Form No. 3359-331 Rev B Reelmaster®5210/5410/5510/5610 Two-Wheel Drive Traction Units Model No. 03660—Serial No. 280000001 and Up Model No. 03670—Serial No. 280000001 and Up Model No. 03680—Serial No. 280000001 and Up Model No. 03690—Serial No. 280000001 and Up Register at www.Toro.com.
This manual uses 2 other words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention. Warning CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Contents Introduction................................................................. 2 Safety .....................................
Safety Operating Tips ................................................... 39 Maintenance............................................................... 41 Recommended Maintenance Schedule(s) ................ 41 Daily Maintenance Checklist............................... 42 Service Interval Chart......................................... 43 Lubrication............................................................. 43 Greasing the Bearings and Bushings.................... 43 Engine Maintenance...................
◊ lack of awareness of the effect of ground conditions, especially slopes; ◊ incorrect hitching and load distribution. • The owner/user can prevent and is responsible for accidents or injuries occurring to himself or herself, other people, or property. Preparation • While mowing, always wear substantial footwear, long trousers, hard hat, safety glasses, and ear protection. Long hair, loose clothing, or jewelry may get tangled in moving parts.
• Reduce the throttle setting during engine run-out and, if the engine is provided with a shut-off valve, turn the fuel off at the conclusion of mowing. • Keep hands and feet away from the cutting units. • Look behind and down before backing up to be sure of a clear path. • Slow down and use caution when making turns and crossing roads and sidewalks. Stop cylinders/reels if not mowing. • Do not operate the mower under the influence of alcohol or drugs.
– Do not drive close to sand traps, ditches, creeks, or other hazards. with a tachometer. Maximum governed engine speed should be 3200 RPM. – Reduce speed when making sharp turns. Avoid sudden stops and starts. • If major repairs are ever needed or if assistance is desired, contact an Authorized Toro Distributor. – When near or crossing roads, always yield the right-of-way. • Use only Toro-approved attachments and replacement parts. The warranty may be voided if used with unapproved attachments.
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. 108-5278 1. Read the Operator’s Manual. 106-6754 1. Warning—do not touch the hot surface. 2. Cutting/dismemberment hazard, fan and entanglement hazard, belt—stay away from moving parts. 93-7272 1. Cutting/dismemberment hazard; fan—stay away fro moving parts. 110-0986 93-6696 1.
110-8921 110-8924 1. Traction unit speed 2. Slow 3. Fast 1. Warning—read the Operator’s Manual and receive training. 2. Thrown object hazard—keep bystanders a safe distance from the machine. 3. Warning—do not park the machine on slopes; engage the parking brake, lower the cutting units, stop the engine and remove the ignition key before leaving the machine. 4. Tipping hazard—slow machine before turning, do not turn at high speeds; lower the cutting unit when driving down slopes. 5.
110-0998 1. 2. 3. 4. Headlights Reels—enabled Reels disabled—lift only Reels lowered and on when enabled—forward and backlap 5. 6. 7. 8. Reels raised and off Throttle—fast Throttle—slow Read the Operator’s Manual.
114–8891 (Use for Models 5510 & 5610 with 7 inch reel cutting units) 1. Front reels circuit controls 2. Rear reels circuit controls 3. Mow and backlap 4. Read the Operator’s Manual. 5. Height-of-cut 6. Traction unit speed 114–8890 (Use for Models 5210 & 5410 with 5 inch reel cutting units) 1. Front reels circuit controls 2. Rear reels circuit controls 3. Mow and backlap 4. Read the Operator’s Manual. 10 5. Height-of-cut 6.
0-0990 1. Read the Operator’s Manual. Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 2. No fire, open flame, or smoking. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 5. Read the Operator’s Manual. 6. Keep bystanders a safe distance from the battery. 7. Wear eye protection; explosive gases can cause blindness and other injuries 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 10.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 4 5 6 7 8 9 10 Description Use Qty. No parts required – Adjust the tire pressure. No parts required – Adjust the step height. No parts required – Adjust the control arm position. No parts required – Install the cutting units No parts required – Adjust the turf compensation spring. Varies Install rear weights (order from your Toro Distributor). Rear weights (size varies with configuration).
