Toro 03673 Reelmaster 5410-G Operator'S Manual Download

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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

*3391-854* A

Summary of Contents for 03673 Reelmaster 5410-G

Page 1: ... 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 Original Instructions EN 3391 854 A ...

Page 2: ...nd maintain your product properly and to avoid injury and product damage You are responsible for operating the product properly and safely You may contact Toro directly at www Toro com for product safety and operation training materials accessory information help finding a dealer or to register your product Whenever you need service genuine Toro parts or additional information contact an Authorize...

Page 3: ... Functions 29 Operating Tips 30 Maintenance 31 Recommended Maintenance Schedule s 31 Daily Maintenance Checklist 32 Service Interval Chart 33 Lubrication 33 Greasing the Bearings and Bushings 33 Engine Maintenance 35 Servicing the Air Cleaner 35 Servicing the Engine Oil and Filter 35 Replacing the Spark Plugs 36 Fuel System Maintenance 37 Replacing the Fuel Filter 37 Checking the Fuel Lines and Co...

Page 4: ...ty silencers mufflers Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job Only use accessories and attachments approved by the manufacturer Check that the operator s presence controls safety switches and shields are attached and functioning properly Do not operate unless they are functioning properly Safe Handling of Fuels To avoid p...

Page 5: ...severe injury or death If lightning is seen or thunder is heard in the area do not operate the machine seek shelter Use care when loading or unloading the machine into a trailer or truck Use care when approaching blind corners shrubs trees or other objects that may obscure vision Maintenance and Storage Keep all nuts bolts and screws tight to be sure the equipment is in safe working condition Neve...

Page 6: ... pet appears unexpectedly in or near the mowing area stop mowing Careless operation combined with terrain angles ricochets or improperly positioned guards can lead to thrown object injuries Do not resume mowing until the area is cleared Maintenance and Storage Make sure all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition before applying pressure to the s...

Page 7: ...the Operator s Manual 93 6688 1 Warning read the instructions before servicing or performing maintenance 2 Cutting hazard of hand or foot stop the engine and wait for moving parts to stop 98 4387 1 Warning wear hearing protection 112 5019 106 6754 1 Warning do not touch the hot surface 2 Cutting dismemberment hazard fan and entanglement hazard belt stay away from moving parts 110 0986 1 Press the ...

Page 8: ...e computer management B 7 5 amp 9 Engine computer management A 7 5 amp 110 8921 1 Traction unit speed 2 Slow 3 Fast 110 8869 1 Warning read the Operator s Manual do not operate this machine unless you are trained 2 Thrown object hazard keep bystanders a safe distance from the machine 3 Tipping hazard slow machine before turning do not turn at high speeds lower the cutting unit when driving down sl...

Page 9: ...uries 3 Caustic liquid chemical burn hazard 8 Battery acid can cause blindness or severe burns 4 Wear eye protection 9 Flush eyes immediately with water and get medical help fast 5 Read the Operator s Manual 10 Contains lead do not discard 125 8754 1 Head lights 6 Slow 2 Engage 7 Lower the cutting units 3 Power take off PTO 8 Raise the cutting units 4 Disengage 9 Read the Operator s Manual 5 Fast ...

Page 10: ... part numbers Operator training material 1 Review the training material before operating the machine Cutting Performance Paper 1 Use the paper for adjusting the cutting unit bedknife to reel contact Shim 1 Use the shim for adjusting the cutting unit bedknife to reel contact Note Determine the left and right sides of the machine from the normal operating position 1 Adjusting the Tire Pressure No Pa...

Page 11: ... 1 Control arm 3 Bolts 2 2 Retaining brackets 2 Rotate the control arm to the desired position and tighten the 2 bolts 4 Installing the Cutting Units Parts needed for this procedure 1 Front hose guide right hand 1 Front hose guide left hand Procedure 1 Remove the reel motors from the shipping brackets 2 Remove the shipping brackets and discard 3 Remove the cutting units from the cartons Assemble a...

Page 12: ...he carrier frame tab Figure 5 Remove the assembly C Mount the spring tube bolt to the opposite tab on the carrier frame and secure with the flange nut The bolt head is to be positioned to the outer side of the tab as shown in Figure 6 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 Important On the 4 lef...

Page 13: ...nd the cap from the lift arm pivot yoke Figure 10 Figure 10 1 Snapper pin 2 Cap 8 For the front cutting units slide a cutting unit under the lift arm while inserting the carrier frame shaft up into the lift arm pivot yoke Figure 11 Figure 11 1 Lift arm 3 Lift arm pivot yoke 2 Carrier frame shaft 9 Use the following procedure on the rear cutting units when the height of cut is above 19 5 mm 3 4 inc...

Page 14: ...ective hose guide 14 Coat the spline shaft of the reel motor with clean grease 15 Oil the reel motor O ring and install it onto the motor flange 16 Install the motor by rotating it clockwise so that the motor flanges clear the bolts Figure 14 Rotate the motor counterclockwise until the flanges encircle the bolts then tighten the bolts Important Make sure the reel motor hoses are not twisted kinked...

