Form No. 3377-475 Rev A Reelmaster® 5610 Traction Unit Model No. 03691—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. This manual identifies potential hazards and has safety messages identified by the safety alert symbol (Figure 1), which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions. WARNING CALIFORNIA Proposition 65 Warning Figure 1 1.
Safety Understanding the Diagnostic Light..........................30 Using the Diagnostic ACE Display............................31 Checking the Interlock Switches ...............................31 Identifying the Hydraulic Valve Solenoid Functions ..........................................................33 Operating Tips ......................................................33 Maintenance .................................................................34 Recommended Maintenance Schedule(s) ............
Preparation • 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 • 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.
Maintenance and Storage WARNING • Keep all nuts, bolts and screws tight to be sure the • • • • • • • • • • • • • • • • Engine exhaust contains carbon monoxide, which is an odorless, deadly poison that can kill you. equipment is in safe working condition. Never store the equipment with fuel in the tank inside a building where fumes may reach an open flame or spark. Allow the engine to cool before storing in any enclosure.
Sound Pressure Level • 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.
106-6754 110-8924 1. Warning—do not touch the hot surface. 2. Cutting/dismemberment hazard, fan and entanglement hazard, belt—stay away from moving parts. 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.
110-8921 1. Traction unit speed 2. Slow 3. Fast 110-9642 1. Stored energy hazard—read the Operator's Manual. 2. Move the cotter pin to the hole closest to the rod bracket and then remove the lift arm and pivot yoke. 117–0170 1. Head lights 6. Continuous variable throttle setting 2. Engage 7. Slow 3. Power take-off (PTO) 8. Lower cutting units 4. Disengage 5. Fast 9. Raise cutting units 10. Read the Operator's Manual. 106-6755 1. Engine coolant under pressure. 3.
114–8891 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 117-0168 1. 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 (right-hand) Front hose guide (left-hand) 1 1 Install the cutting units. No parts required – Adjust the turf compensation spring. Varies Install rear weights (order from your Toro Distributor).
pressure in the front and rear tires is 12 to 15 psi (83 to 103 kPa). 3 Important: Maintain even pressure in all tires to ensure uniform contact with the turf. Adjusting the Control Arm Position 2 No Parts Required Adjusting the Step Height Procedure The control arm position can be adjusted for the operator’s comfort. 1. Loosen the 2 bolts securing the control arm to the retaining bracket (Figure 3). No Parts Required Procedure The height of the steps can be adjusted for the operator’s comfort. 1.
Note: Position the bolt head to the outer side of the tab as shown in Figure 6. 2. Remove the shipping brackets and discard them. 3. Remove the cutting units from the cartons and assemble and adjust them as described in the cutting unit Operator's Manual. 4. Make sure that 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.
Figure 8 1. Hose guide (#4 cutting unit 3. Nuts shown) 2. Rod bracket 1 1 g019284 Figure 9 1. Hose guide (each guide must lean toward the center cutting unit) Note: When installing or removing the cutting units, make sure that 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.
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. Note: 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). Figure 10 1. Snapper pin 2. Cap 12.
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 15). Figure 14 1. Reel drive motor 2. Mounting bolts Figure 15 16. Rotate the motor counterclockwise until the flanges encircle the bolts, then tighten the bolts. Important: Make sure that the reel motor hoses are not twisted, kinked, or pinched. 1.
to determine the combinations of weights required for your configuration. Order parts from your local Authorized Toro Distributor.
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 17).
Figure 21 1. Gauge bar 4. Holes used for setting the groomer height of cut 2. Height adjusting screw 5. Hole not used Figure 20 1. Chain bracket 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 21).
Traction Pedal Product Overview The traction pedal (Figure 24) controls the forward and reverse operation. Press the top of the pedal to move forward and the bottom to move rearward. Ground speed depends on how far you press the pedal. For no load, maximum ground speed, fully press the pedal while the 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 22 1. Engine hood 5. Steering wheel 2.
Throttle Control Lower Mow/Raise Control Lever Move the throttle control (Figure 25) forward to increase the engine speed and rearward to decrease speed. This lever (Figure 25) raises and lowers the cutting units and also starts and stops the cutterheads when the cutterheads are enabled in the mow mode. 5 6 7 8 4 Glow Plug Indicator Light 9 This light (Figure 25) illuminates when the glow plugs are preheating.
Fuel Gauge The fuel gauge (Figure 29) shows the amount of fuel in the tank. Figure 27 1. Hour meter Hydraulic Filter Restriction Indicator With the engine running at normal operating temperature, view the indicator (Figure 28), it should be in the Green zone. When the indicator is in the Red zone, change the hydraulic filters. Figure 29 1. Fuel tank cap 2. Fuel gauge Headlight Switch Pivot the switch downward to turn on the headlights (Figure 30). Figure 28 1.
