Form No. 3391-854 Rev A Reelmaster® 5410-G or 5510-G Traction Unit Model No. 03608—Serial No. 315000001 and Up Model No. 03609—Serial No. 315000001 and Up Register at www.Toro.com.
WARNING 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. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Figure 1 1. Safety alert symbol This manual uses 2 words to highlight information.
Contents Adjusting the Service Brakes ....................................41 Adjusting the Parking Brake ....................................41 Belt Maintenance ......................................................42 Tensioning the Alternator Belt .................................42 Hydraulic System Maintenance ....................................42 Changing the Hydraulic Fluid...................................42 Replacing the Hydraulic Filters .................................
Safety • Evaluate the terrain to determine what accessories and Improper using or maintaining the machine can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means Caution, Warning, or Danger—personal safety instruction. Failure to comply with the instruction may result in personal injury or death. • attachments are needed to properly and safely perform the job.
• • • • • • • • • • • • • • • Lightning can cause severe injury or death. If lightning – 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.
Toro Riding Mower Safety with terrain angles, ricochets, or improperly positioned guards can lead to thrown object injuries. Do not resume mowing until the area is cleared. The following list contains safety information specific to Toro products or other safety information that you must know that is not included in the CEN, ISO, or ANSI standard. Maintenance and Storage This product is capable of amputating hands and feet and throwing objects.
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. 93-6681 98-4387 1. Cutting/dismemberment—hazard, fan-stay away from moving parts. 1. Warning—wear hearing protection. 93–6689 112-5019 1. Danger—no riders. 93-7272 1. Cutting/dismemberment—hazard, fan-stay away from moving parts. 106-6754 1. Warning—do not touch the hot surface. 2.
110-8921 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. 1. Traction unit speed 2. Slow 3. Fast 110-9642 1. Stored energy hazard—read the Operator's Manual. 110-8869 2. Move the cotter pin to the hole closest to the rod bracket and then remove the lift arm and pivot yoke. 1. Warning—read the Operator's Manual, do not operate this machine unless you are trained. 2.
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. 10. Contains lead; do not discard.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 4 5 6 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 (right-hand) Front hose guide (left-hand) 1 1 Install the cutting units. No parts required – Adjust the turf compensation spring. Cutting unit kickstand 1 Install the Cutting Unit Kickstand.
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). Important: On the #4 (left front) and #5 (right front) cutting units (Figure 7), use the rod bracket mounting nuts to install the hose guides to the front of the cutting unit tabs (Figure 8). The hose guides should lean toward the center cutting unit (Figure 8 and Figure 9). Figure 4 1. Counter weight 5.
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. 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. Remove the snapper pin and the cap from the lift arm pivot yoke (Figure 10). Figure 11 1. Lift arm 3.
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. Hairpin cotter 4. Hex nuts Figure 16 1. Cutting unit kickstand 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). Secure the kickstand to the chain bracket with the snapper pin (Figure 17).
Product Overview 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. To stop, reduce foot pressure on the traction pedal and allow it to return to the center position. Figure 18 1. Engine hood 5. Seat adjusting controls 2. Operator's seat 6. Front cutting units 3. Control arm 7. Rear cutting units 4. Steering wheel Figure 20 Controls 1. Traction pedal 4. Brake pedal 2. Mow speed limiter 5.
1 increase or decrease the engine speed in 100-rpm increments. By holding the switch down, the engine speed automatically moves to High or Low idle, depending on which end of the switch you press. 2 1 3 4 5 6 G021208 Figure 21 1. Lower mow/raise control lever 2. Key switch 4. Enable/disable switch 3. InfoCenter 6. Headlight switch g021209 Figure 22 5. Engine speed switch 1.
InfoCenter Icon Description SERVICE DUE Indicates when scheduled service should be performed Engine rpm/status—indicates the engine speed Hour meter Info icon Fast Slow Figure 24 1.
Using the Menus InfoCenter Icon Description (cont'd.) To access the InfoCenter menu system, press the menu access button while at the main screen. This brings you to the main menu. Refer to the following tables for a synopsis of the options available from the menus: Engine Key switch Main Menu Indicates when the cutting units are being lowered Menu Item Description Faults The Faults menu contains a list of the recent machine faults.