Page 15: ... 12 7 mm 1 2 inch this slightly decreases ground following 6 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 ...

Page 16: ...pressure on the traction pedal and allow it to return to the center position Figure 20 1 Traction pedal 4 Brake pedal 2 Mow speed limiter 5 Parking brake 3 Spacers 6 Tilt steering pedal Mow Speed Limiter When the mow speed limiter Figure 20 is flipped up it controls the mow speed and allows the cutting units to be engaged Each spacer adjusts the mowing speed by 0 8 km h 1 2 mph The more spacers yo...

Page 17: ...sitions Off On Run and Start Lower Mow Raise Control Lever This lever Figure 21 raises and lowers the cutting units and also starts and stops the cutterheads when the cutterheads are enabled in the mow mode The cutter heads cannot be lowered when the mow transport lever is in the transport position Headlight Switch Pivot the switch downward to turn on the headlights Figure 21 Backlap Levers Use th...

Page 18: ... Middle Button use this button to scroll down menus Right Button use this button to open a menu where a right arrow indicates additional content Note The purpose of each button may change depending on what is required at the time Each button will be labeled with an icon displaying its current function InfoCenter Icon Description SERVICE DUE Indicates when scheduled service should be performed Engi...

Page 19: ... on the Faults menu and the information contained there Service The Service menu contains information on the machine such as hours of use counters and other similar numbers Diagnostics The Diagnostics menu displays the state of each machine switch sensor and control output You can use this to troubleshoot certain issues as it quickly tells you which machine controls are on and which are off Settin...

Page 20: ...ing configuration settings that are adjustable within the Settings Menu of the InfoCenter auto idle time delay Blade Count Mow Speed Height of Cut HOC F Reel RPM and R Reel RPM These settings can be locked by using the Protected Menu Note At the time of delivery the initial password code is programmed by your distributor Accessing the Protected Menu Settings To access the Protected Menu Settings F...

Page 21: ... right button to select the appropriate HOC setting If the exact setting is not displayed select the nearest HOC setting from the list displayed Press the left button to exit HOC and save the setting Setting the Front and Rear Reel Speeds Although the front and rear reel speeds are calculated by inputting the number of blades mow speed and HOC into the InfoCenter the setting can be manually change...

Page 22: ...our Authorized Service Dealer or Distributor or go to www Toro com for a list of all approved attachments and accessories 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 s...

Page 23: ...itions are extremely dusty and dirty Refer to Removing Debris from the Cooling System page 40 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 CAUTION If the engine has been runnin...

Page 24: ...ricity 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 Always place fuel containers on the ground away from your vehicle before filling Do not fill fuel containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the lo...

Page 25: ...ter content new fluid 500 ppm maximum Industry Specifications Vickers I 286 S Vickers M 2950 S Denison HF 0 Vickers 35 VQ 25 Eaton ATS373 C The proper hydraulic fluids must be specified for mobile machinery as opposed to industrial plant usage multiweight type with ZnDTP or ZDDP anti wear additive package not an ashless type fluid Important Many hydraulic fluids are almost colorless making it diff...

Page 26: ...otate the ignition key clockwise until the engine starts Stopping the Engine 1 Move all controls to Neutral set the parking brake move the engine speed switch to the low idle position and allow the engine to reach low idle speed 2 Turn the key to the Off position and remove it from the switch Setting the Reel Speed To achieve a consistent high quality of cut and a uniform after cut appearance it i...

Page 27: ...ht or move the switch up to decrease the lift arm turn around height Tighten the mounting screws Figure 31 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 3 to 4 8 km h 2 to 3 mph b...

Page 28: ...ont tire Figure 34 Figure 34 1 Front tie down Rear each side of the machine on the rear frame Figure 35 Figure 35 1 Rear tie down Understanding the Diagnostic Light The machine is equipped with a diagnostic light which indicates if the machine detects a malfunction The diagnostic light is located on the InfoCenter above the display screen Figure 36 When the machine is functioning properly and the ...

Page 29: ...d 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 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 Verifyi...

Page 30: ...ble switch to the Enable position and use the Lower Mow Raise lever to control the cutting units the front cutting units are timed to lower before the rear cutting units To move forward and cut grass press the traction pedal forward Note Allow the engine to idle for 5 minutes before shutting it off after a full load operation Failure to do so may lead to turbo charger trouble Driving the Machine i...

Page 31: ...gs and bushings grease them immediately after every washing regardless of the interval listed Check the condition of and clean the battery Check the battery cable connections Every 100 hours Inspect the cooling system hoses Check the condition and tension of the alternator belt Every 200 hours Change the engine oil and filter Drain moisture from the hydraulic fluid tank Check the reel bearing prel...

Page 32: ...ydraulic hoses for damage Check for fluid leaks Check the tire pressure Check the instrument operation Check the reel to bedknife adjustment Check the height of cut adjustment Check all grease fittings for lubrication 2 Touch up damaged paint 1 Check with the engine running and the oil at operating temperature 2 Immediately after every washing regardless of the interval listed Notation for Areas o...

