Form No. 3375-128 Rev A Reelmaster® 5010 Series Traction Unit Model No. 03660—Serial No. 313000001 and Up Model No. 03670—Serial No. 313000001 and Up Model No. 03680—Serial No. 313000001 and Up Model No. 03690—Serial No. 313000001 and Up Register at www.Toro.com.
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 Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. This manual uses 2 other words to highlight information.
Contents Adjusting the Throttle.............................................45 Fuel System Maintenance ...........................................46 Draining the Fuel Tank ...........................................46 Checking the Fuel Lines and Connections ..................46 Servicing the Water Separator ..................................46 Fuel Pick-up Tube Screen ........................................46 Bleeding Air from the Fuel Injectors..........................46 Electrical System Maintenance ..
Preparation Safety • While mowing, always wear substantial footwear, long This machine meets or exceeds CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-2004 specifications in effect at time of production, when equipped with rear weight. Refer to the section in this manual on Installing Rear Weight. • Improper use or maintenance by the operator or owner can result in injury.
Maintenance and Storage • Watch out for traffic when crossing or near roadways. • Stop the blades rotating before crossing surfaces other • • • • • • • • • • • • • • • Keep all nuts, bolts and screws tight to be sure the than grass. When using any attachments, never direct discharge of material toward bystanders nor allow anyone near the machine while in operation. Never operate the machine with damaged guards, shields, or without safety protective devices in place.
Use of this product for purposes other than its intended use could prove dangerous to user and bystanders. WARNING Engine exhaust contains carbon monoxide, which is an odorless, deadly poison that can kill you. • Do not run engine indoors or in an enclosed area. • Know how to stop the engine quickly. • Do not operate the machine while wearing tennis shoes • or sneakers. • • Wearing safety shoes and long pants is advisable and required by some local ordinances and insurance regulations.
Hand-Arm This unit has a sound pressure level at the operator’s ear of 86 dBA, which includes an Uncertainty Value (K) of 1 dBA. Measured vibration level for right hand = .37 m/s2 Sound pressure level was determined according to the procedures outlined in EN 836. Measured vibration level for left hand = 51 m/s2 Uncertainty Value (K) = 0.5 m/s2 Sound Pressure Level Measured values were determined according to the procedures outlined in EN 836.
93–6696 1. Stored energy hazard—read the Operator's Manual. 110-0989 1. Read the Operator's Manual. 117–2385 1. Read the Operators Manual. 2. Engine—start 3. Engine—preheat 4. Engine—stop 110-8924 1. Warning—read the Operator's Manual and receive training. 106-6754 2. Thrown object hazard—keep bystanders a safe distance from the machine. 3.
110-8986 (Affix over part no. 110–8924 for CE*) 106-6755 * This safety decal includes a slope warning required on the machine for compliance to the European Lawn Mower Safety Standard EN836:1997. The conservative maximum slope angles indicated for operation of this machine are prescribed by and required by this standard. 1. 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. 1.
114–8891 (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 114–8890 (Use for Models 5210 & 5410 with 5 inch reel cutting units) 1. Front reels circuit controls 3. Mow and backlap 5. Height-of-cut 2. Rear reels circuit controls 4. Read the Operator's Manual. 6.
7-0168 1. Read the Operator's Manual. Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. Keep bystanders a safe distance from the battery. 2. No fire, open flame, or smoking. 7. Wear eye protection; explosive gases can cause blindness and other injuries 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 5. Read the Operator's Manual.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description 1 2 3 4 5 6 7 8 9 Use Qty. No parts required – Adjust the tire pressure. No parts required – Adjust the step height. No parts required – Adjust the control arm position. Front hose guide-R.H. Front hose guide-L.H. 1 1 Install the cutting units No parts required – Adjust the turf compensation spring. Varies Install rear weights (order from your Toro Distributor).
1 3 Adjusting the Tire Pressure Adjusting the Control Arm Position No Parts Required No Parts Required Procedure 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 12 to 15 psi (83 to 103 kPa). The control arm position can be adjusted for the operators comfort. 1. Loosen the 2 bolts securing the control arm to the retaining bracket (Figure 3).
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. Make sure the counter weight (Figure 4) is installed to the proper end of the cutting unit as described in the cutting unit Operator's Manual. 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).
