Form No. 3376-894 Rev B Reelmaster® 5410-D and 5510-D Traction Units Model No. 03672—Serial No. 313000001 and Up Model No. 03687—Serial No. 313000001 and Up Register at www.Toro.com.
Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready. The model and serial numbers are on a plate mounted on the left side of the frame under the foot rest. Write the numbers in the space provided. This product complies with all relevant European directives, for details please see the separate product specific Declaration of Conformity (DOC) sheet.
Contents Checking the Fuel Lines and Connections.................................................. 50 Fuel Pick-up Tube Screen................................. 50 Electrical System Maintenance ........................... 51 Servicing the Battery......................................... 51 Fuses................................................................ 51 Drive System Maintenance .................................. 52 Adjusting the Traction Drive for Neutral .............
Preparation Safety • 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. Do not operate the equipment when barefoot or wearing open sandals. Improper use or maintenance by the operator or owner can result in injury.
• Slow down and use caution when making – 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. • Watch out for traffic when crossing or near • roadways. • Stop the blades rotating before crossing surfaces • other than grass.
• Raise the cutting units when driving from one work • Use care when checking the cylinders/reels. Wear area to another. gloves and use caution when servicing them. • Keep hands and feet away from moving parts. If • Do not touch the engine, silencer/muffler, or possible, do not make adjustments with the engine running. exhaust pipe while the engine is running or soon after it has stopped because these areas could be hot enough to cause burns.
Sound Power Level This unit has a guaranteed sound power level of 103 dBA, which includes an Uncertainty Value (K) of 1 dBA. Sound power level was determined according to the procedures outlined in ISO 11094. Sound Pressure Level This unit has a sound pressure level at the operator’s ear of 86 dBA, which includes an Uncertainty Value (K) of 1 dBA. Sound pressure level was determined according to the procedures outlined in EN 836. Vibration Level Hand-Arm Measured vibration level for right hand = .
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. decal93-7272 93-7272 1. Cutting/dismemberment—hazard, fan-stay away from moving parts. decal106-6755 106-6755 1. Engine coolant under pressure. 3. Warning—do not touch the hot surface. 2. Explosion hazard—read the Operator's Manual. 4. Warning—read the Operator's Manual. decal93-6696 93–6696 1.
r:\decal110-8869 110-8869 1. Warning—read the Operator's Manual, do not operate this machine unless you are trained. 2. Thrown object hazard—keep bystanders a safe distance from the machine. 3. Tipping hazard—slow machine before turning, do not turn at high speeds; lower the cutting unit when driving down slopes; use a roll over protection system and wear the seat belt. Always wear a seat belt when a ROPS is in place. r:\decal117-0169 4.
decal110-8924 110-8924 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.
decal125-2927 125–2927 1. Read the Operator’s Manual for maintenance information.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description 1 2 3 4 5 6 Use Qty. No parts required – Adjust the tire pressure. No parts required – Adjust the step height. No parts required – Adjust the control arm position. Front hose guide-R.H. Front hose guide-L.H. 1 1 Install the cutting units No parts required – Adjust the turf compensation spring. Cutting unit kickstand 1 Install the Cutting Unit Kickstand.
1 2. Raise or lower the step to the desired height and re-secure the brackets to the frame with the 2 bolts and nuts. 3. Repeat the procedure on the other step. Adjusting the Tire Pressure 3 No Parts Required Adjusting the Control Arm Position Procedure The tires are over-inflated for shipping. Therefore, release some of the air to reduce the pressure. Correct air pressure in the front and rear tires is 83 to 103 kPa (12 to 15 psi).