Engine Run Indicates the inputs, qualifiers and outputs for starting the engine. Backlap Indicates the inputs, qualifiers and outputs for operating the backlap function. Machine Controller Revision Lists the software revision of the master controller. InfoCenter Revision Lists the software revision of the InfoCenter. CAN Bus Lists the machine communication bus status. Settings Menu Item Description Units Controls the units used on the InfoCenter.
Setting 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. Setting the Mow Speed • In the Settings Menu, scroll down to Mow Speed. • Press the right button to select mow speed. • Use the center and right button to select the appropriate mow speed set on the mechanical mow speed limiter on the traction pedal. • Press the left button to exit mow speed and save the setting.
Specifications Note: Specifications and design are subject to change without notice.
Above 25 degrees C (77 degrees F) SAE30 or SAE 10W-30 SAE 15W-40 0 degrees C to 25 degrees C (32 degrees F to 77 degrees F) SAE20 or SAE 10W-30 0 degrees C to –20 degrees C (32 degrees F to –4 degrees F) The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol antifreeze. Check the level of the coolant in the expansion tank at the beginning of each day before starting the engine. The capacity of the cooling system is 6.6 liters (7.0 US qt).
such as E15 (contains 15% ethanol), E20 (contains 20% ethanol), or E85 (contains up to 85% ethanol). Using unapproved gasoline may cause performance problems and/or engine damage which may not be covered under warranty. DANGER 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.
High Viscosity Index/Low Pour Point Antiwear Hydraulic Fluid, ISO VG 46 Multigrade Material Properties: Viscosity, ASTM D445 cSt @ 40°C (104°F) 44 to 48 cSt @ 100°C (212°F) 7.9 to 9.1 Viscosity index, ASTM 140 or higher (high D2270 viscosity index indicates a multiweight fluid) Pour point, ASTM D97 -36.
Starting and Stopping the Engine 1 Starting the Engine 1. Sit on the seat, keep your foot off of the traction pedal so that it is in Neutral, engage the parking brake, set the engine speed switch to the Mid position and ensure that the Enable/Disable switch is in the Disable position. 2. Remove your foot from the traction pedal and make sure the pedal is in the Neutral position. 3. Insert and rotate the ignition key clockwise until the engine starts. g021215 Figure 29 Stopping the Engine 1.
2. Insert a tube or similar object onto the long spring end and pivot it around the spring actuator to the desired position (Figure 30). CAUTION The springs are under tension. Use caution when adjusting them. Figure 31 1. Switch 2. Lift arm sensing device 1 2 g019276 Pushing or Towing the Machine Figure 30 1. Spring 2. Spring actuator 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. 3.
Important: Running the engine with the bypass valve open causes the transmission to overheat. Locating the Jacking Points Note: Use jack stands to support the machine when required. • Front—rectangular pad, under the axle tube, inside each front tire (Figure 33) Figure 34 1. Front tie down • Rear—each side of the machine on the rear frame (Figure 35). Figure 33 1.
5. If a switch is closed and the appropriate indicator does not change, 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. When a fault message is displayed, the light blinks until the fault is resolved 1 TORO Note: The InfoCenter display also has the ability to detect which output solenoids or relays are turned on. This is a quick way to determine if a machine malfunction is electrical or hydraulic.
Operating Tips Becoming Familiar with the Machine Before mowing grass, practice operating the machine in an open area. Start and stop the engine. Operate in forward and reverse. Lower and raise the cutting units and engage and disengage the reels. When you feel familiar with the machine, practice operating up and down slopes at different speeds. Understanding the Warning System 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 94 to 122 N-m (70 to 90 ft-lb). 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 94 to 122 N-m (70 to 90 ft-lb).
Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Mon. Maintenance Check Item Tues. Wed. Thurs. Fri. Check the safety interlock operation. Check the brake operation. Check the engine oil and fuel level. Check the air filter restriction indicator. Check the radiator and screen for debris. Check unusual engine noises. Check unusual operating noises. Check the hydraulic system oil level. Check the hydraulic filter indicator. 1 Check hydraulic hoses for damage.