1 1 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. Otherwise, the hairpin cotter must be installed in the hole in the end of the rod. 6. Lower all the lift arms completely. 7. Remove the snapper pin and the cap from the lift arm pivot yoke (Figure 10). Figure 11 1. Lift arm 3. Lift arm pivot yoke 2.
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). 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 10). 12.
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 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 15). Note: When operating on rough terrain decrease the spring length by 1/2 inch. Ground following will be slightly decreased.
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 16 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 17. Figure 17 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 17a).
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. 7 Installing the CE Hood Latch 8 Parts needed for this procedure: 1 Hood latch assembly 1 Washer Using the Cutting Unit Kickstand Procedure Parts needed for this procedure: 1. Unlatch and raise the hood. 2. Remove the rubber grommet from the hole in the left side of the hood (Figure 18).
Figure 22 1. Gauge bar Figure 21 1. Chain bracket 2. Height adjusting screw 3. Cutting unit kickstand 3. Nut 2. Snapper pin 9 Using the Gauge Bar Parts needed for this procedure: 1 Gauge bar Procedure Use the gauge bar to adjust the cutting unit. Refer to the Cutting Unit Operator's Manual for the adjustment procedures (Figure 22). 23 4. Holes used for setting Groomer HOG 5.
Product Overview 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 23 1. Engine hood 5. Seat 2. Operator's seat 6. Front cutting units 3. Control arm 7. Rear cutting units 4. Steering wheel Figure 25 Controls 1. Traction pedal 4. Brake pedal 2. Mow speed limiter 5. Parking brake 3. Spacers 6.
5 6 Glow Plug Indicator Light 7 8 4 This light (Figure 26) illuminates when the glow plugs are preheating. 9 10 Engine Oil Pressure Warning Light 3 This light (Figure 26) indicates dangerously low engine oil pressure. Charge Indicator 2 The charge indicator (Figure 26) illuminates when the system charging circuit malfunctions. 1 Enable/Disable Switch G003956 Use the enable/disable switch (Figure 26) in conjunction with the lower mow/raise control lever to operate the cutterheads.
Figure 28 1. Hour meter Figure 30 1. Fuel tank cap Hydraulic Filter Restriction Indicator 2. Fuel gauge With the engine running at normal operating temperature, view the indicator (Figure 29), it should be in the Green zone. When the indicator is in the Red zone, change the hydraulic filters. Headlight Switch Pivot the switch downward to turn on the headlights (Figure 31). Figure 29 1. Hydraulic filter restriction indicator Fuel Gauge The fuel gauge (Figure 30) shows the amount of fuel in the tank.
Power Point The power point is a 12 volt power supply for electronic devices (Figure 32). Figure 32 1. Power point Specifications Note: Specifications and design are subject to change without notice.
Operation Note: Determine the left and right sides of the machine from the normal operating position. CAUTION If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Lower the cutting units to the ground, set the parking brake and remove the key from the ignition switch before servicing or making adjustments to the machine.
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. Refer to the section on Removing Debris from the Cooling System in Cooling System Maintenance (page 49). 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.
DANGER In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any fuel that spills. • Never fill the fuel tank inside an enclosed trailer. • Never smoke when handling fuel, and stay away from an open flame or where fuel fumes may be ignited by a spark. • Store fuel in an approved container and keep it out of the reach of children.
High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46 Material Properties: Viscosity, ASTM D445 cSt @ 40°C 44 to 48 cSt @ 100°C 7.9 to 8.5 140 to 160 Viscosity Index ASTM D2270 Pour Point, ASTM D97 -34°F to -49°F Industry Specifications: Vickers I-286-S (Quality Level), Vickers M-2950-S (Quality Level), Denison HF-0 Important: The ISO VG 46 Multigrade fluid has been found to offer optimal performance in a wide range of temperature conditions.
Bleeding the Fuel System You must bleed the fuel system before starting the engine if any of the following situations have occurred: • Initial start up of a new machine. • Engine has ceased running due to lack of fuel. • Maintenance has been performed upon fuel system components; i.e., filter replaced, separator serviced, etc. DANGER Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage.
Crank the engine for no longer than 15 seconds. Release the key when the engine starts. If additional preheating is required, turn key to the Off position and then to the On/Preheat position. Repeat this process as required. 4. Run the engine at low idle speed until it warms up. Stopping the Engine 1. Move all controls to Neutral, set the parking brake, move the throttle to the low idle position and allow the engine to reach low idle speed.
