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Toro 03673, Operator'S Manual

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Contents

Introduction .................................................................. 2
Safety ........................................................................... 4

Safe Operating Practices........................................... 4
Toro Riding Mower Safety ........................................ 6
Safety and Instructional Decals ................................. 7

Setup ...........................................................................10

1 Adjusting the Tire Pressure....................................10
2 Adjusting the Step Height .....................................10
3 Adjusting the Control Arm Position........................11
4 Installing the Cutting Units....................................11
5 Adjusting the Turf Compensation Spring.................14
6 Using the Cutting Unit Kickstand ...........................15

Product Overview .........................................................16

Controls ...............................................................16
Specifications ........................................................22
Attachments/Accessories........................................22

Operation ....................................................................23

Checking the Engine Oil Level .................................23
Checking the Cooling System ...................................23
Adding Fuel...........................................................24
Checking the Hydraulic Fluid ...................................25
Checking the Reel to Bedknife Contact ......................26
Check the Torque of the Wheel Nuts .........................26
Starting and Stopping the Engine..............................26
Setting the Reel Speed .............................................26
Adjusting the Lift Arm Counterbalance .....................26
Adjusting the Lift Arm Turn Around Position.............26
Pushing or Towing the Machine................................27
Jacking Points ........................................................27
Tie Downs ............................................................28
Understanding the Diagnostic Light ..........................28
Checking the Interlock Switches ...............................28
Hydraulic Valve Solenoid Functions ..........................29
Operating Tips ......................................................29

Maintenance .................................................................30

Recommended Maintenance Schedule(s) ......................30

Daily Maintenance Checklist ....................................31
Service Interval Chart .............................................32

Lubrication ...............................................................32

Greasing the Bearings and Bushings ..........................32

Engine Maintenance ..................................................34

Servicing the Air Cleaner .........................................34
Servicing the Engine Oil and Filter............................34
Replacing the Spark Plugs ........................................35

Fuel System Maintenance ...........................................36

Replacing the Fuel Filter ..........................................36
Checking the Fuel Lines and Connections ..................36
Fuel Pick-up Tube Screen ........................................36

Electrical System Maintenance ....................................37

Servicing the Battery...............................................37
Fuses ....................................................................37

Drive System Maintenance .........................................38

Adjusting the Traction Drive for Neutral....................38
Adjusting the Rear Wheel Toe-in ..............................38

Cooling System Maintenance ......................................39

Removing Debris from the Cooling System ................39

Brake Maintenance ....................................................40

Adjusting the Service Brakes ....................................40
Adjusting the Parking Brake ....................................40

Belt Maintenance ......................................................41

Tensioning the Alternator Belt .................................41

Hydraulic System Maintenance ....................................41

Changing the Hydraulic Fluid...................................41
Replacing the Hydraulic Filters .................................42
Checking the Hydraulic Lines and Hoses....................42
Hydraulic System Test Ports.....................................43

Cutting Unit System Maintenance.................................44

Backlapping the Cutting Units ..................................44

Storage ........................................................................45

Preparing the Traction Unit .....................................45
Preparing the Engine ..............................................45

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Summary of Contents for 03673

Page 1: ...No 3376 722 Rev B Reelmaster 5410 G and 5510 G Traction Units Model No 03673 Serial No 313000001 and Up Model No 03689 Serial No 313000001 and Up Register at www Toro com Original Instructions EN 3376 722 B ...

Page 2: ...ow to operate and 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 and accessory information help finding a dealer or to register your product Whenever you need service genuine Toro parts or additional information contact an Authorized Service Dealer or T...

Page 3: ...enoid Functions 29 Operating Tips 29 Maintenance 30 Recommended Maintenance Schedule s 30 Daily Maintenance Checklist 31 Service Interval Chart 32 Lubrication 32 Greasing the Bearings and Bushings 32 Engine Maintenance 34 Servicing the Air Cleaner 34 Servicing the Engine Oil and Filter 34 Replacing the Spark Plugs 35 Fuel System Maintenance 36 Replacing the Fuel Filter 36 Checking the Fuel Lines a...

Page 4: ...ing 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 Do not operate the equipment when barefoot or wearing open sandals Thoroughly inspect the area where the equipment is to be used and remove all objects which may be t...

Page 5: ...uel 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 Lightning can cause severe injury or death If lightning is seen or thunde...

Page 6: ...rvice brakes when going downhill to keep forward speed slow and to maintain control of the machine Raise the cutting units when driving from one work area to another Do not touch the engine silencer muffler or exhaust pipe while the engine is running or soon after it has stopped because these areas could be hot enough to cause burns If the engine stalls or loses headway and cannot make it to the t...

Page 7: ...to apply the brake 3 Press the traction pedal to move the machine forward 4 Reel enabled mode 5 Transport mode 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 117 2718 110 8924 1 Warning read the Operator s Manual and receive training 2 Thrown object hazard keep bystanders a safe dist...

Page 8: ...ine computer management A 10 amp 110 8921 1 Traction unit speed 2 Slow 3 Fast 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 8 Battery acid can cause blindness or se...

Page 9: ...21 5643 1 Read the Operator s Manual 3 Engine run 2 Engine start 4 Engine stop 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 9 ...

