Form No. 3427-722 Rev A Reelmaster® 5610 Traction Unit Model No. 03678—Serial No. 403410001 and Up Model No. 03678TE—Serial No. 400000000 and Up Register at www.Toro.com.
on the product. Write the numbers in the space provided. This product complies with all relevant European directives, for details please see the separate product specific Declaration of Conformity (DOC) sheet. Important: With your mobile device, you can scan the QR code (if equipped) on the serial number decal to access warranty, parts, and other product information.
Contents Checking the Fuel Lines and Connections.................................................. 39 Servicing the Water Separator ......................... 39 Servicing the Fuel Pick-up Tube Screen............ 39 Bleeding Air from the Fuel Injectors................... 40 Electrical System Maintenance ........................... 40 Electrical System Safety ................................... 40 Servicing the Battery......................................... 40 Checking the Fuses ...........................
Safety • Keep bystanders and children out of the operating This machine has been designed in accordance with EN ISO 5395 (when you complete the setup procedures) and ANSI B71.4-2017. • Shut off the engine, remove the key (if equipped), General Safety Improperly using or maintaining this machine can result in injury.
decal110-9642 110-9642 1. Stored energy hazard—read the Operator's Manual. 2. Move the cotter pin to the hole closest to the rod bracket and then remove the lift arm and pivot yoke. 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. decal110-0986 110-0986 1. Press the brake pedal and parking brake pedal to set the parking brake. r:\decal117-0169 2.
decal121-5644 121–5644 1. Light switch 6. Slow 2. Engage 7. Lower 3. Power take-off 4. Disengage 8. Raise 9. Read the Operator’s Manual. 5.
decal133-2930 133-2930 1. Warning—do not operate this machine unless you are trained. 4. Tipping hazard—drive slowly when turning; do not turn sharply while traveling fast; only drive on slopes with the cutting units lowered; always wear a seatbelt. 2. Warning—wear hearing protection. 5. Warning—do not park on slopes; engage the parking brake, lower the cutting units, shut off the engine, and remove the ignition key before leaving the machine. 3.
decal138-6975 138-6975 1. Read the Operator's Manual. decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 6. Keep bystanders away 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.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description 1 2 3 4 5 6 7 No parts required – Adjust the tire pressure. 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. Varies Install rear weights (order from your Toro Distributor). Rear weights (size varies with configuration) 8 Use Qty.
1. Loosen the 2 bolts securing the control arm to the retaining bracket (Figure 3). g003320 Figure 4 1. Counter weight g004152 Figure 3 1. Control arm 5. 3. Bolts (2) 2. Retaining brackets 2. Rotate the control arm to the desired position and tighten the 2 bolts. Mount the turf-compensation spring to the same side of the cutting unit as the reel-drive motor.
g003967 Figure 6 1. Opposite carrier-frame tab D. 2. Rod bracket Mount the rod bracket to the cutting-unit tabs with the carriage bolts and nuts (Figure 6). Important: On cutting unit 4 (left front) and cutting unit 5 (right front) , use the rod-bracket mounting nuts to install the hose guides to the front of the cutting-unit tabs (Figure 7 and Figure 8). The hose guides should lean toward the center cutting unit (Figure 8 and Figure 9). g015160 Figure 8 1. Hose guide (cutting unit 4 shown) 3.
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 lift arms completely. 7. Remove the lynch pin from the lift-arm pivot yoke. Then, remove the cap (Figure 10). slide the lift-arm-pivot shaft out of the lift arm (Figure 12). g003979 Figure 12 1. Lynch pin and washer 1.
16. Install the motor by rotating it clockwise so that the motor flanges clear the bolts (Figure 14). Note: Rotate the motor counterclockwise until the flanges encircle the bolts then tighten the bolts. Important: Make sure that the reel-motor hoses are not twisted, kinked or in the risk of being pinched. g003863 Figure 15 1. Turf-compensation spring 3. Spring rod 2. Hairpin cotter 4. Hex nuts 2.
5 Installing Rear Weights Parts needed for this procedure: Varies Rear weights (size varies with configuration) Procedure This machine complies with EN ISO 5395 and ANSI B71.4-2017 when equipped with rear weights and/or 41 kg (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. Order parts from your local authorized Toro distributor.
1. Remove the 3 bolts, washers, and spacers securing the traction manifold to the bottom of the rear bumper (Figure 16a). 2. Position the appropriate amount of weight on the top and/or bottom of the rear bumper. 3. Mount the weight(s) and the traction manifold to the bumper with the 3 bolts, washers and spacers previously removed (Figure 16b). Note: Do not use the spacers when installing more than two weights under the bumper (Figure 16c). 4.
