Form No. 3387-277 Rev D Reelmaster® 5410-D and 5510–D Traction Units Model No. Model No. Model No. Model No. Register at www.Toro.com. Original Instructions (EN) 03606—Serial No. 315000001 and Up 03606A—Serial No. 315000001 and Up 03607—Serial No. 315000001 and Up 03607A—Serial No.
This product complies with all relevant European directives; for details, please see the separate product specific Declaration of Conformity (DOC) sheet. Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready. The model and serial numbers are on a plate mounted on the left side of the frame under the foot rest. Write the numbers in the space provided.
Contents Servicing the Engine-Fuel Filter ........................ 52 Checking the Fuel Lines and Connections.................................................. 52 Fuel Pick-up Tube Screen................................. 52 Electrical System Maintenance ........................... 53 Servicing the Battery......................................... 53 Fuses................................................................ 53 Drive System Maintenance ..................................
Preparation Safety • While mowing, always wear substantial, Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means Caution, Warning, or Danger—personal safety instruction. Failure to comply with the instruction may result in personal injury or death.
• Before attempting to start the engine, disengage • • • • • • • • • • – after striking a foreign object or if an abnormal vibration occurs. Inspect the mower for damage and make repairs before restarting and operating the equipment all blade attachment clutches, shift into neutral, and engage the parking brake. Remember, there is no such thing as a safe slope. Travel on grass slopes requires particular care. To guard against overturning: – Do not stop or start suddenly when going up or downhill.
• Wearing substantial, slip-resistant footwear and • Clean grass and debris from cutting units, drives, • • • • • • silencers/mufflers, and engine to help prevent fires. Clean up oil or fuel spills. Use jack stands to support components when required. Carefully release pressure from components with stored energy. Disconnect battery before making any repairs. Disconnect the negative terminal first and the positive last. Connect positive first and negative last. Use care when checking the cylinders/reels.
Sound pressure level was determined according to the procedures outlined in EN ISO 5395:2013. lowering the cutting units and attachments to the ground. • Check all fuel lines for tightness and wear on a regular basis. Tighten or repair them as needed. Vibration Level • If the engine must be running to perform a maintenance adjustment, keep hands, feet, clothing, and any parts of the body away from the cutting units, attachments, and any moving parts. Keep everyone away.
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. decal93-7272 93-7272 1. Cutting/dismemberment hazard, fan—stay away from moving parts. decal106-6755 106-6755 1. Engine coolant under pressure. 3. Warning—do not touch the hot surface. 2. Explosion hazard—read the Operator's Manual. 4. Warning—read the Operator's Manual. decal93-6696 93–6696 1.
r:\decal110-8869 110-8869 1. Warning—read the Operator's Manual, do not operate this machine unless you are trained. 2. Thrown object hazard—keep bystanders a safe distance from the machine. 3. Tipping hazard—slow machine before turning, do not turn at high speeds; lower the cutting unit when driving down slopes; use a rollover-protection system and wear the seat belt. Always wear a seat belt when a ROPS is in place. r:\decal117-0169 4.
decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. Keep bystanders a safe distance from the battery. 2. No fire, open flame, or smoking. 7. Wear eye protection; explosive gases can cause blindness and other injuries 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 5. Read the Operator's Manual. 10.
decal125-2927 125–2927 1. Read the Operator’s Manual for maintenance information.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description 1 2 3 4 5 6 Use Qty. No parts required – Adjust the tire pressure. No parts required – Adjust the step height. No parts required – Adjust the control-arm position. Right front hose guide Left front hose guide 1 1 Install the cutting units. No parts required – Adjust the turf-compensation spring. Cutting-unit kickstand 1 Install the cutting-unit kickstand.
1 2. Raise or lower the step to the desired height and secure the brackets to the frame with the 2 bolts and nuts. 3. Repeat the procedure on the other step. Adjusting the Tire Pressure 3 No Parts Required Adjusting the Control-Arm Position Procedure The tires are over-inflated for shipping. Therefore, release some of the air to reduce the pressure. Correct air pressure in the front and rear tires is 83 to 103 kPa (12 to 15 psi).