Figure 2 1. Step 2. Step brackets Figure 3 1. Control arm 2. Retaining brackets 2. Raise or lower the step to the desired height and re-secure the brackets to the frame with the 2 bolts and nuts. 3. Bolts (2) 2. Rotate the control arm to the desired position and tighten the 2 bolts. 3. Repeat the procedure on the other step. 3 4 Adjusting the Control Arm Position Installing the Cutting Units No Parts Required No Parts Required Procedure Procedure 1.
Figure 6 1. Opposite carrier frame tab 2. Rod bracket D. Mount the rod bracket to the cutting unit tabs with the carriage bolts and nuts (Figure 6). Note: When installing or removing the cutting units, make sure the hairpin cotter is installed in the spring rod hole next to the rod bracket. Otherwise, the hairpin cotter must be installed in the hole in the end of the rod. Figure 4 1. Counter weight 6. Lower all the lift arms completely. 7.
Figure 10 1. Lift arm chain 2. Chain bracket 13. Coat the spline shaft of the reel motor with clean grease. Figure 8 1. Lift arm 2. Carrier frame shaft 14. Oil the reel motor O-ring and install it onto the motor flange. 3. Lift arm pivot yoke 15. Install the motor by rotating it clockwise so that the motor flanges clear the capscrews (Figure 11). Rotate the motor counterclockwise until the flanges encircle the capscrews then tighten the capscrews. 9.
5 Adjusting the Turf Compensation Spring No Parts Required Procedure The turf compensation spring (Figure 12) transfers weight from the front to the rear roller. (This helps to reduce a wave pattern in the turf, also known as marcelling or bobbing.) Important: Make spring adjustments with the cutting unit mounted to the traction unit, pointing straight ahead and lowered to the shop floor. 1. Make sure the hairpin cotter is installed in the rear hole in the spring rod (Figure 12). Figure 12 1.
6 Installing Rear Weights Parts needed for this procedure: Varies Rear weights (size varies with configuration). Procedure The Reelmaster 5210/5410/5510 and 5610 Traction Units comply with CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-2004 Standards when equipped with rear weights and/or 90 lb of calcium chloride ballast is added to rear wheels. Use the following charts to determine the combinations of weights required for your configuration.
Use the following chart to determine the rear weight requirements when a 4 Post ROPS Conversion Kit is added.
Use the following chart to determine the rear weight requirements when the traction unit is also equipped with a Sunshade Canopy on a 2 Post ROPS.
Figure 13 1. Weight 2. Carriage bolt 3. Nut On four wheel drive models, use the following procedure to mount the appropriate amount of weight (see weight charts) to the top or bottom of the rear bumper as shown in Figure 14. Figure 14 1. 2. 3. 4. Traction manifold Spacers Bolts Washers 5. Weight(s) 6. Carriage bolt 7. Nut • Remove the 3 bolts, washers, and spacers securing the traction manifold to the bottom of the rear bumper (Figure 14a).
4. Outside the hood, insert the hook end of the latch through the hole in the hood. Make sure the rubber sealing washer remains to the outer side of the hood. 7 5. Inside the hood, insert the metal washer onto the latch and secure with the nut. Make sure the latch engages the frame catch when it is locked. Use the enclosed hood latch key to operate the hood latch. Installing the CE Hood Latch Parts needed for this procedure: 1 Hood latch assembly 1 Washer 8 Procedure 1. Unlatch and raise the hood.
