Form No. 3362-225 Rev A Reelmaster®5210/5410/5510/5610 Two-Wheel Drive Traction Units Model No. 03660—Serial No. 290000001 and Up Model No. 03670—Serial No. 290000001 and Up Model No. 03680—Serial No. 290000001 and Up Model No. 03690—Serial No. 290000001 and Up Model No. 03691—Serial No. 290000001 and Up To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com.
This manual uses 2 other words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention. Warning CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Contents Introduction................................................................. 2 Safety .....................................
Safety Operating Tips ................................................... 38 Maintenance............................................................... 39 Recommended Maintenance Schedule(s) ................ 39 Daily Maintenance Checklist............................... 40 Service Interval Chart......................................... 41 Lubrication............................................................. 41 Greasing the Bearings and Bushings.................... 41 Engine Maintenance...................
◊ lack of awareness of the effect of ground conditions, especially slopes; ◊ 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. Preparation • 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.
• Reduce the throttle setting during engine run-out and, if the engine is provided with a shut-off valve, turn the fuel off at the conclusion of mowing. • Keep hands and feet away from the cutting units. • Look behind and down before backing up to be sure of a clear path. • Slow down and use caution when making turns and crossing roads and sidewalks. Stop cylinders/reels if not mowing. • Do not operate the mower under the influence of alcohol or drugs.
– Do not drive close to sand traps, ditches, creeks, or other hazards. with a tachometer. Maximum governed engine speed should be 3200 RPM. – Reduce speed when making sharp turns. Avoid sudden stops and starts. • If major repairs are ever needed or if assistance is desired, contact an Authorized Toro Distributor. – When near or crossing roads, always yield the right-of-way. • Use only Toro-approved attachments and replacement parts. The warranty may be voided if used with unapproved attachments.
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. 93- 6696 110-0986 93-6696 1.
110-8921 110-8924 1. Traction unit speed 2. Slow 3. Fast 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.
Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 2. No fire, open flame, or smoking. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 5. Read the Operator’s Manual. 110-0998 1. 2. 3. 4. Headlights Reels—enabled Reels disabled—lift only Reels lowered and on when enabled—forward and backlap 5. 6. 7. 8. Reels raised and off Throttle—fast Throttle—slow Read the Operator’s Manual. 9 6. Keep bystanders a safe distance from the battery. 7.
114–8891 (Use for Models 5510 & 5610 with 7 inch reel cutting units) 1. Front reels circuit controls 2. Rear reels circuit controls 3. Mow and backlap 4. Read the Operator’s Manual. 5. Height-of-cut 6. Traction unit speed 114–8890 (Use for Models 5210 & 5410 with 5 inch reel cutting units) 1. Front reels circuit controls 2. Rear reels circuit controls 3. Mow and backlap 4. Read the Operator’s Manual. 10 5. Height-of-cut 6.
4-0429 1. 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 Description Use Qty. No parts required – Adjust the tire pressure. No parts required – Adjust the step height. No parts required – Adjust the control arm position. Front hose guide-R.H. Front hose guide-L.H. 1 1 Install the cutting units No parts required – Adjust the turf compensation spring. Varies Install rear weights (order from your Toro Distributor).
Figure 2 1. Step 2. Step brackets Figure 3 1. Control arm 2. Retaining brackets 2. Raise or lower the step to the desired height and re-secure the brackets to the frame with the 2 bolts and nuts. 3. Bolts (2) 2. Rotate the control arm to the desired position and tighten the 2 bolts. 3. Repeat the procedure on the other step. 3 4 Adjusting the Control Arm Position Installing the Cutting Units Parts needed for this procedure: No Parts Required Procedure 1 Front hose guide-R.H.
Figure 6 1. Opposite carrier frame tab 2. Rod bracket D. Mount the rod bracket to the cutting unit tabs with the carriage bolts and nuts (Figure 6). Also, on the #4 cutting unit, mount the left hand hose guide to the front of the cutting unit tabs when reinstalling the rod bracket (Figure 7). Note: On the #5 cutting unit, use the rod bracket mounting nuts to install the right hand hose guide to the front of the cutting unit tabs. Figure 4 1. Counter weight 5.
B. Insert the lift arm yoke onto the carrier frame shaft (Figure 9). C. Insert the lift arm shaft into the lift arm and secure it with the washer and lynch pin (Figure 10). 10. Insert the cap over the carrier frame shaft and lift arm yoke. 11. Secure the cap and the carrier frame shaft to the lift arm yoke with the snapper pin. Use the slot if a steering cutting unit is desired or use the hole if the cutting unit is to be locked in position (Figure 8). Figure 8 1. Snapper pin 2. Cap 12.