8 Applying the CE Decals Parts needed for this procedure: 1 Warning decal 1 CE decal 1 Production year decal Procedure On machines requiring CE compliance, apply the production year decal (Part No. 133-5615) near the serial plate, the CE decal (Part No. 93-7252) near the hood lock, and the CE warning decal (Part No. 133-2931) over the standard warning decal (Part No. 133-2930). g003985 Figure 19 1. Cutting-unit kickstand Secure the kickstand to the chain bracket with the snapper pin (Figure 20).
Traction Pedal Product Overview The traction pedal (Figure 23) controls the forward and reverse operation. 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, 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.
Tilt-Steering Pedal Backlap Levers To tilt the steering wheel toward you, press the foot pedal (Figure 23) down, and pull the steering tower toward you to the most comfortable position and then release the pedal. Use the backlap levers in conjunction with the lower mow/raise control lever for backlapping the reels (Figure 25). Throttle Control Move the throttle control (Figure 24) forward to increase the engine speed and rearward to decrease speed. g021209 g025902 Figure 25 Figure 24 1.
Power Point use it to back out of any menu you are currently using. The power point is a 12 V power supply for electronic devices (Figure 27). • Middle Button—use this button to scroll down menus. • Right Button—use this button to open a menu where a right arrow indicates additional content. Note: The purpose of each button may change depending on what is required at the time. Each button is labeled with an icon displaying its current function.
Using the Menus InfoCenter Icon Description (cont'd.) To access the InfoCenter menu system, press the menu access button while at the main screen. This brings you to the main menu. Refer to the following tables for a synopsis of the options available from the menus: Denied or not allowed Engine Start Main Menu Stop or shutdown Engine Menu Item Description Faults The Faults menu contains a list of the recent machine faults.
PTO Indicates the inputs, qualifiers, and outputs for enabling the PTO circuit. Engine Run Indicates the inputs, qualifiers, and outputs for starting the engine. Backlap Indicates the inputs, qualifiers and outputs for operating the backlap function. 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.
Setting the Blade Count 1. In the Settings Menu, scroll down to Blade Count. 2. Press the right button to change the blade count between 5, 8, or 11 blade reels. Specifications Note: Specifications and design are subject to change without notice. Specification Setting the Mow Speed 1. In the Settings Menu, scroll down to Mow Speed. 2. Press the right button to select mow speed. 3.
Performing Daily Maintenance Operation Before Operation Service Interval: Before each use or daily Before Operation Safety Before starting the machine each day, perform the Each Use/Daily procedures listed in Maintenance (page 31). General Safety Adding Fuel • Never allow children or untrained people to Use only clean, fresh diesel fuel or biodiesel fuels with low (<500 ppm) or ultra low (<15 ppm) sulfur content. The minimum cetane rating should be 40.
3. • Keep your hands and feet away from the cutting Remove the cap from the fuel tank (Figure 29). units. • Look behind and down before backing up to be sure of a clear path. • Use care when approaching blind corners, shrubs, trees, or other objects that may obscure your vision. • Stop the cutting units whenever you are not mowing. • Slow down and use caution when making turns g021210 and crossing roads and sidewalks with the machine. Always yield the right-of-way. Figure 29 1. Fuel-tank cap 4.
overheating the brakes. An adjustment to the brakes may be required after break-in; refer to Adjusting the Parking Brakes (page 45). operation. Operating the machine on any slope requires extra caution. • Evaluate the site conditions to determine if the slope is safe for machine operation, including surveying the site. Always use common sense and good judgment when performing this survey.
Crank the engine for no longer than 15 seconds. Release the key when the engine starts. If additional preheating is required, turn the 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. Shutting Off the Engine 1. Important: Allow the engine to idle for 5 minutes before shutting it off after a full load operation. Failure to do so may lead to trouble on a turbocharged engine. g003993 Figure 30 2. 1.
You can position the springs on the back side of the first spring actuator to remove all counter balance (fourth position). 1. Park the machine on a level surface, lower the cutting units, engage the parking brake, shut off the engine, and remove the key. 2. Insert a tube or similar object onto the long spring end and pivot it around the spring actuator to the desired position (Figure 31). CAUTION The springs are under tension and could cause personal injury.
