Form No. 3406-284 Rev A Reelmaster® 5210/5410/5510/5610 Traction Unit Model No. Model No. Model No. Model No. Register at www.Toro.com. Original Instructions (EN) 03660—Serial No. 03670—Serial No. 03680—Serial No. 03690—Serial No.
This product complies with all relevant European directives, for details please see the separate product specific Declaration of Conformity (DOC) sheet. Figure 1 WARNING 1. Safety alert symbol CALIFORNIA Proposition 65 Warning This product contains a chemical or chemicals known to the State of California to cause cancer, birth defects, or reproductive harm. Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
Safety Operating Tips ......................................................38 Maintenance .................................................................40 Recommended Maintenance Schedule(s) ......................40 Daily Maintenance Checklist ....................................41 Service Interval Chart .............................................42 Lubrication ...............................................................42 Greasing the Bearings and Bushings ..........................
Preparation • Use care when pulling loads or using heavy equipment. • Watch out for traffic when crossing or near roadways. • Stop the blades rotating before crossing surfaces other • 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.
• Never store the equipment with fuel in the tank inside a WARNING building where fumes may reach an open flame or spark. Engine exhaust contains carbon monoxide, which is an odorless, deadly poison that can kill you. • Allow the engine to cool before storing in any enclosure. • To reduce the fire hazard, keep the engine, Do not run engine indoors or in an enclosed area. silencer/muffler, battery compartment and fuel storage area free of grass, leaves, or excessive grease.
sufficient force to penetrate the skin and cause serious injury. Seek immediate medical attention if fluid is injected into skin. • Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved by stopping the engine and lowering the cutting units and attachments to the ground. • Check all fuel lines for tightness and wear on a regular basis. Tighten or repair them as needed.
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. 108-5278 1. Read the Operator's Manual. 106-6754 1. Warning—do not touch the hot surface. 2. Cutting/dismemberment hazard, fan and entanglement hazard, belt—stay away from moving parts. 93-7272 1. Cutting/dismemberment hazard; fan—stay away fro moving parts. 110-0986 93–6696 1.
110-8921 110-8924 1. Warning—read the Operator's Manual and receive training. 1. Traction unit speed 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. 2. Slow 3. Fast 4. Tipping hazard—slow machine before turning, do not turn at high speeds; lower the cutting unit when driving down slopes. 5.
110-0998 1. Headlights 5. Reels raised and off 2. Reels—enabled 3. Reels disabled—lift only 6. Throttle—fast 7. Throttle—slow 4. Reels lowered and on when enabled—forward and backlap 8. Read the Operator’s Manual.
110-0996 (Use for Models 5510 & 5610 with 7 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 110-8923 (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.
0-0990 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.
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 11 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. Install the cutting units No parts required Rear weights (size varies with configuration). – 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. 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. Retaining brackets 2. Rotate the control arm to the desired position and tighten the 2 bolts. 3. Repeat the procedure on the other step.
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). Note: When installing or removing the cutting units, make sure the hairpin cotter is installed in the spring rod hole next to the rod bracket. Otherwise, the hairpin cotter must be installed in the hole in the end of the rod. Figure 4 1.
Figure 10 1. Lift arm chain 2. Chain bracket 13. Coat the spline shaft of the reel motor with clean grease. Figure 8 1. Lift arm 14. Oil the reel motor O-ring and install it onto the motor flange. 3. Lift arm pivot yoke 2. Carrier frame shaft 15. Install the motor by rotating it clockwise so that the motor flanges clear the capscrews (Figure 11). Rotate the motor counterclockwise until the flanges encircle the capscrews then tighten the capscrews. 9.
5 Adjusting the Turf Compensation Spring No Parts Required Procedure The turf compensation spring (Figure 12) transfers weight from the front to the rear roller. (This helps to reduce a wave pattern in the turf, also known as marcelling or bobbing.) Important: Make spring adjustments with the cutting unit mounted to the traction unit, pointing straight ahead and lowered to the shop floor. 1. Make sure the hairpin cotter is installed in the rear hole in the spring rod (Figure 12). Figure 12 1.
6 Installing Rear Weights Parts needed for this procedure: Varies Rear weights (size varies with configuration). Procedure The Reelmaster 5410/5510 and 5610 Traction Units comply with CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-2004 Standards when equipped with rear weights and/or 90 lb of calcium chloride ballast is added to rear wheels. Use the following charts to determine the combinations of weights required for your configuration.
Use the following chart to determine the rear weight requirements when a 4 Post ROPS Conversion Kit is added.
Use the following chart to determine the rear weight requirements when the traction unit is also equipped with a Sunshade Canopy on a 2 Post ROPS.