Figure 13 1. Turf compensation spring 2. Hair pin cotter 3. Spring rod 4. Hex nuts Figure 12 1. Reel drive motor 2. Tighten the hex nuts on the front end of the spring rod until the compressed length of the spring is 5 inches (12.7 cm) on Reelmaster 5210 & 5410, 5 inch cutting units or 6.25 inches (15.9 cm) on Reelmaster 5510 & 5610, 7 inch cutting units (Figure 13). 2. Mounting capscrews 5 Note: When operating on rough terrain decrease the spring length by 1/2 inch.
6 Installing Rear Weights Parts needed for this procedure: Varies Rear weights (size varies with configuration). Procedure The Reelmaster 5210/5410/5510 and 5610 Traction Units comply with CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-2004 Standards when equipped with rear weights and/or 90 lb of calcium chloride ballast is added to rear wheels. Use the following charts to determine the combinations of weights required for your configuration.
Use the following chart to determine the rear weight requirements when a 4 Post ROPS Conversion Kit is added.
Use the following chart to determine the rear weight requirements when the traction unit is also equipped with a Sunshade Canopy on a 2 Post ROPS.
Figure 14 1. Weight 2. Carriage bolt 3. Nut On four wheel drive models, use the following procedure to mount the appropriate amount of weight (see weight charts) to the top or bottom of the rear bumper as shown in Figure 15. Figure 15 1. 2. 3. 4. Traction manifold Spacers Bolts Washers 5. Weight(s) 6. Carriage bolt 7. Nut • Remove the 3 bolts, washers, and spacers securing the traction manifold to the bottom of the rear bumper (Figure 15a).
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 20 1. Gauge bar Figure 19 1. Chain bracket 2. Snapper pin 2. Height adjusting screw 3. Nut 3. Cutting unit kickstand 10 9 Reading the Manual and Viewing the Safety Video Using the Gauge Bar Parts needed for this procedure: 1 4. Holes used for setting Groomer HOG 5. Hole not used Parts needed for this procedure: Gauge bar Procedure Use the gauge bar to adjust the cutting unit. Refer to the Cutting Unit Operator’s Manual for the adjustment procedures (Figure 20).
Product Overview speed depends on how far you press the pedal. For no load, maximum ground speed, fully press the pedal while the throttle is in the Fast position. To stop, reduce foot pressure on the traction pedal and allow it to return to the center position. Figure 21 1. 2. 3. 4. Engine hood Operator’s seat Control arm Steering wheel 5. Seat 6. Front cutting units 7. Rear cutting units Figure 23 Controls 1. Traction pedal 2. Mow speed limiter 3.
Throttle Control Lower Mow/Raise Control Lever Move the throttle control (Figure 24) forward to increase the engine speed and rearward to decrease speed. This lever (Figure 24) raises and lowers the cutting units and also starts and stops the reels when the reels are enabled in the mow mode. Glow Plug Indicator Light This light (Figure 24) illuminates when the glow plugs are preheating. Engine Oil Pressure Warning Light This light (Figure 24) indicates dangerously low engine oil pressure.
Hour Meter Fuel Gauge The hour meter (Figure 26) shows the total hours that the machine has been operated. The fuel gauge (Figure 28) shows the amount of fuel in the tank. Figure 26 1. Hour meter Figure 28 1. Fuel tank cap 2. Fuel gauge Hydraulic Filter Restriction Indicator With the engine running at normal operating temperature, view the indicator (Figure 27), it should be in the Green zone. When the indicator is in the Red zone, change the hydraulic filters.
Power Point The power point is a 12 volt power supply for electronic devices (Figure 30). Figure 30 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. 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. Figure 31 Checking the Engine Oil Level 1.
gauge. Engine failure may occur as a result of over filling or under filling the engine oil. 6. Install the oil fill cap and close the hood. 2. If the coolant level is low, remove the expansion tank cap and replenish the system. Do not overfill. 3. Install the expansion tank cap. Checking the Cooling System Adding Fuel Clean debris off of the screen, oil cooler, and front of the radiator daily and more often if conditions are extremely dusty and dirty.
• Monitor seals, hoses, gaskets in contact with fuel as they may be degraded over time. In certain conditions during fueling, static electricity can be released causing a spark which can ignite the fuel vapors. A fire or explosion from fuel can burn you and others and can damage property. • Fuel filter plugging may be expected for a time after converting to biodiesel blended. • Contact your distributor if you wish for more information on biodiesel.
4. Fill the tank until the level is to the bottom of the filler neck with diesel fuel. by mineral-based hydraulic fluids will change the biodegradability and toxicity of this oil. When changing from standard fluid to the biodegradable type, be certain to follow the approved flushing procedure. Contact your local Toro Distributor for details. 5. Install fuel tank cap tightly after filling tank. Note: If possible, fill the fuel tank after each use.
• 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. 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.