A. 4 Remove the 2 carriage bolts and nuts securing the rod bracket to the cutting-unit tabs (Figure 5). Installing the Cutting Units Parts needed for this procedure: 1 Right front hose guide 1 Left front hose guide g003949 Figure 5 1. Turf-compensation spring Procedure 1. 3. Spring tube 2. Rod bracket Remove the reel motors from the shipping brackets. B. Remove the flange nut securing the spring-tube bolt to the carrier-frame tab (Figure 5). Remove the assembly. C.
Note: When installing or removing the cutting units, make sure that the hairpin cotter is installed in the spring-rod hole next to the rod bracket. When not installing or removing the cutting units, the hairpin cotter must be installed in the hole in the end of the rod. g030896 Figure 7 1. Cutting unit 1 5. Cutting unit 5 2. Cutting unit 2 6. Reel motor 3. Cutting unit 3 7. Weight g015160 Figure 8 4. Cutting unit 4 1. Hose guide (cutting unit 4 shown) 3. Nut 2. Rod bracket g019284 Figure 9 1.
6. Lower all lift arms completely. 7. Remove the snapper pin and the cap from the lift-arm-pivot yoke (Figure 10). g003979 Figure 12 1. Lynch pin and washer g003975 Figure 10 1. Snapper pin 8. 2. Cap For the front cutting units, slide a cutting unit under the lift arm while inserting the carrier-frame shaft up into the lift-arm-pivot yoke (Figure 11). B. Insert the lift-arm yoke onto the carrier-frame shaft (Figure 11). C.
Note: Rotate the motor counterclockwise until the flanges encircle the bolts and then tighten the bolts. 5 Important: Make sure that the reel-motor Adjusting the Turf-Compensation Spring hoses are not twisted, kinked or in the risk of being pinched. No Parts Required Procedure The turf-compensation spring transfers weight from the front to the rear roller (Figure 15). This helps to reduce a wave pattern in the turf, also known as marcelling or bobbing.
6 Using the Cutting-Unit Kickstand Parts needed for this procedure: 1 Cutting-unit kickstand Procedure Whenever you need to tip the cutting unit to expose the bedknife/reel, prop up the rear of the cutting unit with the kickstand to make sure that the nuts on the back end of the bedbar-adjusting screws are not resting on the work surface (Figure 16). g004144 Figure 17 1. Chain bracket 2. Snapper pin g003985 Figure 16 1.
Traction Pedal Product Overview The traction pedal controls the forward and reverse operation (Figure 20). Press the top of the pedal to move forward and the bottom to move rearward. Ground speed depends on how far you press the pedal. For no load, maximum ground speed, set the engine speed to the FASTposition and fully press the pedal. To stop, reduce foot pressure on the traction pedal and allow it to return to the center position. g003945 Figure 18 1. Engine hood 5. Seat 2. Operator's seat 6.
Tilt-Steering Pedal Lower Mow/Raise Control Lever To tilt the steering wheel toward you, press the foot pedal down, pull the steering tower toward you to the most comfortable position, and release the pedal (Figure 20). This lever raises and lowers the cutting units and also starts and stops the cutting units when the cutting units are enabled in the MOW mode (Figure 21). You cannot lower the cutting units when the mow/transport lever is in the transport position.
Using the InfoCenter LCD Display The InfoCenter LCD display shows information about your machine, such as the operating status, various diagnostics, and other information about the machine (Figure 25). There is a splash screen and main information screen of the InfoCenter. You can switch between the splash screen and main information screen, at any time, by pressing any of the InfoCenter buttons and then selecting the appropriate directional arrow. g004132 Figure 23 1.
InfoCenter Icon Description SERVICE DUE InfoCenter Icon Description (cont'd.