Figure 19 1. Gauge bar Figure 18 1. Chain bracket 2. Snapper pin 2. Height adjusting screw 3. Nut 3. Cutting unit kickstand 10 9 Reading the Manual and Viewing the Safety Video Using the Gauge Bar Parts needed for this procedure: 1 4. Holes used for setting Groomer HOG 5. Hole not used Parts needed for this procedure: Gauge bar Procedure Use the gauge bar to adjust the cutting unit. Refer to the Cutting Unit Operator’s Manual for the adjustment procedures (Figure 19).
Product Overview speed depends on how far you press the pedal. For no load, maximum ground speed, fully press the pedal while the throttle is in the Fast position. To stop, reduce foot pressure on the traction pedal and allow it to return to the center position. Figure 20 1. 2. 3. 4. Engine hood Operator’s seat Control arm Steering wheel 5. Seat 6. Front cutting units 7. Rear cutting units Figure 22 Controls 1. Traction pedal 2. Mow speed limiter 3.
Throttle Control Lower Mow/Raise Control Lever Move the throttle control (Figure 23) forward to increase the engine speed and rearward to decrease speed. This lever (Figure 23) raises and lowers the cutting units and also starts and stops the reels when the reels are enabled in the mow mode. Glow Plug Indicator Light This light (Figure 23) illuminates when the glow plugs are preheating. Engine Oil Pressure Warning Light This light (Figure 23) indicates dangerously low engine oil pressure.
Hour Meter Fuel Gauge The hour meter (Figure 25) shows the total hours that the machine has been operated. The fuel gauge (Figure 27) shows the amount of fuel in the tank. Figure 25 1. Hour meter Figure 27 1. Fuel tank cap 2. Fuel gauge Hydraulic Filter Restriction Indicator With the engine running at normal operating temperature, view the indicator (Figure 26), it should be in the Green zone. When the indicator is in the Red zone, change the hydraulic filters.
Power Point The power point is a 12 volt power supply for electronic devices (Figure 29). Figure 29 1.
Specifications Note: Specifications and design are subject to change without notice.
Operation Note: Determine the left and right sides of the machine from the normal operating position. If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. 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. Figure 30 Checking the Engine Oil Level 1.
gauge. Engine failure may occur as a result of over filling or under filling the engine oil. 6. Install the oil fill cap and close the hood. Checking the Cooling System Clean debris off of the screen, oil cooler, and front of the radiator daily and more often if conditions are extremely dusty and dirty. Refer to the section on Removing Debris from the Cooling System in Cooling System Maintenance , page 51. The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol antifreeze.
Fuel is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious injury and illness. In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. • Avoid prolonged breathing of vapors. • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any fuel that spills. • Keep face away from nozzle and gas tank or conditioner opening. • Keep fuel away from eyes and skin.
Viscosity, ASTM D445 2. Using a clean rag, clean area around fuel tank cap. 3. Remove cap from the fuel tank (Figure 33). cSt @ 40°C 44 to 48 cSt @ 100°C 7.9 to 8.5 140 to 160 Viscosity Index ASTM D2270 Pour Point, ASTM D97 -34°F to -49°F Industry Specifications: Vickers I-286-S (Quality Level), Vickers M-2950-S (Quality Level), Denison HF-0 Note: Many hydraulic fluids are almost colorless, making it difficult to spot leaks. A red dye additive for the hydraulic system oil is available in 2/3 oz.
Figure 35 1. Hydraulic tank cap 4. Remove dipstick from filler neck and wipe it with a clean rag. Insert dipstick into filler neck; then remove it and check level of fluid. Fluid level should be 1/4 inch of mark on dipstick. Do not overfill. 5. If level is low, add appropriate fluid to raise level to full mark. 6. Install dipstick and cap onto filler neck.
Bleeding the Fuel System You must bleed the fuel system before starting the engine if any of the following situations have occurred: • Initial start up of a new machine. • Engine has ceased running due to lack of fuel. • Maintenance has been performed upon fuel system components; i.e., filter replaced, separator serviced, etc. Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage.