Page 10: ...ference part numbers Operator Training Material 1 Review before operating the machine Cutting Performance Paper 1 Used for adjusting the cutting unit bedknife to reel Shim 1 Used for adjusting the cutting unit bedknife to reel Note Determine the left and right sides of the machine from the normal operating position 1 Adjusting the Tire Pressure No Parts Required Procedure The tires are over inflat...

Page 11: ...Figure 3 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 R H 1 Front hose guide L H 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 and ad...

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: ...in and 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 3 4 inch A ...

Page 14: ...ve 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 or ...

Page 15: ...12 7 mm 1 2 inch Ground following will be slightly decreased 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 Figur...

Page 16: ...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 will control the mow speed and allow the cutting units to be engaged Each spacer adjusts the mowing speed by 8 kph mile per hour The more spacers you have on the top of the bolt the s...

Page 17: ...d 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 the backlap levers in c...

Page 18: ... are currently using 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 shou...

Page 19: ...aults 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 will quickly tell you which machine controls are on and which are off Settings Th...

Page 20: ...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 From ...

Page 21: ... 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 To Set 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 changed to ac...

Page 22: ...s installed 1 247 kg 2 750 lb 1 335 kg 2 943 lb Engine Kubota 49 hp WG1605 EFI Kubota 49 hp WG1605 EFI Fuel tank capacity 53 liters 14 US gallons 53 liters 14 US gallons Transport speed 0 16 kph 0 10 mph 0 16 kph 0 10 mph Mowing speed 0 13 kph 0 8 mph 0 13 kph 0 8 mph Attachments Accessories A selection of Toro approved attachments and accessories is available for use with the machine to enhance a...

Page 23: ...ipstick and check oil level on dipstick The oil level should be up to the Full mark 5 If the oil level is below the Full mark remove the fill cap Figure 26 and add oil until level reaches the Full mark on dipstick Do not overfill 6 After adding oil wait more than 5 minutes and check the oil level again It takes some time for the oil to drain down to the pan g02121 1 2 1 Figure 26 1 Dipstick 2 Oil ...

Page 24: ...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 Never buy more than a 30 day supply of fuel Do not operate without entire exhaust system in place and in proper working condition DANGER In certain conditions during fueling static electricity can be released causing a spark ...

Page 25: ...rtant 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 18 C 65 F to 49 C 120 F ISO VG 68 hydraulic fluid may offer improved performance Premium Biodegradable Hydraulic Fluid Mobil EAL EnviroSyn 46H Important Mobil EAL EnviroSyn 46H is the only synthetic biodegradable fluid ap...

Page 26: ...d HOC to calculate the proper reel speed 2 If further adjustments are required scroll down on the InfoCenter to the F Reel RPM R Reel RPM or both 3 Press the right button to change the reel speed value As the speed setting is changed the display will continue to show the calculated reel speed based on blade count mow speed and HOC but the new value will also be displayed Note The reel speed may ne...

Page 27: ... valve must be open whenever the machine is pushed or towed 1 The bypass valve is located on the left side of the hydrostat Figure 32 Rotate the bolt 1 1 2 turns to open and allow oil to bypass internally Because fluid is bypassed the machine can be moved slowly without damaging the transmission Figure 32 1 Bypass valve 2 Close the bypass valve before starting the engine However do not exceed 7 11...

Page 28: ...ostic light 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 In addition the engine should stop when the traction pedal is pressed with operator off of the seat or...

Page 29: ...he hydraulic manifold Each solenoid must be energized to allow function to occur Solenoid Function SP2 Front reel circuit SP1 Rear reel circuit SVRV Lift lower cutting units SV1 Lift lower front cutting units SV3 Lift lower rear cutting units SV2 Raise any cutting units Operating Tips Familiarization Before mowing grass practice operating the machine in an open area Start and stop the engine Opera...

Page 30: ... 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 preload Ev...

Page 31: ...vel Check the hydraulic filter indicator 1 Check hydraulic 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 rega...

Page 32: ...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 Lubricate 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 33: ...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 33 ...

Page 34: ...ris 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 elem...

Page 35: ... and checked whenever the engine malfunctions 1 Clean the area around the spark plugs so 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 Important Repl...

Page 36: ...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 37: ...ns 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 a...

Page 38: ... 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 39: ...e 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 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 39 ...

Page 40: ...nt nuts 2 Tighten the rear nut to move the cable backward until brake pedals have 1 27 to 1 9 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 Adjusting the Parking Brake If the parking brake fails to engage an adjustment to the brake pawl is required 1 Loosen the 2 screws securing the parking br...

Page 41: ...ulic 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 Place a large drain pan under the fitting secured to the bottom of the hydraulic fluid reservoir Figure 62...

Page 42: ... mounting area and place a drain pan under filter Figure 64 and Figure 65 g021271 1 Figure 64 1 Hydraulic filter Figure 65 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 pro...

Page 43: ...rk on the hydraulic system Get immediate medical help if fluid is injected into skin 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 66 to assist in troubleshooting the traction circuit Figure 66 1 Traction circuit test port Use th...

Page 44: ...eeding 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 handled brush 8 If the reels stall or become erratic while backlapping select a higher reel speed setting until the speed...

Page 45: ...sed stabilizer conditioner to fuel in the tank Follow the mixing instructions from 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 Stop the engine allow it to cool and drain the f...

Page 46: ...Notes 46 ...

Page 47: ...Notes 47 ...

Page 48: ...ted 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 make the f...

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