Using the Menus To access the InfoCenter menu system, press the menu access button while at the main screen. This will bring you to the main menu. Refer to the following tables for a synopsis of the options available from the menus: Menu Item Description Faults Contains a list of the recent machine faults. Refer to the Service Manual or your Authorized Toro Distributor for more information on the Faults menu and the information contained there.
Machine-Controller Revision Lists the software revision of the master controller. InfoCenter Revision Lists the software revision of the InfoCenter. CAN Bus Lists the machine communication bus status. Protected Menus There are 8 operating configuration settings that are adjustable within the Settings Menu of the InfoCenter: auto idle time delay, Blade Count, Mow Speed, Height of Cut (HOC), F Reel RPM and R Reel RPM. These settings can be locked by using the Protected Menu.
To Set the Auto Idle To Set the Height of Cut (HOC) • In the Settings Menu, scroll down to Auto Idle. • In the Settings Menu, scroll down to HOC. • Press the right button to select HOC. • Use the center and right button to select the • Press the right button to change the auto idle time between OFF, 8S, 10S, 15S, 20S, and 30S. appropriate HOC setting. (If the exact setting is not displayed, select the nearest HOC setting from the list displayed).
Operation Note: Determine the left and right sides of the machine from the normal operating position. CAUTION g009027 Figure 28 If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. 1. Wear safety glasses. 2. Wear hearing protection. Lower the cutting units to the ground, set the parking brake, and remove the key from the ignition switch before servicing or making adjustments to the machine.
Petroleum Diesel DANGER Cetane rating: 45 or higher In certain conditions during fueling, static electricity can be released, causing a spark that can ignite the fuel vapors. A fire or explosion from fuel can burn you and others and can damage property. • Always place fuel containers on the ground away from your vehicle before filling.
Fuel Tank Capacity Checking the Cooling System 53 L (14 US gallons) Clean debris off the screen, oil cooler, and front of the radiator daily and more often if conditions are extremely dusty and dirty. Refer to Removing Debris from the Cooling System (page 55). Adding Fuel 1. Park the machine on a level surface. 2. Using a clean rag, clean area around fuel-tank cap. 3. The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol antifreeze.
Checking the Hydraulic Fluid Important: Many hydraulic fluids are almost colorless, making it difficult to spot leaks. A red dye additive for the hydraulic system oil is available in 20 ml (2/3 oz) bottles. 1 bottle is sufficient for 15 to 22 L (4 to 6 gallons) of hydraulic oil. Order Part Number 44-2500 from your Toro Distributor. This red dye is not recommended for use with biodegradable fluids. Use food coloring.
Checking the Reel-to-Bedknife Contact parking brake, set the engine-speed switch to the MIDDLE position and ensure that the Enable/Disable switch is in the DISABLE position. Each day before operating, check 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 the bedknife (refer to Adjusting the Reel to Bedknife in the Operator's Manual for the cutting units). 2.
Cutting Grass with the Machine Diesel Particulate Filter Regeneration Note: Cutting grass at a rate that loads the engine The diesel particulate filter (DPF) is part of the exhaust system. The diesel-oxidation catalyst of the DPF reduces harmful gasses and the soot filter removes soot from the engine exhaust. promotes DPF regeneration. 1. Move the machine to the job site and align the machine outside the cutting area for the first cutting pass. 2.
DPF Soot Accumulation • DPF regeneration is a process that heats the DPF to convert the soot to ash. • Over time, the DPF accumulates soot in the soot • In addition to the warning messages, the computer filter. The computer for the engine monitors the soot level in the DPF. reduces the power produced by the engine at different soot-accumulation levels. • When enough soot accumulates, the computer informs you that it is time to regenerate the diesel particulate filter.
DPF Ash Accumulation • When enough ash accumulates, the engine • The lighter ash is discharged through the exhaust system; the heavier ash collects in the soot filter. • Ash is a residue of the regeneration process. Over • time, the diesel particulate filter accumulates ash that does not discharge with the engine exhaust. • • The computer for the engine calculates the amount of ash accumulated in the DPF.