3. After preheating the glow plugs, turn key to the Start position. 2. Choose the desired ground speed best suited for conditions. Crank the engine for no longer than 15 seconds. Release the key when the engine starts. If additional preheating is required, turn key to the Off position and then to the On/Preheat position. Repeat this process as required. 3.
Figure 39 1. Front reels circuit controls 2. Rear reels circuit controls 3. Reel—mow and backlap 4. Read the Operator’s Manual. 5. Reel—height of cut 6. Machine speed Adjusting the Lift Arm Counterbalance You can adjust the counterbalance on the rear cutting unit lift arms to compensate for different turf conditions and to maintain a uniform height-of-cut in the rough conditions or in areas of thatch build up. You can adjust each counterbalance spring to one of four settings.
2. The lift arm switch is located underneath the hydraulic tank behind the front right lift arm (Figure 41). 3. Loosen the switch mounting screws (Figure 41) and move the switch down to increase the lift arm turn around height or move the switch up to decrease the lift arm turn around height. Tighten the mounting screws. Figure 42 1. Bypass valve 2. Close the bypass valve before starting the engine. However, do not exceed 5-8 ft.-lb. (7-11 N·m) torque to close the valve.
Tie Downs is functioning correctly and the key switch is moved to the On position, the controller diagnostic light will turn ON for 3 seconds and turn OFF to indicate the light is working properly. If the machine kills the light will turn on steady until the key position is changed. The light will blink if the controller detects a malfunction in the electrical system. The light will stop blinking and automatically reset when the key switch is turned to the Off position once the fault has been resolved.
Diagnostic Ace Display The machine is equipped with an electronic controller which controls most machine functions. The controller determines what function is required for various input switches (i.e. seat switch, key switch, etc.) and turns on the outputs to actuate solenoids or relays for the requested machine function. For the electronic controller to control the machine as desired, each of the input switches, output solenoids, and relays must be connected and functioning properly.
Note: If the correct output LEDs do not illuminate, verify that the required input switches are in the necessary positions to allow that function to occur. Verify correct switch function. If the output LEDs are on as specified, but the machine does not function properly, this indicates a non-electrical problem. Repair as necessary. 8. Individually, change each of the switches from open to closed (i.e., sit on seat, engage traction pedal, etc.
Warning System If a warning light comes on during operation, stop the machine immediately and correct the problem before continuing operation. Serious damage could occur if you operate the machine with a malfunction. Mowing Start the engine and move the throttle to the Fast position. Move the Enable/Disable switch to the Enable position and use the Lower Mow/Raise lever to control the cutting units (the front cutting units are timed to lower before the rear cutting units).
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval After the first hour Maintenance Procedure • Torque the wheel lug nuts to 70 to 90 ft-lb (94 to 122 N⋅m). After the first 8 hours • Check the condition and tension of the alternator belt. After the first 10 hours • Torque the wheel lug nuts to 70 to 90 ft-lb (94 to 122 N⋅m).
Daily Maintenance Checklist Duplicate this page for routine use. Maintenance Check Item For the week of: Mon. Tues. Wed. Thurs. Fri. Sat. 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 Figure 49 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 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 General Purpose Lithium Base Grease.
• Lift arm pivots (1 each) (Figure 51) • Axle steering pivot (1) (Figure 55) • Cutting unit carrier frame and pivot (2 each) (Figure 52) Figure 55 • Steering cylinder ball joints (2) (Figure 56) Figure 52 • Lift arm pivot shaft (1 each) (Figure 53) Figure 56 Figure 53 • Brake pedal (1) (Figure 57) • Rear axle tie rod (2) (Figure 54) Figure 57 Figure 54 44
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. Service the air cleaner filter only when the service indicator (Figure 58) requires it. Changing the air filter before it is necessary only increases the chance of dirt entering the engine when the filter is removed.