Checking the Interlock Switches The purpose of the interlock switches is to prevent the engine from cranking or starting unless the traction pedal is in the NEUTRAL position, the Enable/Disable switch is in the DISABLE position, and the Lower Mow/Raise control is in the NEUTRAL position. In addition, the engine should shut off when you press the traction pedal while you are off the seat or if you leave the parking brake engaged.
Mowing Identifying the Tie-Down Points Start the engine and move the engine-speed switch 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.
Jacking Points Note: Support the machine with jack stands whenever you work under the machine. • Front—rectangular pad, under the axle tube, inside each front tire (Figure 36). g003995 Figure 37 1. Bypass valve 2. Important: Running the engine with the bypass valve open causes the transmission to overheat. g031850 Figure 36 1. Front jacking point • Rear—rectangular axle tube on the rear axle.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Maintenance Safety • If possible, do not perform maintenance while the • Before you leave the operator’s position, do the • following: – Park the machine on a level surface. • – Disengage the cutting unit(s) and lower the attachments. • – Engage the parking brake. • • – Shut off the engine and remove the key (if equipped). – Wait for all movement to stop.
Maintenance Service Interval Maintenance Procedure Every 400 hours • Service the air cleaner. (Service the air cleaner earlier if the air-cleaner indicator shows red. Service it more frequently in extremely dirty or dusty conditions.) • Check the fuel lines and connections for deterioration, damage, or loose connections. • Replace the fuel filter canister. • Check the engine speed (idle and full throttle). Every 800 hours • Drain and clean the fuel tank. • Check the rear wheel toe-in.
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 fluid level. Check the hydraulic filter indicator.
Lubrication • Lift-arm pivots (1 each) (Figure 39) • Cutting unit carrier frame and pivot (2 each) (Figure 40) 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. Lubricate the bearings and bushings immediately after every washing, regardless of the interval listed.
• Axle steering pivot (1) (Figure 43) g004169 Figure 43 • Steering-cylinder-ball joints (2) (Figure 44) g003987 Figure 42 g003966 Figure 44 • Brake pedal (1) (Figure 45) g011615 Figure 45 35
Engine Maintenance Cleaning of the used element is not recommended due to the possibility of damage to the filter media. Inspect the new filter for shipping damage, checking the sealing end of the filter and the body. Do not use a damaged element. Insert the new filter by applying pressure to the outer rim of the element to seat it in the canister. Do not apply pressure to the flexible center of the filter. Engine Safety • Shut off the engine before checking the oil or adding oil to the crankcase.
1. Park the machine on a level surface, shut off the engine, set the parking brake, and remove the key from the ignition switch. 2. Open the hood. 3. Remove the dipstick, wipe it clean, and install it (Figure 48). g004134 Figure 49 1. Oil-fill cap Important: Do not overfill. Be sure to keep the engine-oil level between the upper and lower limits on the oil gauge. Engine failure may occur as a result of over filling or under filling the engine oil. g003950 Figure 48 1. Dipstick 6. 4.
3. Adjusting the Throttle Remove the oil filter (Figure 51). 1. Position the throttle lever forward so it is approximately 3 mm (1/8 inch) from the front of the control arm slot. 2. Loosen the throttle cable connector, on the throttle cable, next to the injection-pump lever (Figure 52). g007917 g003971 Figure 52 Figure 51 1. Oil filter 4. 5. Apply a light coat of clean oil to the new filter seal. Install the replacement oil filter to the filter adapter.
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. g007367 Figure 53 1. Filter canister • Do not fill the fuel tank completely full.
Bleeding Air from the Fuel Injectors Electrical System Maintenance Note: This procedure should be used only if the fuel system has been purged of air through normal priming procedures and the engine does not start; refer to Bleeding the Fuel System (page 25). Important: Before welding on the machine, 1. 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.
Checking the Fuses Drive System Maintenance There are 8 fuses in the electrical system. The fuse block is located behind the control-arm-access panel (Figure 55). Checking the Tire Pressure Service Interval: Before each use or daily Check the tire pressure. The correct air pressure in the front and rear tires is 83 to 103 kPa (12 to 15 psi). DANGER Low tire pressure decreases machine side hill stability. This could cause a rollover, which may result in personal injury or death.
g004136 Figure 58 1. Jam nut 2. Tie rod g004147 3. Wrench slot Figure 57 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 6 mm (1/4 inch) of the distance measured at the rear of the wheels. 5. Repeat procedure as required.