Types of Diesel Particulate Filter Regeneration Types of diesel particulate filter regeneration that are performed while the machine is operating: Type of Regeneration Conditions for DPF regeneration DPF description of operation Passive Occurs during normal operation of the machine at high-engine speed or high-engine load The InfoCenter does not display an icon indicating passive regeneration.
Types of diesel particulate filter regeneration that require you to park the machine: (cont'd.) Type of Regeneration Conditions for DPF regeneration DPF description of operation Recovery Occurs as a result of ignoring parked regeneration requests and continuing operation, adding more soot when the DPF is already in need of a parked regeneration When the recovery-regeneration icon is displayed in the InfoCenter, a recovery regeneration is requested.
Parked Regeneration Reset Regeneration g214713 g214711 Figure 39 Assist/reset-regeneration icon Figure 40 Parked-regeneration request icon • The assist/reset-regeneration icon displays in the • The parked-regeneration requested icon displays in the InfoCenter (Figure 40). If a parked regeneration is needed, the InfoCenter displays engine warning SPN 3719, FMI 16 (Figure 41) and the engine computer derates engine power to 85%. InfoCenter (Figure 39).
6. Engage the parking brake. 7. Set the throttle to the low IDLE position. Performing a Parked Regeneration Note: For instructions on unlocking protected menus, refer to Accessing Protected Menus (page 24). 1. Access the protected menu and unlock the protected settings submenu (Figure 42); refer to Accessing Protected Menus (page 24). g212138 Figure 44 4. When the “Initiate DPF Regen. Are you sure?” message displays, press the center button (Figure 45). g028523 Figure 42 2.
g211986 g212405 Figure 46 6. Figure 48 Move the throttle control to LOW IDLE and press the center button (Figure 47). B. The “Waiting on (Figure 49). ” message displays g212372 g212406 Figure 47 7. Figure 49 The following messages display as the parked regeneration process begins: A. C. The “Initiating DPF Regen.” message displays (Figure 48). The computer determines whether the regeneration runs.
The engine is cold—wait. The engine is warm—wait. The engine hot—regeneration in progress (percent complete). 9. g213424 The parked regeneration is complete when the “Regen Complete” message displays in the InfoCenter. Press the left button to exit to the home screen (Figure 52). Figure 50 • If the regeneration process is not allowed by the engine computer, the “DPF Regen Not Allowed” message displays in the InfoCenter (Figure 51).
Adjusting the Lift-Arm Turnaround Position • Perform a recovery-regeneration whenever there is a loss of engine power and a parked regeneration cannot effectively clean the DPF of soot. 1. • A recovery regeneration requires up to 4 hours to complete. • You need a distributor technician to perform the 2. recovery regeneration process; contact your Authorized Toro Distributor. 3.
Tie Downs • Front—the hole in the rectangular pad, under the axle tube, inside each front tire (Figure 58). g003995 Figure 56 1. Bypass-valve bolt 2. Close the bypass valve before starting the engine. However, do not exceed 7 to 11 N-m (5 to 8 ft-lb) torque to close the valve. g004558 Important: Running the engine with Figure 58 the bypass valve open will cause the transmission to overheat. 1. Front tie down • Rear—each side of the machine on the rear frame Jacking Points (Figure 59).
Understanding the Diagnostic Light Verifying the Interlock-Switch Function The machine is equipped with a diagnostic light, which indicates if the machine detects a malfunction. The diagnostic light is located on the InfoCenter, above the display screen (Figure 60). When the machine is functioning properly and the key switch is moved to the ON/RUN position, the diagnostic light turns on briefly to indicate the light is working properly.
Hydraulic-Valve Solenoid Functions avoid sharp turns on slopes to prevent roll overs. Lower the cutting units when going downhill for steering control. Use the list below to identify and describe the different functions of the solenoids in the hydraulic manifold. Each solenoid must be energized to allow function to occur.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first hour • Torque the wheel lug nuts to 94 to 122 N-m (70 to 90 ft-lb). After the first 10 hours • Torque the wheel lug nuts to 94 to 122 N-m (70 to 90 ft-lb). • Check the alternator-belt tension. Before each use or daily • • • • • • Check the cooling system. Check the hydraulic-fluid level.
Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Mon. Maintenance Check Item Tues. Wed. Thurs. Fri. Sat. Sun. Check the safety-interlock operation. Check the brake operation. Check the engine oil and fuel level. Drain the water/fuel separator. Check the air-filter-restriction indicator. Check the radiator and screen for debris. Check unusual engine noises.1 Check unusual operating noises. Check the hydraulic-system-oil level. Check the hydraulic-filter indicator.
Service Interval Chart decal125-2927 Figure 61 CAUTION If you leave the key in the switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the switch before you do any maintenance. Lubrication Greasing the Bearings and Bushings If you operate the machine under normal conditions, lubricate all grease fittings for the bearings and bushings after every 50 hours of operation with No. 2 lithium grease.
• Cutting-unit lift-arm cylinders (2 each) (Figure 63) g012150 Figure 63 • Lift-arm pivots (1 each) (Figure 63) • Cutting-unit carrier-frame and pivot (2 each) (Figure 64) g003987 Figure 66 • Axle-steering pivot (1) (Figure 67) g003960 Figure 64 g004169 • Lift-arm-pivot shaft (1 each) (Figure 65) Figure 67 • Steering-cylinder ball joints (2) (Figure 68) g004157 Figure 65 • Rear axle tie rod (2) (Figure 66) g003966 Figure 68 • Brake pedal (1) (Figure 69) 47
Engine Maintenance Servicing the Air Cleaner Check the air-cleaner body for damage which could cause an air leak. Replace if damaged. Check the whole intake system for leaks, damage or loose hose clamps. g011615 Figure 69 Service the air-cleaner filter only when the service indicator requires it (Figure 70). Changing the air filter before it is necessary only increases the chance of dirt entering the engine when the filter is removed.
3. Before removing the filter, use low-pressure air (40 psi, clean and dry) to help remove large accumulations of debris packed between outside of the filter and the canister. Servicing the Engine Oil Important: Avoid using high-pressure air, which could force dirt through the filter into the intake tract.
Crankcase Oil Capacity 5.2 L (5.5 US qt) with the filter Changing the Engine Oil and Filter Service Interval: Every 250 hours—Change the engine oil and filter. 1. Remove the drain plug and let the oil flow into a drain pan (Figure 73). g021901 Figure 72 1. Dipstick 4. 2. Oil-fill cap If the oil level is low, remove the fill cap and add oil until it is between the FULL and ADD marks (Figure 72). Note: Do not overfill. 5. 6. Install the oil-fill cap and dipstick.
Servicing the Diesel-Oxidation Catalyst (DOC) and the Soot Filter Fuel System Maintenance DANGER Service Interval: Every 6,000 hours or clean the soot filter if engine faults SPN 3720 FMI 16, SPN 3720 FMI 0, or SPN 3720 FMI 16 display in the InfoCenter. • If advisory message ADVISORY 179 displays in the InfoCenter, the DPF is nearing the recommended point for servicing the diesel-oxidation catalyst and the soot filter.
5. Lubricate the gasket on the filter canister with clean oil. 6. Install the filter canister by hand until the gasket contacts mounting surface, then rotate it an additional 1/2 turn. 7. Checking the Fuel Lines and Connections Check the fuel lines and connections every 400 hours or yearly, whichever comes first. Inspect them for deterioration, damage, or loose connections. Tighten the drain plug on the bottom of the filter canister and close the vent on the top of the canister mount.
Fuses Electrical System Maintenance There are 8 fuses in the electrical system. The fuse block is located behind the control arm access panel (Figure 78). Important: Before welding on the machine, disconnect both cables from the battery, both wire harness plugs from the electronic control module, and the terminal connector from the alternator to prevent damage to the electrical system.