3. Hold the injection pump lever arm against the high idle stop (Figure 62). 4. While pulling the throttle cable, to remove any slack, tighten the throttle cable connector. Note: When tightened, the cable pivot must be free to swivel on the injection pump lever arm. 5. If the throttle does not stay in position during operation, increase the torque on the locknut, used to set the friction device on the throttle lever. Figure 61 1. Oil filter 4. Apply a light coat of clean oil to the new filter seal. 5.
Fuel System Maintenance Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage. • Use a funnel and fill the fuel tank outdoors, in an open area, when the engine is off and is cold. Wipe up any fuel that spills. Figure 63 1. Water separator filter canister • Do not fill the fuel tank completely full. Add fuel to the fuel tank until the level is 1/4 to 1/2 in.
Electrical System Maintenance 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. Servicing the Battery Figure 64 Warning 1.
Fuses Drive System Maintenance There are 8 fuses in the electrical system. The fuse block (Figure 65) is located behind the control arm access panel. 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. Disconnect the left brake cable from the brake pedal (Figure 67) and set the parking brake. Figure 65 1.
Figure 69 1. Jam nut 2. Tie rod 3. Wrench slot Figure 68 1. Locknut 2. Traction adjustment cam 3. Using the wrench slot, rotate the tie rod 4. Measure the distance at the front and rear of the rear wheels at axle height. The distance at the front of the rear wheels should be less than 1/4 inch (6 mm) of the distance measured at the rear of the wheels. The engine must be running so the final adjustment of the traction adjustment cam can be performed. This could cause personal injury. 5.
Cooling System Maintenance Removing Debris from the Cooling System Remove debris from the screen, oil coolers, and radiator 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 70). Figure 71 1. Oil cooler 2. Oil cooler latches 6. Thoroughly clean both sides of the oil cooler and the radiator (Figure 72) with compressed air.
Brake Maintenance Adjusting the Service Brakes Adjust the service brakes when there is more than 1 inch of free travel of the brake pedal, or when the brakes do not work effectively. Free travel is the distance the brake pedal moves before you feel braking resistance. 1. To reduce free travel of the brake pedals, tighten the brakes by loosening the front nut on the threaded end of the brake cable (Figure 73). Figure 74 1. Brake cables 2. Screws (2) 3. Parking brake pawl 4. Brake detent 2.
Belt Maintenance Hydraulic System Maintenance Check the condition and tension of the alternator belt after the first day of operation and every 100 operating hours thereafter. Changing the Hydraulic Fluid Change hydraulic fluid after every 800 operating hours, in normal conditions. If fluid becomes contaminated, contact your local Toro distributor because the system must be flushed. Contaminated fluid looks milky or black when compared to clean oil. 1. Stop the engine and raise the hood. 2.
Important: Do not over-fill. Replacing the Hydraulic Filters The hydraulic system is equipped with a service interval indicator (Figure 77). With the engine running, view the indicator, it should be in the Green zone. When the indicator is in the Red zone, change the hydraulic filters. Figure 79 1. Hydraulic filter 3. Remove the filter. 4. Lubricate the gasket on the new filter with hydraulic oil. Figure 77 1. Hydraulic filter restriction indicator 5. Ensure that the filter mounting area is clean. 6.
Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • Make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system. • Keep your body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid. • Use cardboard or paper to find hydraulic leaks. Figure 81 1.
Cutting Unit System Maintenance Backlapping the Cutting Units Contact with the reels or other moving parts can result in personal injury. Figure 83 • Keep fingers, hands, and clothing away from the reels or other moving parts. 1. Backlap levers • Never attempt to turn the reels by hand or foot while the engine is running. 2. Reel speed control knobs 6. Select either front, rear or both backlap levers to determine which units to backlap (Figure 83).
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 12 to 15 psi (83 to 103 kPa). 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.
Schematics Hydraulic Schematic, Model 5210 & 5410 (Rev.
Hydraulic Schematic, Model 5510 & 5610 (Rev.
Electrical Schematic (Rev.
Notes: 61
Notes: 62
Notes: 63
Toro General Commercial Products Warranty A Two-Year 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).
