Form No. 3371-206 Rev A Reelmaster® 5210/5410/5510/5610 Traction Unit Model No. 03660—Serial No. 312000001 and Up Model No. 03670—Serial No. 312000001 and Up Model No. 03680—Serial No. 312000001 and Up Model No. 03690—Serial No. 312000001 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. This manual identifies potential hazards and has safety messages identified by the safety alert symbol (Figure 1), which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions.
Contents Daily Maintenance Checklist............................... 42 Service Interval Chart......................................... 43 Lubrication............................................................. 43 Greasing the Bearings and Bushings.................... 43 Engine Maintenance............................................... 45 Servicing the Air Cleaner .................................... 45 Servicing the Engine Oil and Filter...................... 45 Adjusting the Throttle ....................
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. 110-0989 2. Thrown object hazard—keep bystanders a safe distance from the machine. 3.
6-6755 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. 93-6689 1. Warning—do not carry passengers. 117–0170 1. Head lights 6. Continuous variable throttle setting 2. Engage 7. Slow 3. Power take-off (PTO) 8. Lower cutting units 4. Disengage 9. Raise cutting units 5. Fast 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 3. Mow and backlap 5. Height-of-cut 2. Rear reels circuit controls 4. Read the Operator's Manual. 6. Traction unit speed 117-0168 1. Read the Operator's Manual.
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. Contains lead; do not discard.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description 1 2 3 4 5 6 7 8 9 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).
2. Raise or lower the step to the desired height and re-secure the brackets to the frame with the 2 bolts and nuts. 1 3. Repeat the procedure on the other step. Adjusting the Tire Pressure 3 No Parts Required Procedure Adjusting the Control Arm Position 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 12 to 15 psi (83 to 103 kPa).
4 Installing the Cutting Units Parts needed for this procedure: 1 1 Figure 5 1. Turf compensation spring Front hose guide-R.H. 3. Spring tube 2. Rod bracket Front hose guide-L.H. B. Remove the flange nut securing the spring tube bolt to the carrier frame tab (Figure 5) Remove the assembly. Procedure 1. Remove the reel motors from the shipping brackets. C. Mount the spring tube bolt to the opposite tab on the carrier frame and secure with the flange nut.
Figure 10 1. Lift arm 3. Lift arm pivot yoke 2. Carrier frame shaft Figure 8 1. Hose guide (#4 cutting unit 3. Nuts shown) 9. Use the following procedure on the rear cutting units when the height of cut is above 3/4 inch. 2. Rod bracket A. Remove the lynch pin and washer securing the lift arm pivot shaft to the lift arm and slide the lift arm pivot shaft out of the lift arm (Figure 11).
5 Adjusting the Turf Compensation Spring No Parts Required Figure 12 1. Lift arm chain Procedure 2. Chain bracket The turf compensation spring (Figure 14) 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.) 13. On the #4 (left front) and #5 (right front) cutting units, insert the reel motor hoses into the respective hose guide.
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 3. Nut 2. Carriage bolt 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. Traction manifold 5. Weight(s) 2. Spacers 6. Carriage bolt 3. Bolts 4. Washers 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. Height adjusting screw 3. Cutting unit kickstand 3. Nut 2. Snapper pin 9 Using the Gauge Bar Parts needed for this procedure: 1 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). 23 4. Holes used for setting Groomer HOG 5.
Product Overview forward and the bottom to move rearward. Ground 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. Engine hood 5. Seat 2. Operator's seat 6. Front cutting units 3. Control arm 7. Rear cutting units 4.
toward you to the most comfortable position and then release the pedal. cooling system if the gauge goes to the yellow or red range. Throttle Control Diagnostic Light Move the throttle control (Figure 25) forward to increase the engine speed and rearward to decrease speed. It will illuminate should a system fault be recognized.
Figure 26 Figure 28 1. Backlap levers 1. Hydraulic filter restriction indicator 2. Reel speed controls 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 Hydraulic Filter Restriction Indicator 2. Fuel gauge With the engine running at normal operating temperature, view the indicator (Figure 28), it should be in the Green zone.
Power Point The power point is a 12 volt power supply for electronic devices (Figure 31). Figure 30 Figure 31 1. Headlight switch 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. 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.
Note: The reel speed can be increased or decreased to compensate for turf conditions. Figure 39 1. Reel speed control knobs Figure 40 1. Front reels circuit controls 3. Reel—mow and backlap 5. Reel—height of cut 2. Rear reels circuit controls 4. Read the Operator's Manual. 6.
Figure 41 1. Front reels circuit controls 3. Reel—mow and backlap 5. Reel—height of cut 2. Rear reels circuit controls 4. Read the Operator's Manual. 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.
Adjusting the Lift Arm Turn Around Position 1. Position the machine on a level surface, lower the cutting units, stop the engine, engage the parking brakes, and remove the key from ignition switch. 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.
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.
8. Individually, change each of the switches from open to closed (i.e., sit on seat, engage traction pedal, etc.), and note that the appropriate LED on Diagnostic ACE will blink on and off when corresponding switch is closed. Repeat this for all switches that you can change by hand. 9. If a switch is closed and the appropriate LED does not turn on, check all wiring and connections to the switch and/or check the switches with an ohm meter. Replace any defective switches and repair any defective wiring.
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). To move forward and cut grass, press the traction pedal forward.
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 are off the shop floor. Support the machine with jack stands to prevent it from falling accidentally. Figure 67 1.
7. Test drive the machine to make sure it does not creep. Cooling System Maintenance Adjusting the Rear Wheel Toe-in Removing Debris from the Cooling System 1. Rotate the steering wheel so that the rear wheels are straight ahead. Remove debris from the screen, oil coolers, and radiator daily (clean more frequently in dirty conditions). 2. Loosen the jam nut on each end of the tie rod (Figure 70). 1. Turn the engine off and remove the key from the ignition switch. 6. Stop the engine.
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 3. Parking brake pawl 2. Screws (2) 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 at operating temperature, 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.
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. Figure 82 • Never attempt to turn the reels by hand or foot while the engine is running. 1. Mow circuit test ports (2) Note: When backlapping, the front units all operate together, and the rear units operate together.
Storage 6. Select either front, rear or both backlap levers to determine which units to backlap (Figure 84). Preparing the Traction Unit DANGER 1. Thoroughly clean the traction unit, cutting units, and engine. To avoid personal injury, be certain that you are clear of the cutting units before proceeding. 2. Check the tire pressure. Inflate all traction unit tires to 12 to 15 psi (83 to 103 kPa). 7.
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).