Figure 13 1. Weight 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 14. Figure 14 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 14a).
7 Install the CE Decals Parts needed for this procedure: 1 Decal-CE 1 Safety decal-CE Procedure 1. For CE compliance, affix the CE decal, part no. 93–7252, onto the left frame rail of the traction unit. Figure 15 2. For CE compliance, affix the CE safety decal, part no. 110–8986, over existing decal part no. 110–8924. 1. Rubber grommet Note: Safety decal, part no. 110–8986, includes a slope warning required on the machine for compliance to the European Lawn Mower Safety Standard EN836:1997.
9 Using the Cutting Unit Kickstand Parts needed for this procedure: 1 Cutting unit kickstand Procedure Whenever the cutting unit has to be tipped to expose the bedknife/reel, prop up the rear of the cutting unit with the kickstand to make sure the nuts on the back end of the bedbar adjusting screws are not resting on the work surface (Figure 17). Figure 18 1. Chain bracket 3. Cutting unit kickstand 2.
Product Overview Figure 19 1. Gauge bar 2. Height adjusting screw Figure 20 4. Holes used for setting Groomer HOG 5. Hole not used 3. Nut 1. Engine hood 5. Seat 2. Operator's seat 6. Front cutting units 3. Control arm 7. Rear cutting units 4. Steering wheel 11 Controls Seat Adjusting Knobs Reading the Manual and Viewing the Safety Video The seat adjusting lever (Figure 21) allows you to adjust the seat fore and aft. The weight adjusting knob adjusts the seat for the operator's weight.
5 speed, fully press the pedal while the throttle is in the Fast position. 6 7 8 4 To stop, reduce foot pressure on the traction pedal and allow it to return to the center position. 9 10 3 2 1 G003956 Figure 23 Figure 22 1. Traction pedal 4. Brake pedal 2. Mow speed limiter 5. Parking brake 3. Spacers 6. Tilt steering pedal 1. Throttle control 6. Engine coolant temperature gauge 2. Enable/disable switch 7. Engine oil pressure warning light 3. Glow plug indicator light 8.
Lower Mow/Raise Control Lever This lever (Figure 23) raises and lowers the cutting units and also starts and stops the cutterheads when the cutterheads are enabled in the mow mode. Glow Plug Indicator Light This light (Figure 23) illuminates when the glow plugs are preheating. Engine Oil Pressure Warning Light This light (Figure 23) indicates dangerously low engine oil pressure. Figure 25 Charge Indicator 1.
Power Point The power point is a 12 volt power supply for electronic devices (Figure 29). Figure 27 Figure 29 1. Fuel tank cap 1. Power point 2. Fuel gauge Headlight Switch Pivot the switch downward to turn on the headlights (Figure 28). Figure 28 1.
Specifications Note: Specifications and design are subject to change without notice.
Operation Note: Determine the left and right sides of the machine from the normal operating position. 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.
Checking the Cooling System Filling the Fuel Tank Clean debris off of the screen, oil cooler, and front of the radiator daily and more often if conditions are extremely dusty and dirty. Refer to the section on Removing Debris from the Cooling System in Cooling System Maintenance (page 50). Fuel tank capacity 13.5 gallons (51 l). 1. Remove the fuel tank cap (Figure 33). The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol antifreeze.
Checking the Hydraulic Fluid The machines reservoir is filled at the factory with approximately 8 U.S. gallons (30 l) 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: Toro Premium All Season Hydraulic Fluid (Available in 5 gallon pails or 55 gallon drums. See parts catalog or Toro distributor for part numbers.
Figure 35 1. Hydraulic tank cap 4. Remove dipstick from filler neck and wipe it with a clean rag. Insert dipstick into filler neck; then remove it and check level of fluid. Fluid level should be 1/4 inch of mark on dipstick. Do not overfill. 5. If level is low, add appropriate fluid to raise level to full mark. 6. Install dipstick and cap onto filler neck.
Bleeding the Fuel System You must bleed the fuel system before starting the engine if any of the following situations have occurred: • Initial start up of a new machine. • Engine has ceased running due to lack of fuel. • Maintenance has been performed upon fuel system components; i.e., filter replaced, separator serviced, etc. 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.
2. Choose the desired ground speed best suited for conditions. Crank the engine for no longer than 15 seconds. Release the key when the engine starts. If additional preheating is required, turn key to the Off position and then to the On/Preheat position. Repeat this process as required. 3.
Figure 39 1. Front reels circuit controls 3. Reel—mow and backlap 5. Reel—height-of-cut 2. Rear reels circuit controls 4. Read the Operator's Manual. 6. Traction unit 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. 1 You can adjust each counterbalance spring to one of four settings.