Setting the Reel Speed bleed screw. Leave the key in the On position until a solid stream of fuel flows out around the screw. To achieve a consistent, high quality-of-cut and a uniform after cut appearance, it is important that you set the reel speed controls (located under the seat) correctly. Adjust the reel speed controls as follows: 5. Tighten the screw and turn the key to the Off position. Note: Normally, the engine should start after the above bleeding procedures are followed.
Figure 39 1. Front reels circuit controls 2. Rear reels circuit controls 3. Reel—mow and backlap 4. Read the Operator’s Manual. 5. Reel—height of cut 6. Machine speed Figure 40 1. Front reels circuit controls 2. Rear reels circuit controls 3. Reel—mow and backlap 4. Read the Operator’s Manual. Adjusting the Lift Arm Counterbalance 5. Reel—height of cut 6. Machine speed springs can be positioned on the back side of the spring actuator to remove all counter balance (forth position). 1.
The springs are under tension. Use caution when adjusting them. 3. While relieving the spring tension, remove the bolt and locknut securing the spring actuator to the bracket (Figure 41). Figure 42 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. Important: Do not push or tow the machine faster than 2-3 mph (3-4.
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 44). Figure 45 1. Front tie down • Rear—each side of the machine on the rear frame (Figure 46). Figure 44 1. Front jacking point • Rear—rectangular axle tube on the rear axle.
Diagnostic Ace Display 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. 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.
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.
Warning System Note: If the correct output LEDs do not illuminate, verify that the required input switches are in the necessary positions to allow that function to occur. Verify correct switch function. If the output LEDs are on as specified, but the machine does not function properly, this indicates a non-electrical problem. Repair as necessary. If a warning light comes on during operation, stop the machine immediately and correct the problem before continuing operation.
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 50 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 52) • Axle steering pivot (1) (Figure 56) • Cutting unit carrier frame and pivot (2 each) (Figure 53) Figure 56 • Steering cylinder ball joints (2) (Figure 57) Figure 53 • Lift arm pivot shaft (1 each) (Figure 54) Figure 57 Figure 54 • Brake pedal (1) (Figure 58) • Rear axle tie rod (2) (Figure 55) Figure 58 Figure 55 42
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 59) 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 63). 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 62 1. Oil filter 4. Apply a light coat of clean oil to the new filter seal. 5.
Fuel System Maintenance 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 64 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 Figure 65 Warning 1.
Fuses Drive System Maintenance There are 8 fuses in the electrical system. The fuse block (Figure 66) is located behind the control arm access panel. 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 66 1.
Figure 70 1. Jam nut 2. Tie rod 3. Wrench slot Figure 69 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 1/4 inch (6 mm) of the distance measured at the rear of the wheels. The engine must be running so the final adjustment of the traction adjustment cam can be performed. This could cause personal injury. 5.
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. 3. Unlatch the clamp and pivot open the rear screen (Figure 71). Figure 72 1. Oil cooler 2. Oil cooler latches 6. Thoroughly clean both sides of the oil cooler and the radiator (Figure 73) with compressed air.
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 75 1. Brake cables 2. Screws (2) 3. Parking brake pawl 4. Brake detent 2.
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. 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.
Replacing the Hydraulic Filters The hydraulic system is equipped with a service interval indicator (Figure 78). With the engine running, view the indicator, it should be in the Green zone. When the indicator is in the Red zone, change the hydraulic filters. Figure 80 1. Hydraulic filter Figure 78 3. Remove the filter. 1. Hydraulic filter restriction indicator 4. Lubricate the gasket on the new filter with hydraulic oil. Important: Use of any other filters may void the warranty on some components. 5.
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. Figure 82 1.
Cutting Unit System Maintenance Backlapping the Cutting Units Contact with the reels or other moving parts can result in personal injury. Figure 84 • Keep fingers, hands, and clothing away from the reels or other moving parts. 1. Backlap levers • Never attempt to turn the reels by hand or foot while the engine is running. 2. Reel speed control knobs 6. Select either front, rear or both backlap levers to determine which units to backlap (Figure 84).
Storage Preparing the Traction Unit 1. Thoroughly clean the traction unit, cutting units, and engine. 2. Check the tire pressure. Inflate all traction unit tires to 12 to 15 psi (83 to 103 kPa). 3. Check all fasteners for looseness and tighten them as necessary. 4. Grease all grease fittings and pivot points. Wipe up any excess lubricant. 5. Lightly sand and use touch-up paint on painted areas that are scratched, chipped, or rusted. Repair any dents in the metal body. 6.
Schematics Hydraulic Schematic, Model 5210 & 5410 (Rev.
Hydraulic Schematic, Model 5510 & 5610 (Rev.
Electrical Schematic (Rev.
Notes: 59
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. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty statements for these products).
