Page 51: Schematics
Schematics g015568 Hydraulic Schematic (Rev. A) - Page 52 G015569 Electrical Schematic (Rev. A)
- Page 53 Electric Reel Schematic (Rev. A)
- Page 54 Notes:...
- Page 55 Notes:...
- Page 56 Countries Other than the United States or Canada Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor (Dealer) to obtain guarantee policies for your country, province, or state. If for any reason you are dissatisfied with your Distributor's service or have difficulty obtaining guarantee information, contact the Toro importer.