4 Installing the Cutting Units g003949 Parts needed for this procedure: 1 1 Figure 5 Front hose guide-R.H. 1. Turf compensation spring Front hose guide-L.H. 2. Rod bracket Procedure 1. Remove the reel motors from the shipping brackets. 2. Remove the shipping brackets and discard. 3. Remove the cutting units from the cartons. Assemble and adjust as described in the cutting unit Operator's Manual. 4.
g015160 Figure 8 1. Hose guide (#4 cutting unit 3. Nuts shown) 2. Rod bracket g019284 Figure 9 1. Hose guides (each must lean toward the center 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. When not installing or removing the cutting units, the hairpin cotter must be installed in the hole in the end of the rod. 6. Lower all the lift arms completely. 7.
g003979 Figure 12 1. Lift arm pivot shaft lynch pin and washer g003975 Figure 10 1. Snapper pin 8. B. Insert the lift arm yoke onto the carrier frame shaft (Figure 11). C. Insert the lift arm shaft into the lift arm and secure it with the washer and lynch pin (Figure 12). 2. Cap For the front cutting units, slide a cutting unit under the lift arm while inserting the carrier frame shaft up into the lift arm pivot yoke (Figure 11). 10. Insert the cap over the carrier frame shaft and lift arm yoke.
Important: Make sure 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. Hair pin cotter 4. Hex nuts 2. Tighten the hex nuts on the front end of the spring rod until the compressed length of the spring is 12.7 cm (5 inches) on Reelmaster 5410, 5 inch cutting units or 15.9 cm (6.25 inches) on Reelmaster 5510, 7 inch cutting units (Figure 15). g004127 Figure 14 1. Reel drive motor 2.
Product Overview g003985 g003945 Figure 16 Figure 18 1. Cutting unit kickstand Secure the kickstand to the chain bracket with the snapper pin (Figure 17). 1. Engine hood 5. Seat 2. Operator's seat 6. Front cutting units 3. Control arm 7. Rear cutting units 4. Steering wheel Controls Seat Adjusting Knobs The seat adjusting lever (Figure 19) allows you to adjust the seat fore and aft. The weight adjusting knob adjusts the seat for the operator's weight.
Traction Pedal Tilt Steering Pedal The traction pedal (Figure 20) 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 engine speed setting is in the Fast position.
Hydraulic Filter Restriction Indicator Lower Mow/Raise Control Lever This lever (Figure 21) raises and lowers the cutting units and also starts and stops the cutterheads when the cutterheads are enabled in the mow mode. The cutter heads cannot be lowered when the mow/transport lever is in the transport position. With the engine running at normal operating temperature, view the indicator (Figure 23), it should be in the Green zone. When the indicator is in the Red zone, change the hydraulic filters.
Using the InfoCenter LCD Display InfoCenter Icon Description SERVICE DUE The InfoCenter LCD display shows information about your machine such as the operating status, various diagnostics and other information about the machine (Figure 25) There is a splash screen and main information screen of the InfoCenter. You can switch between the splash screen and main information screen, at any time, by pressing any of the InfoCenter buttons and then selecting the appropriate directional arrow.
InfoCenter Icon Description (cont'd.) Main Menu Menu Item Description Faults The Faults menu contains a list of the recent machine faults. Refer to the Service Manual or your Authorized Toro Distributor for more information on the Faults menu and the information contained there. Service The Service menu contains information on the machine such as hours of use counters and other similar numbers. Diagnostics The Diagnostics menu displays the state of each machine switch, sensor and control output.
Protected Menus Settings Menu Item Description Units Controls the units used on the InfoCenter. The menu choices are English or Metric Language Controls the language used on the InfoCenter*. LCD Backlight Controls the brightness of the LCD display. LCD Contrast Controls the contrast of the LCD display. Front Backlap Reel Speed Controls the speed of the front reels in backlap mode. Rear Backlap Reel Speed Controls the speed of the rear reels in backlap mode.
To Set the Auto Idle • In the Settings Menu, scroll down to Auto Idle. • Press the right button to change the auto idle time between OFF, 8S, 10S, 15S, 20S, & 30S. To Set the Blade Count • In the Settings Menu, scroll down to Blade Count • Press the right button to change the blade count between 5, 8 or 11 blade reels. To Set the Mow Speed • In the Settings Menu, scroll down to Mow Speed. • Press the right button to select mow speed.
Specifications Note: Specifications and design are subject to change without notice.