Drive System Maintenance Adjusting the Traction Drive for Neutral The machine must not creep when the traction pedal is released. If it does creep, adjust as follows: 1. Park the machine on a level surface, stop the engine, and lower the cutting units to the floor. 2. Jack up the front of the machine until the front tires are off the shop floor. Support the machine with jack stands to prevent it from falling accidentally. 4.
Cooling System Maintenance 4. Thoroughly clean both sides of the and the radiator/oil cooler with compressed air (Figure 83). Removing Debris from the Cooling System Remove debris from the screen and radiator/oil cooler daily (clean more frequently in dirty conditions). 1. Turn the engine off and remove the key from the ignition switch. 2. Thoroughly clean all debris out of the engine area. 3. Unlatch the clamp and pivot open the rear screen (Figure 82). g021880 Figure 83 1.
Brake Maintenance Note: Ensure that the cable conduit does not rotate during tightening procedure. Adjusting the Parking Brakes Adjust the brakes when there is more than 2.5 cm (1 inch) of free travel of the brake pedal, or when more holding force is required (Figure 84). Free travel is the distance the brake pedal moves before you feel braking resistance. g026816 Figure 84 1.
Belt Maintenance Adjusting the Parking-Brake Latch Servicing the Alternator Belt If the parking brake fails to engage and latch, adjust the brake pawl. 1. Loosen the 2 screws securing the parking-brake pawl to the frame (Figure 86). Service Interval: After the first 10 hours Every 100 hours Note: Proper tension will allow 10 mm (3/8 inch) deflection when a force of 44 N (10 lb) is applied on the belt midway between the pulleys. 1.
Hydraulic System Maintenance 9. Check the level of the hydraulic fluid and add enough to raise level to the Full mark on the dipstick. Important: Do not overfill. Changing the Hydraulic Fluid Replacing the Hydraulic Filters Service Interval: Every 800 hours The hydraulic system is equipped with a service-interval indicator (Figure 89). With the engine running at operating temperature, view the indicator, it should be in the Green zone.
Checking the Hydraulic Lines and Hoses Daily, check hydraulic lines and hoses for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration. Make all necessary repairs before operating. WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury.
g003982 g003983 Figure 92 Figure 94 1. Traction-circuit test port 1. Lift-circuit test port Use the test ports on the mow manifold block to assist in troubleshooting the mow circuit (Figure 93). g021221 Figure 93 1. Mow-circuit test ports Use the test port on the lift manifold block to assist in troubleshooting the lift circuit (Figure 94).
Cutting Unit System Maintenance 7. Apply lapping compound with a long handle brush. Important: Never use a short-handled brush. Backlapping the Cutting Units 8. 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 your desired speed. 9. Contact with the reels or other moving parts can result in personal injury.
Storage Preparing the Traction Unit 1. Thoroughly clean the traction unit, cutting units, and engine. 2. Check the tire pressure. Inflate all traction unit tires to 83 to 103 kPa (12 to 15 psi). 3. Check all fasteners for looseness and tighten them as necessary. 4. Grease all grease fittings and pivot points. Wipe up any excess lubricant. 5. Lightly sand and use touch-up paint on painted areas that are scratched, chipped, or rusted. Repair any dents in the metal body. 6.
International Distributor List Distributor: Country: Phone Number: Distributor: Phone Number: 57 1 236 4079 Colombia Japan 81 3 3252 2285 Czech Republic 420 255 704 220 420 255 704 Slovakia 220 Argentina 54 11 4 821 9999 Russia 7 495 411 61 20 Ecuador 593 4 239 6970 Finland 358 987 00733 Agrolanc Kft Balama Prima Engineering Equip. B-Ray Corporation Hungary Hong Kong Korea 36 27 539 640 852 2155 2163 82 32 551 2076 Maquiver S.A. Maruyama Mfg. Co. Inc. Mountfield a.s.
The Toro Total Coverage Guarantee A Limited Warranty Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty statements for these products).