Figure 41 1. Front reels circuit controls 3. Reel—mow and backlap 5. Reel—height of cut 2. Rear reels circuit controls 4. Read the Operator's Manual. 6. Machine speed Figure 42 1. Front reels circuit controls 3. Reel—mow and backlap 5. Reel—height of cut 2. Rear reels circuit controls 4. Read the Operator's Manual. 6. Machine speed Adjusting the Lift Arm Counterbalance springs can be positioned on the back side of the first spring actuator to remove all counter balance (forth position). 1.
Adjusting the Lift Arm Turn Around Position CAUTION The springs are under tension. 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. Use caution when adjusting them. 2. The lift arm switch is located underneath the hydraulic tank behind the front right lift arm (Figure 44). 3.
Tie Downs • Front—the hole in the rectangular pad, under the axle tube, inside each front tire (Figure 47). Figure 45 1. Bypass valve 2. Close the bypass valve before starting the engine. However, do not exceed 5-8 ft.-lb. (7-11 N-m) torque to close the valve. Important: Running the engine with the bypass valve open will cause the transmission to overheat. Figure 47 1. Front tie down Jacking Points • Rear—each side of the machine on the rear frame (Figure 48).
Diagnostic Ace Display 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.
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. Note: The Diagnostic ACE also has the ability to detect which output solenoids or relays are turned on.
Transport 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.
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. 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 52 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 54) • Axle steering pivot (1) (Figure 58) • Cutting unit carrier frame and pivot (2 each) (Figure 55) Figure 58 • Steering cylinder ball joints (2) (Figure 59) Figure 55 • Lift arm pivot shaft (1 each) (Figure 56) Figure 59 Figure 56 • Brake pedal (1) (Figure 60) • Rear axle tie rod (2) (Figure 57) G011615 Figure 60 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 61) requires it. Changing the air filter before it is necessary only increases the chance of dirt entering the engine when the filter is removed.
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 64 1. Oil filter 4. Apply a light coat of clean oil to the new filter seal. 5. 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. Figure 66 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 67 WARNING 2. Turn the key in the key switch to the On position and watch the fuel flow around the connector. When you observe a solid flow of fuel, turn the key to the Off position.
Drive System Maintenance Adjusting the Traction Drive for Neutral The machine must not creep when the traction pedal is released. If it does creep, adjust as follows: 1. Park the machine on a level surface, stop the engine, and lower the cutting units to the floor. 2. Jack up the front of the machine until the front tires are off the shop floor. Support the machine with jack stands to prevent it from falling accidentally. Figure 68 1.
Cooling System Maintenance 6. Stop the engine. Remove the jack stands and lower the machine to the shop floor. 7. Test drive the machine to make sure it does not creep. Adjusting the Rear Wheel Toe-in Removing Debris from the Cooling System 1. Rotate the steering wheel so that the rear wheels are straight ahead. Remove debris from the screen, oil coolers, and radiator daily (clean more frequently in dirty conditions). 2. Loosen the jam nut on each end of the tie rod (Figure 71). 1.
Brake Maintenance Adjusting the Service Brakes Adjust the service brakes when there is more than 1 inch of free travel of the brake pedal, or when the brakes do not work effectively. Free travel is the distance the brake pedal moves before you feel braking resistance. Note: Use the wheel motor backlash to rock the drums back and forth to ensure that the drums are free prior to and after adjustment. 1.
Belt Maintenance Check the condition and tension of the alternator belt after the first day of operation and every 100 operating hours thereafter. Tensioning the Alternator Belt 1. Open the hood. 2. Check the tension of the alternator belt by depressing it (Figure 77) midway between the alternator and the crankshaft pulleys with 22 lb (10 kg) of force. Figure 76 1. Brake cables 3. Parking brake pawl 2. Screws (2) 4. Brake detent 2.
Hydraulic System Maintenance temperature, view the indicator, it should be in the Green zone. When the indicator is in the Red zone, change the hydraulic filters. Changing the Hydraulic Fluid Change hydraulic fluid after every 800 operating hours, in normal conditions. 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 83 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.
Notes: 59
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).