Operation DANGER In certain conditions during fueling, static electricity can be released, causing a spark that can ignite the fuel vapors. A fire or explosion from fuel can burn you and others and can damage property. • Always place fuel containers on the ground away from your vehicle before filling. • Do not fill fuel containers inside a vehicle or on a truck or trailer bed, because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge.
Petroleum Diesel Fuel Tank Capacity Cetane rating: 45 or higher 53 L (14 US gallons) Sulfur content: Ultra-low sulfur (<15 ppm) Adding Fuel Fuel Table Diesel fuel specification Location ASTM D975 No. 1-D S15 1. Park the machine on a level surface. 2. Using a clean rag, clean area around fuel-tank cap. 3. Remove the cap from the fuel tank (Figure 28). USA No. 2-D S15 EN 590 European Union ISO 8217 DMX International JIS K2204 Grade No.
Checking the Hydraulic Fluid CAUTION If the engine has been running, the pressurized, hot coolant can escape and cause burns. The machines reservoir is filled at the factory with approximately 30 liters (8 U.S. gallons) of high quality hydraulic fluid. Check the level of the hydraulic fluid before the engine is first started and daily thereafter. The recommended replacement fluid is as follows: • Do not open the radiator cap when the engine is running.
Toro distributor. This red dye is not recommended for use with biodegradable fluids. Use food coloring. 1. Position machine on a level surface, lower the cutting units and stop the engine. 2. Clean area around filler neck and cap of hydraulic tank (Figure 30). Remove cap from filler neck. WARNING Failure to maintain proper torque of the wheel nuts could result in personal injury.
3. Diesel Particulate Filter Regeneration Press the right button to change the reel speed value. As the speed setting is changed, the display will continue to show the calculated reel speed based on blade count, mow speed and HOC, but the new value will also be displayed. The diesel particulate filter (DPF) is part of the exhaust system. The diesel-oxidation catalyst of the DPF reduces harmful gasses and the soot filter removes soot from the engine exhaust.
DPF Soot Accumulation • DPF regeneration is a process that heats the DPF to convert the soot to ash. • Over time, the DPF accumulates soot in the soot • In addition to the warning messages, the computer filter. The computer for the engine monitors the soot level in the DPF. reduces the power produced by the engine at different soot-accumulation levels. • When enough soot accumulates, the computer informs you that it is time to regenerate the diesel particulate filter.
DPF Ash Accumulation • When enough ash accumulates, the engine • The lighter ash is discharged through the exhaust system; the heavier ash collects in the soot filter. • Ash is a residue of the regeneration process. Over • time, the diesel particulate filter accumulates ash that does not discharge with the engine exhaust. • • The computer for the engine calculates the amount of ash accumulated in the DPF.
Types of Diesel Particulate Filter Regeneration Types of diesel particulate filter regeneration that are performed while the machine is operating: Type of Regeneration Conditions for DPF regeneration DPF description of operation Passive Occurs during normal operation of the machine at high-engine speed or high-engine load The InfoCenter does not display an icon indicating passive regeneration.
Types of diesel particulate filter regeneration that require you to park the machine: (cont'd.) Type of Regeneration Conditions for DPF regeneration DPF description of operation Recovery Occurs as a result of ignoring parked regeneration requests and continuing operation, adding more soot when the DPF is already in need of a parked regeneration When the recovery-regeneration icon is displayed in the InfoCenter, a recovery regeneration is requested.
Parked Regeneration Reset Regeneration g214713 g214711 Figure 38 Assist/reset-regeneration icon Figure 39 Parked-regeneration request icon • The assist/reset-regeneration icon displays in the • The parked-regeneration requested icon displays in the InfoCenter (Figure 39). If a parked regeneration is needed, the InfoCenter displays engine warning SPN 3719, FMI 16 (Figure 40) and the engine computer derates engine power to 85%. InfoCenter (Figure 38).