Page 33: ...you operate the machine under normal conditions lubricate all grease fittings for the bearings and bushings after every 50 hours of operation with 2 general purpose lithium base grease Lubricate the bearings and bushings immediately after every washing regardless of the interval listed The grease fitting locations and quantities are as follows Pump drive shaft 3 Figure 38 g021216 Figure 38 Cutting...

Page 34: ...Figure 40 Figure 40 Lift arm pivot shaft 1 each Figure 41 Figure 41 Rear axle tie rod 2 Figure 42 Figure 42 Axle steering pivot 1 Figure 43 Figure 43 Steering cylinder ball joints 2 Figure 44 Figure 44 Brake pedal 1 Figure 45 G011615 Figure 45 34 ...

Page 35: ...debris from migrating into the intake when the filter is removed 3 Remove and replace the filter Figure 47 Cleaning of the used element is not recommended due to the possibility of damage to the filter media Inspect the new filter for shipping damage checking the sealing end of the filter and the body Do not use a damaged element Insert the new filter by applying pressure to the outer rim of the e...

Page 36: ...oved and checked whenever the engine malfunctions 1 Clean the area around the spark plugs so that foreign matter cannot fall into the cylinder when the spark plug is removed 2 Pull the spark plug wires off of the spark plugs and remove the plugs from the cylinder head 3 Check the condition of the side electrode center electrode and center electrode insulator to ensure that there is no damage Impor...

Page 37: ...1236 Figure 52 1 Fuel pump 3 Fuel line fuel filter 2 Hose clamp 4 Remove the fuel pump cap from the top of the fuel tank Figure 52 5 Remove the fuel pump assembly and fuel filter from the tank Figure 52 6 Remove the clamp securing the fuel filter hose to the fuel pump fitting Remove the hose from the fitting Figure 52 7 Insert the new hose clamp onto the new fuel filter hose 8 Insert the hose onto...

Page 38: ...Do not drink electrolyte and avoid contact with skin eyes or clothing Wear safety glasses to shield your eyes and rubber gloves to protect your hands Fill the battery where clean water is always available for flushing the skin WARNING Charging the battery produces gasses that can explode Never smoke near the battery and keep sparks and flames away from it Check the battery condition weekly or afte...

Page 39: ... injury Keep hands feet face and other body parts away from the muffler other hot parts of the engine and any rotating parts 4 Start the engine and rotate the cam hex in either direction until the wheels cease rotation 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 cre...

Page 40: ...ff 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 Figure 57 1 Rear screen latch 2 Rear screen 4 Thoroughly clean both sides of the and the radiator oil cooler Figure 58 with compressed air g021238 1 Figure 58 1 Radiator oil cooler 5 Close the screen and secure the latch 40 ...

Page 41: ...rear nut to move the cable backward until brake pedals have 1 27 to 1 95 cm 1 2 to 3 4 inch of free travel before wheel lock up is achieved 3 Tighten the front nuts ensuring that both cables actuate the brakes simultaneously Note Ensure that the cable conduit does not rotate during the tightening procedure Adjusting the Parking Brake If the parking brake fails to engage an adjustment to the brake ...

Page 42: ...nge 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 Place a large drain pan under the fitting secured to the bottom of the hydraulic fluid reservoir Figure 63 Figure 63 1 H...

Page 43: ...mounting area and place a drain pan under the filter Figure 65 and Figure 66 g021271 1 Figure 65 1 Hydraulic filter Figure 66 1 Hydraulic filter 3 Remove the filter 4 Lubricate the gasket on the new filter with hydraulic oil 5 Ensure that the filter mounting area is clean 6 Install the filter by hand until the gasket contacts the mounting surface then rotate it an additional 1 2 turn 7 Repeat the ...

Page 44: ... the hydraulic system Get immediate medical help if fluid is injected into skin Using the Hydraulic System Test Ports Use the hydraulic system test ports to test the pressure in the hydraulic circuits Contact your local Toro distributor for assistance Use the test ports on the front hydraulic tubes Figure 67 to assist in troubleshooting the traction circuit Figure 67 1 Traction circuit test port U...

Page 45: ...oceeding 6 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 7 Apply lapping compound with a long handle brush Never use a short handle brush 8 If the reels stall or become erratic while backlapping select a higher reel speed setting until the spee...

Page 46: ...fuel system as follows Add a petroleum based stabilizer conditioner to fuel in the tank Follow the mixing instructions from the stabilizer manufacturer Do not use an alcohol based stabilizer ethanol or methanol Note A fuel stabilizer conditioner is most effective when mixed with fresh gasoline and used at all times Run the engine to distribute conditioned fuel through the fuel system 5 minutes Sto...

Page 47: ...Notes 47 ...

Page 48: ...not limited to damage to seats due to wear or abrasion worn painted surfaces scratched decals or windows etc Parts Parts scheduled for replacement as required maintenance are warranted for the period of time up to the scheduled replacement time for that part Parts replaced under this warranty are covered for the duration of the original product warranty and become the property of Toro Toro will ma...

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