Power Point Operation The power point is a 12 volt power supply for electronic devices (Figure 31). 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 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 Removing Debris from the Cooling System (page 43) in Cooling System Maintenance (page 43). The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol antifreeze. Check the level of coolant in the expansion tank at the beginning of each day before starting the engine.
Adding Fuel 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. 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. Purchase fuel in quantities that can be used within 180 days to ensure fuel freshness. • Fill the fuel tank outdoors, in an open area, when the engine is cold.
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. For operation in consistently high ambient temperatures, 65 °F (18 °C) to 120 °F (49 °C), ISO VG 68 hydraulic fluid may offer improved performance.
Figure 37 1. Hydraulic tank cap 4. Remove the dipstick from the filler neck and wipe it with a clean rag. Insert the dipstick into the filler neck; then remove it and check the level of fluid. The fluid level should be within 1/4 inch of the mark on the dipstick. Do not overfill the hydraulic tank. 5. If the level is low, add the appropriate fluid to raise the level to the full mark. 6. Install the dipstick and the cap onto the filler neck.
• The engine has ceased running, due to lack of fuel. • Maintenance has been performed upon fuel system key in the On position until a solid stream of fuel flows out around the screw. components; i.e., filter replaced, separator serviced, etc. 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.
controls (located under the seat) correctly. Adjust the reel speed controls as follows: 1. Select the height-of-cut at which the cutting units are set. 2. Choose the desired ground speed best suited for conditions. 3. Using the appropriate graph on decal 110–0996 (Figure 40) determine the proper reel speed setting. To set the reel speed, rotate knobs (Figure 39) until the indicator arrows are in line with the number designating the desired setting. Figure 39 1.
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 to 3 mph (3 to 4.8 km/h) because internal transmission damage may occur. The bypass valve must be open whenever the machine is pushed or towed. 1 2 g019276 Figure 41 1. Spring 1. The bypass valve is located on the left side of the hydrostat (Figure 43).
Figure 46 Figure 44 1. Rear tie down 1. Front jacking point Understanding the Diagnostic Light • Rear—rectangular axle tube on the rear axle. Tie Downs The machine is equipped with a diagnostic light which indicates if the electronic controller senses an electronic malfunction. The diagnostic light is located on the control arm (Figure 47).
Use the Diagnostic ACE display to help verify and correct electrical functions of the machine. Checking the Interlock Switches The purpose of the interlock switches is to prevent the engine from cranking or starting unless the traction pedal is in the Neutral position, the Enable/Disable switch is in the Disable position, and the Lower Mow/Raise control is in the Neutral position.
5. Connect the Diagnostic ACE connector to the harness connector. Note: Make sure that the correct overlay decal is positioned on the Diagnostic ACE. 6. Turn the key switch to the On position, but do not start machine. Note: The red text on the overlay decal refers to input switches and the green text refers to outputs. 7. The “outputs displayed” LED, on lower right column of the Diagnostic ACE, should be illuminated.
Identifying the Hydraulic Valve Solenoid Functions Use the list below to identify and describe the different functions of the solenoids in the hydraulic manifold. Each solenoid must be energized to allow the function to occur.
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 50 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 Number 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) G011615 Figure 58 Figure 55 37
Engine Maintenance Servicing the Air Cleaner Check the air cleaner body for damage which could cause an air leak. Replace it if it is 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.
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. 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 64 1. Water separator filter canister • Do not fill the fuel tank completely full.
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 Service Interval: Every 50 hours Every 50 hours Figure 65 1. Fuel injectors WARNING 2. Turn the key in the key switch to the On position and watch the fuel flow around the connector.
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 it as follows: 1. Park the machine on a level surface, stop the engine, and lower the cutting units to the floor. Figure 66 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. 1.
Cooling System Maintenance WARNING The engine must be running so the final adjustment of the traction adjustment cam can be performed. This could cause personal injury. Removing Debris from the Cooling System Keep hands, feet, face, and other body parts away from the muffler, other hot parts of the engine, and any rotating parts. Service Interval: Before each use or daily Every 100 hours 4. Start the engine and rotate the cam hex in either direction until the wheels cease rotation.
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.
Adjusting the Parking Brake Belt Maintenance If the parking brake fails to engage, adjust the parking brake pawl. Check the condition and tension of the alternator belt after the first day of operation and every 100 operating hours thereafter. 1. Loosen the 2 screws securing the parking brake pawl to the frame (Figure 74). Tensioning the Alternator Belt Service Interval: After the first 8 hours Every 100 hours 1. Open the hood. 2.
Replacing the Hydraulic Filters Hydraulic System Maintenance Service Interval: Every 800 hours The hydraulic system is equipped with a service interval indicator (Figure 77). 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. Changing the Hydraulic Fluid Service Interval: Every 800 hours Every 2 years Change hydraulic fluid after every 800 operating hours, in normal conditions.
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 81 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 (Rev.
Electrical Schematic (Rev.
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).