6. Engage the parking brake. 7. Set the throttle to the low IDLE position. Performing a Parked Regeneration Note: For instructions on unlocking protected menus, refer to Accessing Protected Menus (page 23). 1. Access the protected menu and unlock the protected settings submenu (Figure 41); refer to Accessing Protected Menus (page 23). g212138 Figure 43 4. When the “Initiate DPF Regen. Are you sure?” message displays, press the center button (Figure 44). g028523 Figure 41 2.
g211986 g212405 Figure 45 6. Figure 47 Move the throttle control to LOW IDLE and press the center button (Figure 46). B. The “Waiting on (Figure 48). ” message displays g212372 g212406 Figure 46 7. Figure 48 The following messages display as the parked regeneration process begins: A. C. The “Initiating DPF Regen.” message displays (Figure 47). The computer determines whether the regeneration runs.
The engine is cold—wait. The engine is warm—wait. The engine hot—regeneration in progress (percent complete). 9. g213424 The parked regeneration is complete when the “Regen Complete” message displays in the InfoCenter. Press the left button to exit to the home screen (Figure 51). Figure 49 • If the regeneration process is not allowed by the engine computer, the “DPF Regen Not Allowed” message displays in the InfoCenter (Figure 50).
Adjusting the Lift Arm Turn Around Position • Perform a recovery-regeneration whenever there is a loss of engine power and a parked regeneration cannot effectively clean the DPF of soot. • A recovery regeneration requires up to 4 hours 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 54). 3.
Tie Downs • Front—the hole in the rectangular pad, under the axle tube, inside each front tire (Figure 57). g003995 Figure 55 1. Bypass valve 2. Close the bypass valve before starting the engine. However, do not exceed 7-11 N-m. (5-8 ft.-lb) torque to close the valve. g004558 Important: Running the engine with Figure 57 the bypass valve open will cause the transmission to overheat. 1. Front tie down • Rear—each side of the machine on the rear frame Jacking Points (Figure 58).
Understanding the Diagnostic Light Verifying the Interlock Switch Function The machine is equipped with a diagnostic light which indicates if the machine detects a malfunction. The diagnostic light is located on the InfoCenter, above the display screen (Figure 59). When the machine is functioning properly and the key switch is moved to the On/Run position, the diagnostic light will turn on briefly to indicate the light is working properly.
Hydraulic Valve Solenoid Functions Use the list below to identify and describe the different functions of the solenoids in the hydraulic manifold. Each solenoid must be energized to allow function to occur. Function Solenoid SP2 Front reel circuit SP1 Rear reel circuit SVRV Lift/lower cutting units SV1 Lift/lower front cutting units SV3 Lift/lower rear cutting units SV2 Raise any cutting units Operating Tips Familiarization Before mowing grass, practice operating the machine in an open area.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first hour • Torque the wheel lug nuts to 94 to 122 N-m (70 to 90 ft-lb). After the first 10 hours • Torque the wheel lug nuts to 94 to 122 N-m (70 to 90 ft-lb). • Check the alternator belt tension. Before each use or daily • • • • • • Check the cooling system. Check the hydraulic fluid level.
Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Mon. Maintenance Check Item Tues. Wed. Thurs. Fri. Sat. Check the safety interlock operation. Check the brake operation. Check the engine oil and fuel level. Drain the water/fuel separator. Check the air filter restriction indicator. Check the radiator and screen for debris. Check unusual engine noises.1 Check unusual operating noises. Check the hydraulic system oil level. Check the hydraulic filter indicator.
Service Interval Chart decal125-2927 Figure 60 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 62) • Axle steering pivot (1) (Figure 66) • Cutting unit carrier frame and pivot (2 each) (Figure 63) g004169 Figure 66 • Steering cylinder ball joints (2) (Figure 67) g003960 Figure 63 • Lift arm pivot shaft (1 each) (Figure 64) g003966 Figure 67 g004157 Figure 64 • Brake pedal (1) (Figure 68) • Rear axle tie rod (2) (Figure 65) g011615 Figure 68 g003987 Figure 65 46
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. g021218 Figure 70 Service the air cleaner filter only when the service indicator (Figure 69) requires it. Changing the air filter before it is necessary only increases the chance of dirt entering the engine when the filter is removed. 1. Air cleaner cover 2. Air cleaner filter 3.