Cooling System Maintenance Cooling System Safety • Swallowing engine coolant can cause poisoning; keep out of reach from children and pets. • Discharge of hot, pressurized coolant or touching a hot radiator and surrounding parts can cause severe burns. – Always allow the engine to cool at least 15 minutes before removing the radiator cap. – Use a rag when opening the radiator cap, and open the cap slowly to allow steam to escape. g003951 Figure 59 Checking the Cooling System 1.
g004138 g004137 Figure 60 1. Rear-screen latch Figure 62 2. Rear screen 1. Radiator 4. Clean the screen thoroughly with compressed air. 7. Pivot the oil cooler back into position and secure the latches. 5. Pivot the latches inward to release the oil cooler (Figure 61). 8. Close the screen and secure the latch. g003974 Figure 61 1. Oil cooler 6. 2. Oil cooler latches Thoroughly clean both sides of the oil cooler and the radiator (Figure 62) with compressed air.
Brake Maintenance Note: Ensure that the cable conduit does not rotate during the tightening procedure. Adjusting the Parking Brakes Adjusting the Parking-Brake Latch Adjust the brakes when there is more than 2.5 cm (1 inch) of free travel (Figure 63) of the brake pedal, or when more holding force is required. Free travel is the distance the brake pedal moves before you feel braking resistance. If the parking brake fails to engage and latch, an adjustment to the brake pawl is required. 1.
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. Hydraulic System Safety Tensioning the Alternator Belt • Seek immediate medical attention if fluid is injected into skin. Injected fluid must be surgically removed within a few hours by a doctor. • Ensure that all hydraulic-fluid hoses and lines are 1. Open the hood. 2.
products only from reputable manufacturers who will stand behind their recommendation. High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46 Material Properties: Viscosity, ASTM D445 cSt @ 40°C (104°F) 44 to 48 140 or higher Viscosity Index ASTM D2270 g021215 Figure 67 1. Hydraulic-tank cap 3. Remove the cap/dipstick from the filler neck and wipe it with a clean rag. 4. Insert the dipstick into the filler neck; then remove it and check level of fluid.
1. Park the machine on a level surface, lower the cutting units, engage the parking brake, shut off the engine, and remove the key. Replacing the Hydraulic Filters 2. Raise the hood. 3. Place a large drain pan under the fitting secured to the bottom of the hydraulic-fluid reservoir (Figure 68). Service Interval: Every 1,000 hours—If you are using the recommended hydraulic fluid, replace the hydraulic filters.
Using the Hydraulic System Test Ports Use the hydraulic system test ports to test the pressure in the hydraulic circuits. Contact your local Toro distributor for assistance. Use the test ports on the front hydraulic tubes (Figure 72) to assist in troubleshooting the traction circuit. g003980 Figure 70 1. Hydraulic filter g031993 Figure 72 1. Traction-circuit-test port Use the test ports on the mow manifold block (Figure 73) to assist in troubleshooting the mow circuit. g004150 Figure 71 1.
Cutting Unit System Maintenance Blade Safety • A worn or damaged blade or bedknife can break, and a piece could be thrown toward you or bystanders, resulting in serious personal injury or death. Inspect the cutting units periodically for excessive wear or damage. Use care when checking the cutting units. Wrap the blades or wear gloves, and use caution when servicing the reels and bedknives. Only replace or sharpen the reels and bedknives; never straighten or weld them.
3. Make initial reel to bedknife adjustments appropriate for backlapping on all cutting units which are to be backlapped; refer to the cutting unit Operator's Manual. 4. Start the engine and run at low idle speed. DANGER Changing the engine speed while backlapping may cause the reels to stall. • Never change the engine speed while backlapping. • Only backlap at idle engine speed. 5. Select either front, rear, or both backlap levers to determine which units to backlap (Figure 75).
Cleaning Storage Washing the Machine Storage Safety • Shut off the engine, remove the key (if equipped), Wash the machine as needed using water alone or with a mild detergent. You may use a rag when washing the machine. Important: Do not use brackish or reclaimed water to clean the machine. and wait for all movement to stop before you leave the operator’s position. Allow the machine to cool before adjusting, servicing, cleaning, or storing it.
6. Flush the fuel tank with fresh, clean fuel. 7. Secure all of the fuel-system fittings. 8. Thoroughly clean and service the air-cleaner assembly. 9. Seal the air-cleaner inlet and the exhaust outlet with weatherproof tape. 10. Check the antifreeze protection and add a 50/50 solution of water and ethylene glycol antifreeze as needed for the expected minimum temperature in your area.
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The Toro Warranty Two-Year or 1,500 Hours 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 2 years or 1,500 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).
