Form No. 3363-293 Rev D Reelmaster® 5210/5410/5510/5610 Two-Wheel Drive Traction Units Model No. 03660—Serial No. 310000001 and Up Model No. 03670—Serial No. 310000001 and Up Model No. 03680—Serial No. 310000001 and Up Model No. 03690—Serial No. 310000001 and Up Model No. 03691—Serial No. 310000001 and Up To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com.
This product complies with all relevant European directives, for details please see the separate product specific Declaration of Conformity (DOC) sheet. (Figure 1), which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions. 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. Figure 1 1.
Contents 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............................................... 45 Servicing the Air Cleaner ..........
Safety ◊ lack of awareness of the effect of ground conditions, especially slopes; This machine meets or exceeds CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-2004 specifications in effect at time of production, when equipped with rear weight. Refer to the section in this manual on Installing Rear Weight. ◊ 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.
• 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; – machine speeds should be kept low on slopes and during tight turns; – stay alert for humps and hollows and other hidden hazards; – Do not turn sharply. Use care when reversing. – Use counterweight(s) or wheel weights when suggested in the operator’s manual. • Stay alert for holes in the terrain and other hidden hazards.
• Clean grass and debris from cutting units, drives, silencers/mufflers, and engine to help prevent fires. Clean up oil or fuel spillage. • 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. Reconnect positive first and negative last. • Use care when checking the cylinders/reels. Wear gloves and use caution when servicing them.
• To ensure safety and accuracy, have an Authorized Toro Distributor check the maximum engine speed with a tachometer. Maximum governed engine speed should be 3200 RPM. • If major repairs are ever needed or if assistance is desired, contact an Authorized Toro Distributor. • Use only Toro-approved attachments and replacement parts. The warranty may be voided if used with unapproved attachments. Sound pressure level was determined according to the procedures outlined in EN 836.
Whole Body Measured values were determined according to the procedures outlined in EN 836. Measured vibration level = .27 m/s2 Uncertainty Value (K) = 0.5 m/s2 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.
110-8986 (Affix over part no. 110–8924 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 indicated for operation of this machine are prescribed by and required by this standard. 1. Warning—read the Operator’s Manual and receive training. 2. Thrown object hazard—keep bystanders a safe distance from the machine. 3.
6-6755 1. Engine coolant under pressure. 2. Explosion hazard—read the Operator’s Manual. 3. Warning—do not touch the hot surface. 4. Warning—read the Operator’s Manual. 93-6689 1. Warning—do not carry passengers. 117–0170 1. Head lights 2. 3. 4. 5. Engage Power take-off (PTO) Disengage Fast 6. Continuous variable throttle setting 7. Slow 8. Lower cutting units 9. Raise cutting units 10. Read the Operator’s Manual. 114–8891 (Use for Models 5510 & 5610 with 7 inch reel cutting units) 1.
4–8890 (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. 117-0168 1. Read the Operator’s Manual. 11 5. Height-of-cut 6.
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. Contains lead; do not discard.
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. Front hose guide-R.H. Front hose guide-L.H. 1 1 Install the cutting units No parts required – Adjust the turf compensation spring. Varies Install rear weights (order from your Toro Distributor).
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 Parts needed for this procedure: No Parts Required Procedure 1 Front hose guide-R.H.
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). Also, on the #4 (left front) cutting unit, mount the left hand hose guide to the front of the cutting unit tabs when reinstalling the rod bracket (Figure 8). Figure 4 1. Counter weight 5. All the cutting units are shipped with the turf compensation spring mounted to the right side of the cutting unit.
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. 6. Lower all the lift arms completely. 7. Remove the snapper pin and the cap from the lift arm pivot yoke (Figure 9). Figure 11 1. Lift arm pivot shaft lynch pin and washer B. Insert the lift arm yoke onto the carrier frame shaft (Figure 10). C.
Figure 14 1. Turf compensation spring 2. Hair pin cotter 3. Spring rod 4. Hex nuts Figure 13 1. Reel drive motor 2. Tighten the hex nuts on the front end of the spring rod until the compressed length of the spring is 5 inches (12.7 cm) on Reelmaster 5210 & 5410, 5 inch cutting units or 6.25 inches (15.9 cm) on Reelmaster 5510 & 5610, 7 inch cutting units (Figure 14). 2. Mounting bolts 5 Note: When operating on rough terrain decrease the spring length by 1/2 inch.
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 15 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 16. Figure 16 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 16a).
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 21 1. Gauge bar Figure 20 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 21).
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 22 1. 2. 3. 4. Engine hood Operator’s seat Control arm Steering wheel 5. Seat 6. Front cutting units 7. Rear cutting units Figure 24 Controls 1. Traction pedal 2. Mow speed limiter 3.