Checking the Engine-Oil Level Crankcase Oil Capacity Service Interval: Before each use or daily 5.2 L (5.5 quarts) Important: Check the engine oil daily. If the engine-oil level is above the Full mark on the dipstick, the engine oil may be diluted with fuel; If the engine oil level is above the Full mark, change the engine oil. Changing the Engine Oil and Filter Service Interval: Every 250 hours Change the oil and filter every 250 hours.
Servicing the Diesel-Oxidation Catalyst (DOC) and the Soot Filter Fuel System Maintenance DANGER Service Interval: Every 6,000 hours or clean the soot filter if engine faults SPN 3720 FMI 16, SPN 3720 FMI 0, or SPN 3720 FMI 16 display in the InfoCenter. • If advisory message ADVISORY 179 displays in the InfoCenter, the DPF is nearing the recommended point for servicing the diesel-oxidation catalyst and the soot filter.
5. Lubricate the gasket on the filter canister with clean oil. 6. Install the filter canister by hand until the gasket contacts mounting surface, then rotate it an additional 1/2 turn. 7. Checking the Fuel Lines and Connections Check the fuel lines and connections every 400 hours or yearly, whichever comes first. Inspect them for deterioration, damage, or loose connections. Tighten the drain plug on the bottom of the filter canister and close the vent on the top of the canister mount.
Fuses Electrical System Maintenance There are 8 fuses in the electrical system. The fuse block (Figure 77) is located behind the control arm access panel. Important: Before welding on the machine, disconnect both cables from the battery, both wire harness plugs from the electronic control module, and the terminal connector from the alternator to prevent damage to the electrical system.
Drive System Maintenance Adjusting the Traction Drive for Neutral The machine must not creep when the traction pedal is released. If it does creep, adjust as follows: 1. Park the machine on a level surface, stop the engine, and lower the cutting units to the floor. 2. Jack up the front of the machine until the front tires are off the shop floor. Support the machine with jack stands to prevent it from falling accidentally. 4.
Cooling System Maintenance Removing Debris from the Cooling System Remove debris from the screen and radiator/oil cooler daily (clean more frequently in dirty conditions). 1. Turn the engine off and remove the key from the ignition switch. 2. Thoroughly clean all debris out of the engine area. 3. Unlatch the clamp and pivot open the rear screen (Figure 81). g021880 Figure 82 1. Radiator/oil cooler 5. g004138 Figure 81 1. Rear screen latch 4. 2.
Brake Maintenance Adjusting the Parking Brake Adjusting the Service Brakes If the parking brake fails to engage, an adjustment to the brake pawl is required. 1. 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. Loosen the 2 screws securing the parking brake pawl to the frame (Figure 84).
Belt Maintenance Hydraulic System Maintenance Servicing the Alternator Belt Changing the Hydraulic Fluid Service Interval: After the first 10 hours Every 100 hours 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. Check the condition and tension of the belt (Figure 85) after every 100 operating hours. 1.
9. Check the level of the hydraulic fluid and add enough to raise level to the Full mark on the dipstick. Important: Do not over-fill. Replacing the Hydraulic Filters The hydraulic system is equipped with a service interval indicator (Figure 87). 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. g004150 Figure 89 1. Hydraulic filter 3. Remove the filter. 4.
Checking the Hydraulic Lines and Hoses Daily, check hydraulic lines and hoses for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration. Make all necessary repairs before operating. WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • 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.
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. g003983 Note: When backlapping, the front units all operate together, and the rear units operate together. Figure 92 1. Lift circuit test port 1.
8. 9. Storage If the reels stall or become erratic while backlapping, select a higher reel speed setting until the speed stabilizes, then return the reel speed to your desired speed. Preparing the Traction Unit To make an adjustment to the cutting units while backlapping, turn the reels off by moving the Lower Mow/Raise lever rearward; the Enable/Disable switch to the Disable position, and stop the engine. After completing adjustments, repeat steps 4 through 8. 1.
Schematics g021293 Hydraulic Schematic, Model 5410 (Rev.
g021222 Hydraulic Schematic, Model 5510 (Rev.
Notes:
Notes:
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).