Important: Running the engine with the bypass valve open will cause the transmission to overheat. Jacking Points Note: Use jack stands to support the machine when required. • Front—rectangular pad, under the axle tube, inside each front tire (Figure 43). Figure 41 1. Switch 2. Lift arm sensing device Pushing or Towing the Machine In an emergency, the machine can be moved by actuating the bypass valve in the variable displacement hydraulic pump and pushing or towing the machine.
Tie Downs 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.
Important: The Diagnostic ACE display must not be left connected to the machine. It is not designed to withstand the environment of the machine's every day use. When done using the Diagnostic ACE, disconnect it from the machine and connect loop-back connector to harness connector. The machine will not operate without loopback connector installed on the harness. Store the Diagnostic ACE in dry, secure location in the shop, not on the machine. will blink on and off when corresponding switch is closed.
Transport Move the Enable/Disable switch to the Disable position and raise the cutting units to the transport position. Move the Mow/Transport lever to the transport position. Be careful when driving between objects so you do not accidentally damage the machine or cutting units. Use extra care when operating the machine on slopes. Drive slowly and avoid sharp turns on slopes to prevent roll overs. Lower the cutting units when going downhill for steering control.
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. For the week of: Mon. Maintenance Check Item Tues. Wed. Thurs. Check the safety interlock operation. Check the brake operation. Check the engine oil and fuel level. Drain the water/fuel separator. Check the air filter restriction indicator. Check the radiator and screen for debris. Check unusual engine noises.1 Check unusual operating noises. Check the hydraulic system oil level. Check the hydraulic filter indicator.
Service Interval Chart Figure 49 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 pivot shaft (1 each) (Figure 53) • Axle steering pivot (1) (Figure 55) Figure 53 Figure 55 • Rear axle tie rod (2) (Figure 54) • Steering cylinder ball joints (2) (Figure 56) Figure 56 • Brake pedal (1) (Figure 57) Figure 54 Figure 57 43
Engine Maintenance Servicing the Air Cleaner Check the air cleaner body for damage which could cause an air leak. Replace if damaged. Check the whole intake system for leaks, damage or loose hose clamps. Service the air cleaner filter only when the service indicator (Figure 58) requires it. Changing the air filter before it is necessary only increases the chance of dirt entering the engine when the filter is removed.
Figure 61 Figure 62 1. Oil filter 1. Injection pump arm 3. High idle stop 2. Throttle cable connector 4. Apply a light coat of clean oil to the new filter seal. 3. Hold the injection pump lever arm against the high idle stop and tighten the cable connector. 5. Install the replacement oil filter to the filter adapter. Turn the oil filter clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 1/2 turn.
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. • Do not fill the fuel tank completely full. Add fuel to the fuel tank until the level is 1/4 to 1/2 in. (6 to 13 mm) below the bottom of the filler neck.
3. Tighten the pipe connector securely. 4. Repeat steps 1 through 3 on the remaining nozzles. Figure 64 2. Clamp both fuel lines that connect to the fuel filter so that the fuel cannot drain when you remove the lines. 3. Loosen the hose clamps at both ends of the filter and pull the fuel lines off. 4. Slide the hose clamps onto ends of the fuel lines. 5. Push the fuel lines onto the new filter and secure them with the hose clamps.
Fuses Electrical System Maintenance There are 8 fuses in the electrical system. The fuse block (Figure 66) 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. Disconnect the left brake cable from the brake pedal (Figure 68) and set the parking brake. Figure 69 1. Locknut 2.
Cooling System Maintenance Removing Debris from the Cooling System Remove debris from the screen, oil coolers, and radiator daily (clean more frequently in dirty conditions). 1. Turn the engine off and remove the key from the ignition switch. 2. Thoroughly clean all debris out of the engine area. Figure 70 1. Jam nut 2. Tie rod 3. Unlatch the clamp and pivot open the rear screen (Figure 71). 3. Wrench slot 3. Using the wrench slot, rotate the tie rod 4.
Brake Maintenance Adjusting the Service Brakes Adjust the service brakes when there is more than 1 inch of free travel of the brake pedal, or when the brakes do not work effectively. Free travel is the distance the brake pedal moves before you feel braking resistance. 1. To reduce free travel of the brake pedals, tighten the brakes by loosening the front nut on the threaded end of the brake cable (Figure 74). Figure 72 1. Oil cooler 2. Oil cooler latches 6.
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.
Hydraulic System Maintenance 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. Contaminated fluid looks milky or black when compared to clean oil. 1. Stop the engine and raise the hood. 2.
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.
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 General Commercial Products Warranty A Two-Year Limited Warranty Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial Product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first.