Service Interval Chart Figure 37 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.
• Cutting unit carrier frame and pivot (2 each) (Figure 40) • Axle steering pivot (1) (Figure 43) Figure 43 • Steering cylinder ball joints (2) (Figure 44) Figure 40 • Lift arm pivot shaft (1 each) (Figure 41) Figure 41 Figure 44 • Rear axle tie rod (2) (Figure 42) • Brake pedal (1) (Figure 45) G011615 Figure 45 Figure 42 34
Engine Maintenance 1 2 3 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 Service the air-cleaner filter only when the service indicator (Figure 46) 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 47 1. Air-cleaner cover 2. Air-cleaner filter 3.
Figure 50 1. Air gap 5. Install the correctly gapped spark plug with gasket seal, and tighten the plug to 25 to 30 N-m (18 to 21.6 ft-lb). If a torque wrench is not used, tighten the plug firmly. g021213 1 Figure 49 1. Oil filter 4. Apply a light coat of clean oil to the new filter gasket. 5. Install the replacement oil filter to the filter adapter. Turn the oil filter clockwise until the rubber gasket contacts the filter adapter, then continue tightening by hand until it is tight.
Fuel System Maintenance Replacing the Fuel Filter DANGER In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property. g021236 Figure 52 • Drain gasoline from the fuel tank when the engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills. 1. Fuel pump • Never smoke when draining gasoline, and stay away from an open flame or where a spark may ignite the gasoline fumes. 4.
Checking the Fuses Electrical System Maintenance There are 8 fuses in the electrical system. The fuse block (Figure 53) is located behind the control arm access panel. Important: Before welding on the machine, disconnect both cables from the battery, both wiring harness plugs from the electronic control module, and the terminal connector from the alternator to prevent damage to the electrical system.
Drive System Maintenance 5. Tighten the locknut to secure the adjustment. 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 Traction Drive for Neutral Adjusting the Rear Wheel Toe-in The machine must not creep when the traction pedal is released. If it does creep, adjust as follows: 1. Rotate the steering wheel so that the rear wheels are straight ahead. 1.
Cooling System Maintenance 1 Removing Debris from the Cooling System Remove debris from the screen and radiator/oil cooler daily (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 57). g021238 Figure 58 1. Radiator/oil cooler 5. Close the screen and secure the latch. Figure 57 1. Rear screen latch 2. Rear screen 4.
Brake Maintenance Adjusting the Parking Brake If the parking brake fails to engage, an adjustment to the brake pawl is required. Adjusting the Service Brakes 1. Loosen the 2 screws securing the parking brake pawl to the frame (Figure 61). Adjust the service brakes when there is more than 25 mm (1 inch) of free travel (Figure 59) 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.
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 Tensioning the Alternator Belt 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. Open the hood. 2.
Replacing the Hydraulic Filters The hydraulic system is equipped with a service interval indicator (Figure 64). 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. Figure 66 1. Hydraulic filter Figure 64 3. Remove the filter. 1. Hydraulic filter restriction indicator 4. Lubricate the gasket on the new filter with hydraulic oil. 5. Ensure that the filter mounting area is clean.
1 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 stabilizes, then return the reel speed to your desired speed. 9. 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 the adjustments, repeat steps 4 through 8. Backlapping the Cutting Units WARNING 1 Contact with the reels or other moving parts can result in personal injury.
Storage • Start the engine and run it until it stops. • Start and run the engine until it does not start again. Preparing the Traction Unit • Dispose of fuel properly. Recycle it according to local codes. 1. Thoroughly clean the traction unit, cutting units, and engine. Important: Do not store stabilizer/conditioned gasoline over 90 days 2. Check the tire pressure. Inflate all traction unit tires to 83 to 103 kPa (12 to 15 psi). 3. Check all fasteners for looseness and tighten them as necessary. 7.
Notes: 47
Toro General Commercial Product 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).