Throttle Control Lower Mow/Raise Control Lever Move the throttle control (Figure 25) forward to increase the engine speed and rearward to decrease speed. This lever (Figure 25) raises and lowers the cutting units and also starts and stops the cutterheads when the cutterheads are enabled in the mow mode. 5 6 7 8 4 Glow Plug Indicator Light 9 This light (Figure 25) illuminates when the glow plugs are preheating.
Hour Meter Fuel Gauge The hour meter (Figure 27) shows the total hours that the machine has been operated. The fuel gauge (Figure 29) shows the amount of fuel in the tank. Figure 27 1. Hour meter Figure 29 1. Fuel tank cap 2. Fuel gauge Hydraulic Filter Restriction Indicator With the engine running at normal operating temperature, view the indicator (Figure 28), 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 31). Figure 31 1. Power point 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. CAUTION 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.
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. 2. If the coolant level is low, remove the expansion tank cap and replenish the system. Do not overfill. 3. Install the expansion tank cap. Checking the Cooling System Adding Fuel Clean debris off of the screen, oil cooler, and front of the radiator daily and more often if conditions are extremely dusty and dirty.
• Monitor seals, hoses, gaskets in contact with fuel as they may be degraded over time. 1. Park the machine on a level surface. 2. Using a clean rag, clean area around fuel tank cap. • Fuel filter plugging may be expected for a time after converting to biodiesel blended. 3. Remove cap from the fuel tank (Figure 35). • Contact your distributor if you wish for more information on biodiesel. DANGER In certain conditions, fuel is extremely flammable and highly explosive.
High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46 Material Properties: Viscosity, ASTM D445 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 Important: The ISO VG 46 Multigrade fluid has been found to offer optimal performance in a wide range of temperature conditions.
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. DANGER 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. 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. 4. Run the engine at low idle speed until it warms up. Stopping the Engine 1.
Figure 39 1. Reel speed control knobs Note: The reel speed can be increased or decreased to compensate for turf conditions. Figure 40 1. Front reels circuit controls 2. Rear reels circuit controls 3. Reel—mow and backlap 4. Read the Operator’s Manual. 34 5. Reel—height of cut 6.
Figure 41 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 43). 3. Loosen the switch mounting screws (Figure 43) 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 44 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 51 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 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 53) • Axle steering pivot (1) (Figure 57) • Cutting unit carrier frame and pivot (2 each) (Figure 54) Figure 57 • Steering cylinder ball joints (2) (Figure 58) Figure 54 • Lift arm pivot shaft (1 each) (Figure 55) Figure 58 Figure 55 • Brake pedal (1) (Figure 59) • Rear axle tie rod (2) (Figure 56) G011615 Figure 59 Figure 56 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 60) 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 64). 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 63 1. Oil filter 4. Apply a light coat of clean oil to the new filter seal. 5.
Fuel System Maintenance DANGER 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 65 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 WARNING Figure 66 1.
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 areoff the shop floor. Support the machine with jack stands to prevent it from falling accidentally. Figure 67 1.
Cooling System Maintenance 6. Stop the engine. Remove the jack stands and lower the machine to the shop floor. 7. Test drive the machine to make sure it does not creep. Removing Debris from the Cooling System Adjusting the Rear Wheel Toe-in Remove debris from the screen, oil coolers, and radiator daily (clean more frequently in dirty conditions). 1. Rotate the steering wheel so that the rear wheels are straight ahead. 1. Turn the engine off and remove the key from the ignition switch. 2.
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. Note: Use the wheel motor backlash to rock the drums back and forth to ensure that the drums are free prior to and after adjustment. 1.
Belt Maintenance Check the condition and tension of the alternator belt after the first day of operation and every 100 operating hours thereafter. Tensioning the Alternator Belt 1. Open the hood. 2. Check the tension of the alternator belt by depressing it (Figure 76) midway between the alternator and the crankshaft pulleys with 22 lb (10 kg) of force. Figure 75 1. Brake cables 2. Screws (2) 3. Parking brake pawl 4. Brake detent 2.
Replacing the Hydraulic Filters Hydraulic System Maintenance The hydraulic system is equipped with a service interval indicator (Figure 78). 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. 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.
WARNING 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.
Cutting Unit System Maintenance Backlapping the Cutting Units 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. Figure 82 1. Mow circuit test ports (2) Note: When backlapping, the front units all operate together, and the rear units operate together. 1.
Storage DANGER To avoid personal injury, be certain that you are clear of the cutting units before proceeding. Preparing the Traction Unit 1. Thoroughly clean the traction unit, cutting units, and engine. 7. With the Mow/Transport lever in the mow position, move the Enable/Disable switch to the Enable position. Move the Lower Mow/Lift control forward to start the backlapping operation on the designated reels. 2. Check the tire pressure. Inflate all traction unit tires to 12 to 15 psi (83 to 103 kPa). 3.
Schematics Hydraulic Schematic, Model 5210 & 5410 (Rev.
Hydraulic Schematic, Model 5510 & 5610 (Rev.
Electrical Schematic (Rev.
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).
